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KAESER Manuals
Air Compressor
ASK 27
Service manual
KAESER ASK 27 Service Manual
Screw compressor. sigma control basic
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
1 Regarding this Document Using this Document
Using this Document
Further Documents
Copyright
Symbols and Labels
Warnings
Tab. 1 Danger Levels and Their Definition (Personal Injury)
Potential Damage Warnings
Other Alerts and Their Symbols
Tab. 2 Danger Levels and Their Definition (Damage to Property)
2 Technical Specifications Nameplate
Options
Weight
Tab. 3 Nameplate
Tab. 4 Options
Temperature
Ambient Conditions
Tab. 5 Machine Weight
Tab. 6 Temperature
Tab. 7 Ambient Conditions
Ventilation
Pressure
Fig. 1 Maximum Relative Humidity of Intake Air
Tab. 8 Overview Ventilation (50Hz)
Tab. 9 Overview Ventilation (60Hz)
Delivery
Tab. 10 Pressure Relief Valve Activating Pressure (50Hz)
Tab. 11 Pressure Relief Valve Activating Pressure (60Hz)
Tab. 12 Delivery (50 Hz)
Tab. 13 Delivery (60 Hz)
Noise Emission [Db(A)]
Motors and Power
Drive Motor
Cooling Oil Recommendation
Tab. 14 Noise Emission [Db(A)]
Tab. 15 Drive Motor
Tab. 16 Drive Motor: Nominal Speed at 50 Hz
Tab. 17 Drive Motor: Nominal Speed at 60 Hz
Tab. 18 Cooling Oil Recommendation
Cooling Oil Charge
Tab. 19 Cooling Oil Recommendation (Food Processing)
Tab. 20 Cooling Oil Recommendation (Machines for Snow Cannons)
Tab. 21 Cooling Oil Charge (Option K1)
Power Supply
Power Supply Specifications
Tab. 22 Cooling Oil Charge (Option W1)
Mains Frequency: 50 Hz
Tab. 23 Mains Supply 200V/3/50Hz
Tab. 24 Mains Supply 230V/3/50Hz
Tab. 25 Mains Supply 400V/3/50Hz
Mains Frequency: 60 Hz
Tab. 26 Supply Conditions at 400V/3/50Hz
Tab. 27 Mains Supply 230V/3/60Hz
Tab. 28 Mains Supply 380V/3/60Hz
Tab. 29 Mains Supply 440V/3/60Hz
Available Heat Capacity
Refrigeration Dryers
Tab. 30 Mains Supply 460V/3/60Hz
Tab. 31 Heat Capacity (Option W1)
Tab. 32 Refrigeration Dryer: Model
Tab. 33 Refrigeration Dryer: Compressed Air System
Tab. 34 Refrigeration Dryer: Refrigerant Circuit
3 Safety and Responsibility Basic Instructions
Specified Use
Improper Use
User's Responsibilities
Observe Statutory and Universally Accepted Regulations
Qualified Personnel
Adhere to Inspection Schedules and Accident Prevention Regulations
Dangers
Safely Dealing with Sources of Danger
Tab. 35 Inspection Intervals According to Regulations
Safe Machine Operation
Organisational Measures
Danger Areas
Safety Devices
Safety Signs
Fig. 2 Location of Safety Signs
Tab. 36 Danger Areas
Emergency Situations
Correct Fire Fighting
Tab. 37 Safety Signs
Treating Injuries from Handling Cooling Oil
Injury from Handling Refrigerant
Warranty
Environment Protection
4 Design and Function
Enclosure
Fig. 3 Enclosure Overview
Machine Function
Fig. 4 Machine Layout
Refrigeration Dryer
Floating Relay Contacts
Options
Machine Mountings
Fig. 5 Refrigeration Dryer
Fig. 6 Machine Mountings
Prepared for External Heat Recovery
Operating Modes and Control Modes
Operating Modes
Control Modes
Tab. 38 Energy-Efficient Control Modes
Refrigeration Dryer Control Modes
Tab. 39 Operating Modes under MODULATING Control
Tab. 40 Refrigeration Dryer Control Modes
Safety Devices
Keys and Leds - SIGMA CONTROL BASIC
Fig. 7 Keys - Overview
Functional Description - SIGMA CONTROL BASIC
Display Layout
Fig. 8 Indicators
Tab. 41 Keys
Tab. 42 Indicators
Parameters
Tab. 43 Display
Messages
Tab. 44 Parameters
5 Installation and Operating Conditions
Ensuring Safety
Installation Conditions
Determining Location and Clearances
Ensuring the Machine Room Ventilation
Fig. 9 Recommended Machine Placement and Dimensions [MM]
Exhaust Duct Design
Operating the Machine in a Compressed Air Network
6 Installation
Ensuring Safety
Installation 6.1 Ensuring Safety
Reporting Transport Damage
Connecting the Machine with the Compressed Air Network
Connecting the Power Supply
Fig. 10 Compressed Pipework
Refrigeration Dryer: Connecting the Transformer According to the Mains Supply
Connecting the Condensate Drain
