Related Manuals for KAESER ASK 40
Summarization of Contents
Regarding this document
Using this document
Guidelines for the proper use and handling of the operating manual.
Further documents
Lists related documents provided with or referenced by the operating manual.
Copyright
Information regarding the copyright protection of the operating manual.
Symbols and labels
Explanation of symbols and labels used throughout the document for safety and information.
Potential damage warnings
Details warnings concerning potential damage to property, not personal injury.
Other alerts and their symbols
Identifies symbols used for particularly important information.
Technical Specifications
Nameplate
Details the machine's model designation and key technical information found on the nameplate.
Mass
Provides the mass specifications for different ASK models.
Temperature
Details temperature specifications, including cut-in and discharge temperatures.
Ambient conditions
Specifies permissible ambient conditions for operation, including altitude and temperature.
Ventilation
Provides guide values for ventilation requirements and flow rates for different mains frequencies.
Pressure
Indicates the maximum working pressure of the machine.
Flow rate (constant delivery volume relative to intake conditions)
Details flow rates for different working pressures and mains frequencies.
Cooling oil recommendation
Recommends specific cooling oils for general applications and food processing.
Cooling oil charge quantity
Specifies cooling oil quantities, including additional volume for heat recovery options.
Motors and power
Details specifications for the machine's motors and power requirements.
Compressor drive motor
Details specifications for the compressor drive motor, including rated power and enclosure protection.
Fan motor
Provides specifications for the fan motor, including rated power and speed.
Noise emission [dB(A)]
Lists the noise emission levels for the machine at different mains frequencies.
Electrical connection
Describes the machine's design compliance with electrical connection standards.
Power supply specifications
Details the electrical power supply requirements and specifications for the machine.
Mains frequency: 50 Hz
Details supply cable, fuse, and current draw for 50 Hz operation at various voltages.
Network conditions at 400V / 3 / 50Hz
Specifies network conditions for machines connected to public mains supplies.
Mains frequency: 60 Hz
Details supply cable, fuse, and current draw for 60 Hz operation at various voltages.
Heat recovery
Explains the function and components of the optional heat recovery system.
Individual design data
Provides a template for entering specific design data for heat recovery.
Component specification
Details the specifications of the heat exchanger used in the heat recovery system.
Safety and Responsibility
Basic instructions
General safety instructions and warnings regarding machine operation to prevent hazards.
User's responsibilities
Outlines the responsibilities of the user concerning safety and regulatory compliance.
Observe statutory and universally accepted regulations
Emphasizes adherence to national and international safety and accident prevention regulations.
Determining personnel
Defines the qualifications and responsibilities required for personnel operating and maintaining the machine.
Keeping to Inspection Schedules and Accident Prevention Regulations
Stresses the importance of following inspection schedules and accident prevention regulations.
Dangers
Describes potential dangers associated with machine operation and their avoidance.
Safely dealing with sources of danger
Provides guidelines for safely handling electrical hazards and the risks of compressed air.
Compressed air quality
Addresses the importance of compressed air composition for safety and specific applications.
Rotating components
Highlights risks related to moving parts and necessary precautions.
Temperature
Warns about high temperatures of components and the need for protective clothing.
Noise
Discusses noise levels and the importance of sound insulation and hearing protection.
Operating fluids/materials
Advises on safe handling of operating fluids and materials to prevent health effects.
Unsuitable spare parts
Warns against using non-approved spare parts, which compromise machine safety.
Conversion or modification of the machine
Prohibits unauthorized modifications and requires manufacturer approval for changes.
Safe machine operation
Provides information for safe handling of the machine throughout its lifecycle.
Personal protective equipment
Specifies necessary personal protective equipment (PPE) for working on the machine.
Transport
Details safety measures required for machine transport to prevent accidents.
Assembly
Provides safety instructions for assembling the machine and its components.
Installation
Covers safety aspects of machine installation, including location, lighting, and ventilation.
Commissioning, operation and maintenance
Highlights dangers during commissioning, operation, and maintenance, and necessary precautions.
De-commissioning, storage and disposal
Addresses environmental dangers from fluids and proper disposal procedures.
Organisational Measures
Outlines organizational measures for ensuring machine safety, including personnel designation and instructions.
Danger Areas
Identifies areas dangerous to personnel and specifies authorized entry.
Safety devices
Explains the function of safety devices and the importance of not disabling them.
Service life of safety functions
Details the assessed category and performance level of safety functions and their service life.
Safety signs
Illustrates the location and meaning of various safety signs on the machine.
Emergency situations
Provides instructions for handling emergency situations like fires and injuries.
Correct fire fighting
Details suitable measures and extinguishing agents for fighting fires.
Treating injuries from handling cooling oil
Offers guidance on first aid for eye and skin contact with cooling oil.
Warranty
Outlines warranty conditions and exclusions for machine use and maintenance.
Environment protection
Addresses environmental considerations, including proper handling and disposal of oils and materials.
Design and Function
Housing
Describes the machine's enclosure, its functions, and unsuitable uses.
Machine function
Explains the operational process of the machine and its main components.
Safety devices
Lists and describes the safety devices integrated into the machine's design.
Floating relay contacts
Explains the purpose and connection of floating relay contacts for signal transfer.
Operating panel SIGMA CONTROL 2
Details the SIGMA CONTROL 2 operating panel, its keys, and indicators.
Keys
Provides an overview of the keys on the SIGMA CONTROL 2 panel and their functions.
LEDs
Explains the meaning of the various LEDs on the SIGMA CONTROL 2 panel.
RFID reader
Describes the RFID reader functionality for machine access and identification.
Operating modes and control modes
Explains the different operating modes and control modes of the machine.
Machine operating modes
Details the STOP, READY, LOAD, and IDLE operating modes of the compressor.
Control modes
Describes control modes (DUAL, QUADRO, VARIO) that manage pressure and energy efficiency.
DUAL
Explains the DUAL control mode, switching between LOAD and IDLE for pressure maintenance.
QUADRO
Describes the QUADRO control mode, which includes transitions to READY after IDLE.
VARIO
Details the VARIO mode, an energy-efficient adaptation of DUAL mode with variable idling time.
MODULATING control
Explains the MODULATING control, a mechanical regulation that adjusts flow rate continuously.
Options
Lists and describes available options for the machine.
Option C3/C48 SIGMA CONTROL 2 controller: Connection to control technology
Describes options for connecting the SIGMA CONTROL 2 controller to external control technology.
Option H1 Machine mountings
Details the options related to machine mountings for anchoring the unit.
Option W2/W3 Heat recovery
Explains the optional heat recovery system, its function, and components.
Installation and Operating Conditions
Ensuring safety
Covers essential safety precautions for machine installation and operation.
Installation conditions
Specifies conditions for machine installation, including location and clearances.
Determining location and clearances
Provides guidance on selecting an appropriate installation location and necessary clearances.
Ensuring the machine room ventilation
Details the requirements for adequate ventilation of the machine room for proper operation.
Exhaust duct design
Offers advice on designing exhaust air ducting to maintain machine cooling and airflow.
Operating the machine in a compressed air network
Addresses considerations for operating the machine within a compressed air network.
Installation
Ensuring safety
Provides safety instructions to be followed during the installation process.
Reporting Transport Damage
Instructs on how to check for and report transport damage to the machine.
Connecting the machine with the compressed air network
Details the procedure and precautions for connecting the machine to the compressed air network.
Connecting the external pressure transducer
Explains how to connect an external pressure transducer for network pressure regulation.
Connecting the machine with the power supply
Provides instructions and safety warnings for connecting the machine to the electrical power supply.
Options
Describes various optional features and their installation requirements.
Option H1 Anchoring the machine
Details the procedure for anchoring the machine using the H1 mounting option.
Option W2/W3 Connecting the heat recovery system
Explains the connection process for the optional heat recovery system.
Initial Start-up
Ensuring safety
Covers essential safety precautions for the initial commissioning of the machine.
Instructions to be observed before commissioning
Lists mandatory steps and checks before commissioning the machine, including after storage.
Checking installation and operating conditions
Provides a checklist for verifying installation and operating conditions before commissioning.
Setting the overload protection cut-out
Details how to set the overload protection for the compressor motor.
Setting the motor overload protection switch
Explains the setting procedure for the fan motor overload protection switch.
Pouring cooling oil into the airend
Describes the procedure for adding cooling oil to the airend before initial start-up.
Option C1 Activating and deactivating the MODULATING control
Explains how to activate and deactivate the MODULATING control via a shut-off valve.
Starting the machine for the first time
Provides step-by-step instructions for the initial start-up of the machine.
Setting the set point pressure
Details how to adjust the system's set point pressure for optimal operating conditions.
Setting the display language
Guides on how to change the display language for system messages.
Operation
Switching on and off
Provides instructions for safely switching the machine on and off using the control panel keys.
Switching on
Details the steps for switching the machine on after ensuring all safety checks are complete.
Switching off
Explains the procedure for safely switching the machine off via the control panel.
Switching off in an emergency and switching on again
Describes how to use the EMERGENCY STOP and restart the machine after rectifying faults.
Using the remote control for switching on and off
Explains how to operate the machine remotely via a control centre.
Using the timer for switching on and off
Details how to use the built-in timer for automated machine start-up and shut-down.
Interpreting operation messages
Guides on understanding and interpreting operational messages displayed by the controller.