Connecting the Remote LOAD-IDLE Control
Fig. 11 Condensate Drain Dimensions [MM]
Fig. 12 Connections SIGMA CONTROL BASIC
Options
Anchoring the Machine
Connecting the External Heat Recovery System
7 Initial Start-Up Ensuring Safety
Instructions to be Observed before Commissioning or Re-Commissioning
Checking Installation and Operating Conditions
Tab. 45 Re-Commissioning after Storage
Setting the Overload Protection Cut-Out
Pouring Cooling Oil into the Airend
Tab. 46 Installation Conditions Checklist
Activating and Deactivating the MODULATING Control
Fig. 13 Inlet Valve Filling Port
Tab. 47 MODULATING Control: Setting the Shut-Off Valve
Checking the Door Interlock Switch
Fig. 14 MODULATING Control: Setting the Shut-Off Valve
Fig. 15 Location of the Interlock Switch
Starting the Machine for the First Time
Setting the Setpoint Pressure
8 Operation
Switching on and off
Switching on
Switching off
Fig. 16 Switching on and off
Operation 8.1 Switching on and off
Switching off in an Emergency and Switching on Again
Fig. 17 Switching off in an Emergency
Tab. 48 Switching off With/Without Run-On Time
Setting Parameters
Acknowledging Alarm and Warning Messages
Fig. 18 Acknowledging Messages
9 Fault Recognition and Rectification
Basic Instructions
Alarm Messages (Machine Shut Down)
Warning Messages
Tab. 49 Alarm Indications
Tab. 50 Warning Messages
Other Faults
Tab. 51 Other Faults and Actions
10 1 Maintenance
Ensuring Safety
Following the Maintenance Plan
Logging Maintenance Work
Resetting Maintenance Interval Counters
Regular Maintenance Tasks
Tab. 52 Regular Maintenance Tasks
Cooling Oil: Change Interval
Regular Service Tasks
Cooler: Cleaning or Renewing the Filter Mats
Tab. 53 Cooling Oil: Change Intervals
Tab. 54 Regular Service Tasks
Control Cabinet: Clean or Renew the Filter Mat
Fig. 19 Filter Mat for the Air and Oil Cooler
Cooler Maintenance
Fig. 20 Switching Cabinet Ventilation
Maintaining the External Heat Recovery System
Fig. 21 Filter Mat for the Air and Oil Cooler
Air Filter Maintenance
Compressor Motor Maintenance
Fig. 22 Air Filter Maintenance
Maintaining the Drive Belts
Fig. 23 Drive Belt Maintenance
Testing the Pressure Relief Valve
Checking the Excess Temperature Safety Shutdown Function
Checking the Cooling Oil Level
Venting the Machine (De-Pressurising)
Fig. 24 Checking the Cooling Oil Level
Fig. 25 Venting the Machine
Replenishing the Cooling Oil
Venting the Machine (De-Pressurising)
Fig. 26 Replenishing the Cooling Oil
Topping up with Cooling Oil and Trial Run
Changing the Cooling Oil
Fig. 27 Changing the Cooling Oil, Oil Separator Tank
Fig. 28 Changing the Cooling Oil, Heat Recovery System
Changing the Oil Filter
Fig. 29 Changing the Oil Filter
Changing the Oil Separator Cartridge
Fig. 30 Changing the Oil Separator Cartridge
Refrigeration Dryer Maintenance
Cleaning the Refrigerant Condenser
Checking the Condensate Drain
Fig. 31 Refrigeration Dryer
Condensate Drain Maintenance
Fig. 32 Checking Condensate Drainage
Fig. 33 Condensate Drain Maintenance
Documenting Maintenance and Service Work
11 Spares, Operating Materials, Service
Note the Nameplate
Ordering Consumable Parts and Operating Fluids/Materials
Kaeser Air Service
Service Addresses
Spare Parts for Service and Repair
12 Decommissioning, Storage and Transport
Putting out of Operation
Packing
Storage
Transport
Safety
Transport with a Forklift Truck
Transport with a Crane
Fig. 34 Transport with a Forklift Truck
Disposal
Fig. 35 Transport with a Crane
13 Annex
Pipeline and Instrument Flow Diagram (P+I Diagram)
Pipeline and Instrument Flow Diagram (P&I Diagram) MODULATING Control
Dimensional Drawing
Electrical Diagram
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Service Manual
Screw Compressor
ASK T
SIGMA CONTROL BASIC
9_5717 20 E
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
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Summarization of Contents
Regarding this document
Symbols and labels
Explains symbols and labels used throughout the document, including warnings and notices.