Acknowledging alarm and warning messages
Explains how to acknowledge and clear alarm and warning messages displayed on the controller.
Fault Recognition and Rectification
Basic instructions
Provides general guidelines for recognizing and rectifying faults based on error message categories.
Other faults
Lists common faults, their possible causes, and recommended remedies.
Maintenance
Ensuring safety
Outlines essential safety precautions for performing maintenance tasks on the machine.
Following the maintenance plan
Guides on how to follow the maintenance plan, log work, and reset interval counters.
Logging maintenance work
Explains the importance of documenting all maintenance and service activities.
Resetting maintenance interval counters
Details the procedure for resetting maintenance interval counters after tasks are performed.
Regular maintenance tasks
Lists the regular maintenance tasks required for the machine.
Cooling oil Change interval
Specifies the intervals for changing the cooling oil based on operating conditions.
Regular service tasks
Lists essential regular service tasks that should be performed by authorized technicians.
Cooler: Cleaning or Renewing the Filter Mats
Describes how to clean or replace filter mats for the air and oil coolers.
Control cabinet: Clean or renew the filter mat
Explains how to clean or replace filter mats in the control cabinet ventilation.
Cooler maintenance
Details regular cleaning procedures for the cooler to ensure reliable cooling.
Maintain the heat recovery system
Provides guidance on maintaining the optional heat recovery system, focusing on heat exchangers.
Air Filter Maintenance
Describes the procedure for maintaining the air filter element.
Motor maintenance
Covers maintenance for drive and fan motors, including bearing checks.
Drive belt maintenance
Details how to check and adjust the drive belt tension and inspect for damage.
Testing the pressure relief valve
Explains the procedure for testing the pressure relief valve's functionality.
Check the safety shut-down due to excessive airend discharge temperature.
Describes how to check the safety shutdown function for high airend discharge temperatures.
Check the EMERGENCY STOP control device
Provides instructions for checking the functionality of the EMERGENCY STOP control device.
Checking the cooling oil level
Details how to check the cooling oil level, especially for frequency-controlled compressors.
Venting the machine (de-pressurising)
Explains the three-stage process for venting (de-pressurising) the machine before maintenance.
Replenish cooling oil
Guides on how to replenish cooling oil, including venting and topping up procedures.
Venting the machine (de-pressurising)
Details the steps for venting the machine as part of the oil replenishment process.
Topping up with cooling oil and trial run
Describes how to top up cooling oil and perform a trial run after replenishment.
Changing the cooling oil
Provides a detailed procedure for draining and changing the cooling oil from various machine components.
Changing the oil filter
Details the procedure for changing the oil filter, including safety precautions.
Changing the oil separator cartridge
Explains the process for changing the oil separator cartridge, noting it cannot be cleaned.
Documenting maintenance and service work
Provides a template for logging all maintenance and service tasks performed on the machine.
Spares, Operating Materials, Service
Note the nameplate
Emphasizes the importance of the machine's nameplate for service and ordering spares.
Ordering consumable parts and operating fluids/materials
Lists consumable parts and operating fluids, stressing the use of original KAESER components.
KAESER AIR SERVICE
Highlights the benefits and services offered by KAESER AIR SERVICE for machine maintenance.
Replacement parts for service and repair
Guides on using spare parts lists for planning material requirements and ordering parts.
Decommissioning, Storage and Transport
De-commissioning
Details procedures for decommissioning the machine, whether temporarily or for scrapping.
Temporary de-commissioning
Provides instructions for temporary de-commissioning, including periodic running to prevent corrosion.
Long-term de-commissioning
Outlines steps for long-term de-commissioning, including draining condensate and isolating supply lines.
Packing
Describes the packing requirements for machine transport, including desiccant and crates.
Storage
Provides guidelines for storing the machine, emphasizing protection against moisture and frost.
Transport
Covers safety aspects and methods for transporting the machine.
Safety
Details safety considerations for transportation, including center of gravity and personnel safety.
Transport with a forklift truck
Explains the procedure for transporting the machine using a forklift truck.
Transport with a crane
Provides detailed instructions and safety warnings for transporting the machine using a crane.
Disposal
Covers procedures for machine disposal, including draining fluids and removing filters.
Dispose of the battery in accordance with local environmental regulations.
Gives guidance on the environmentally friendly disposal of batteries.
Annex
Pipeline and instrument flow diagram (P&I diagram)
Contains pipeline and instrument flow diagrams for understanding the machine's system layout.
Dimensional drawing
Provides dimensional drawings of the machine for installation and planning purposes.
Option C1 Pipeline and instrument flow diagram (P&I diagram) MODULATING control
Presents the P&I diagram for the MODULATING control option.
Electrical Diagram
Contains electrical diagrams for the machine, including power supply and component layouts.
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