Technical Specifications
Nameplate
Details about the machine's nameplate and its location for identification.
Temperature
Specifies temperature ranges and limits for the machine's operation.
Ventilation
Details ventilation requirements for the machine's cooling system.
Motors and Power
Details about the drive motor, its power, and enclosure protection.
Power Supply
Information on electrical power supply requirements and specifications.
Refrigeration dryers
Information on the refrigeration dryer specifications and its components.
Safety and Responsibility
Basic instructions
Fundamental safety instructions for operating the machine safely.
User's Responsibilities
Outlines the user's duties for safe operation and maintenance.
Dangers
Details potential dangers associated with machine operation and their avoidance.
Emergency situations
Procedures for handling emergency situations like fire or injuries.
Design and Function
Machine function
Explains the internal workings and operation of the compressor.
Operating modes and control modes
Explains different operating and control modes of the machine.
Safety devices
Lists and describes the safety devices integrated into the machine.
Functional description – SIGMA CONTROL BASIC
Detailed functional description of the SIGMA CONTROL BASIC controller.
Installation and Operating Conditions
Ensuring safety
Safety precautions to be observed during installation.
Installation conditions
Requirements for the installation environment and location.
Installation
Ensuring safety
Safety instructions for the installation process.
Connecting the power supply
Instructions for connecting the machine to the electrical power supply.
Connecting the Condensate Drain
How to connect the condensate drain hose.
Options
Details on installing optional features like heat recovery.
Initial Start-up
Ensuring safety
Safety precautions for initial start-up.
Instructions to be observed before commissioning or re-commissioning
Checks and procedures before commissioning or recommissioning.
Starting the machine for the first time
Steps for the initial start-up of the machine.
Setting the setpoint pressure
How to adjust the setpoint pressure for the compressor.
Operation
Switching On and Off
Procedures for turning the machine on and off.
Switching off in an emergency and switching on again
Steps for emergency shutdown and restart.
Setting parameters
How to adjust machine parameters via the controller.
Fault Recognition and Rectification
Basic instructions
General guidance for fault finding and rectification.
Alarm messages (machine shut down)
Lists alarm messages causing machine shutdown and remedies.
Warning messages
Lists warning messages and their solutions.
Maintenance
Ensuring safety
Safety precautions for maintenance work.
Following the maintenance plan
How to follow the scheduled maintenance plan.
Changing the cooling oil
Instructions for changing the cooling oil.
Changing the oil filter
How to change the oil filter.
Changing the oil separator cartridge
Procedure for changing the oil separator cartridge.
Refrigeration Dryer Maintenance
Maintenance tasks for the refrigeration dryer.
Spares, Operating Materials, Service
Note the Nameplate
Importance of the nameplate for service and ordering.
Ordering consumable parts and operating fluids/materials
How to order spare parts and operating materials.
Spare Parts for Service and Repair
List of spare parts for service and repair.
Decommissioning, Storage and Transport
Putting Out of Operation
Procedures for taking the machine out of operation.
Transport
Information and procedures for transporting the machine.
Disposal
Procedures for safely disposing of the machine.
Annex
Pipeline and instrument flow diagram (P+I diagram)
Contains the P+I diagram for the machine.
Dimensional drawing
Provides dimensional drawings of the machine.
Electrical Diagram
Contains the electrical wiring diagrams for the machine.
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