KAESER AIRTOWER 4C Manuals

Manuals and User Guides for KAESER AIRTOWER 4C. We have 1 KAESER AIRTOWER 4C manual available for free PDF download: Operator's Manual

KAESER AIRTOWER 4C Operator's Manual (124 pages)

Screw Compressor

Brand: KAESER | Category: Air Compressor | Size: 4 MB

Table of Contents
3
Regarding this Document Using this Document
11
Further Documents
11
Copyright
11
Symbols and Labels
11
Warnings
11
Tab. 1 Danger Levels and Their Definition (Personal Injury)
11
Potential Damage Warnings
12
Other Alerts and Their Symbols
12
Tab. 2 Danger Levels and Their Definition (Damage to Property)
12
Technical Data Nameplate
14
Options
14
Tab. 3 Nameplate
14
Weight
15
Temperature
15
Ambient Conditions
15
Tab. 4 Options
15
Tab. 5 Weight
15
Tab. 6 Temperature
15
Ventilation
16
Pressure
16
Fig. 1 Maximum Relative Humidity of Intake Air
16
Tab. 7 Ambient Conditions
16
Tab. 8 Ventilation
16
Air Receiver
17
Free Air Delivery (FAD)
17
Cooling Oil Recommendation
17
Tab. 9 Safety Relief Valve Activating Pressure
17
Tab. 10 Air Receiver: Volume
17
Tab. 11 Safety Relief Valve: Activating Pressure
17
Tab. 12 Free Air Delivery
17
Basic Information
18
KAESER Lubricants
18
Cooling Oil Charge
19
Motor and Performance
19
Compressor Motor
19
Tab. 13 Cooling Oil Charge
19
Tab. 14 Compressor Motor
19
Tab. 15 Compressor Drive Motor Rated Speed
19
Sound Emission
20
Power Supply
20
Fig. 2 Three-Phase Star (Wye); 4 Wire; Grounded Neutral
20
Fig. 3 Three-Phase Star (Wye); 3 Wire; Grounded Neutral
20
Tab. 16 Sound Emission
20
Power Supply Specifications
21
Tab. 17 Supply 208V/3/60Hz
21
Tab. 18 Supply 230V/3/60Hz
21
Tab. 19 Supply 460V/3/60Hz
21
Refrigerated Dryer
22
Tab. 20 Refrigerated Dryer: Model
22
Tab. 21 Refrigerated Dryer: Compressed Air System
22
Tab. 22 Refrigerated Dryer: Refrigerant System
22
Power Supply Specifications
23
Tab. 23 Power Supply 115V / 1 / 60Hz
23
Safety and Responsibility Basic Instructions
24
Specified Use
24
Improper Use
24
User's Responsibilities
24
Observe Statutory and Universally Accepted Regulations
24
Qualified Personnel
25
Adherence to Inspection Schedules and Accident Prevention Regulations
25
Dangers
25
Safely Dealing with Sources of Danger
25
Safe Machine Operation
28
Organizational Measures
30
Danger Areas
30
Safety Devices
30
Tab. 24 Danger Areas
30
Working Life of Safety Functions
31
Safety Signs
31
Fig. 4 Location of Safety Signs
31
Emergency Situations
33
Correct Fire Fighting
33
Treating Injuries from Handling Cooling Oil
33
Tab. 25 Safety Signs
33
Injury from Handling Refrigerant
34
Warranty
34
Environmental Protection
35
Design and Function
36
Enclosure
36
Fig. 5 Enclosure Overview
36
Machine Function
37
Fig. 6 Machine Overview
37
Refrigerated Dryer
38
Air Receiver
38
Safety Devices
38
Fig. 7 Refrigerated Dryer
38
Floating Relay Contacts
39
Operating Panel SIGMA CONTROL BASIC
39
Fig. 8 Keys - Overview
39
Functional Description - SIGMA CONTROL BASIC
40
Display Layout
40
Fig. 9 Indicators - Overview
40
Tab. 26 Keys
40
Tab. 27 Indicators
40
Parameter
41
Tab. 28 Display
41
Messages
42
Tab. 29 Parameter
42
Operating Modes and Control Modes
43
Machine Operating Modes
43
START-STOP Control
43
Refrigerated Dryer Control Modes
43
Options
43
Machine Mountings
44
Fig. 10 Machine Mountings
44
Installation and Operating Conditions
45
Ensuring Safety
45
Installation Conditions
45
Determining Location and Clearances
45
Ensuring the Machine Room Ventilation
46
Fig. 11 Recommended Machine Placement and Dimensions [In]
46
Operating the Machine in a Compressed Air System
47
Installation
48
Ensuring Safety
48
Reporting Transport Damage
49
Connecting the Machine with the Compressed Air Network
49
Connecting the Condensate Drain
49
Fig. 12 Compressed Pipework
49
Tab. 30 Condensate Line
50
Tab. 31 Condensate Collecting Line
50
Tab. 32 Condensate Collecting Line: Line Diameter
50
Refrigerated Dryer: Connecting the Transformer According to the Power Supply
51
Making the Power Supply Connection
51
Fig. 13 Connecting the Condensate Drain
51
Changing Main Voltage Connections
52
Tab. 33 Voltage Selection
52
Options
53
Anchoring the Machine
53
Tab. 34 Overload Protection Cutout Settings
53
Initial Start-Up Ensuring Safety
54
Instructions to be Observed before Commissioning or Re-Commissioning
55
Checking Installation and Operating Conditions
55
Tab. 35 Re-Commissioning after Storage
55
Setting the Overload Protection Relay
56
Pouring Cooling Oil into the Airend
56
Fig. 14 Inlet Valve Filling Port
56
Tab. 36 Installation Conditions Checklist
56
Starting the Machine for the First Time
57
Setting the Network Setpoint Pressure
57
Operation
59
Switching on and off
59
Switching on
59
Switching off
59
Fig. 15 Switching on and off
59
Switching off in an Emergency and Switching on Again
60
Setting Parameters
60
Fig. 16 Switching off in an Emergency
60
Acknowledging Alarm and Warning Messages
61
Fig. 17 Acknowledging Messages
61
Fault Recognition and Rectification
63
Basic Instructions
63
Fault Messages (Machine Shut Down)
63
Tab. 37 Fault Messages and Remedies
63
Warning Messages
64
Tab. 38 Warning Messages
64
Other Faults
65
Tab. 39 Other Faults and Remedies
65
10 Maintenance
66
Ensuring Safety
66
Tab. 40 Warn Others that the Machine Is Being Serviced
66
Following the Maintenance Plan
67
Logging Maintenance Work
67
Resetting Maintenance Interval Counters
67
Regular Maintenance Tasks
67
Cooling Oil Changing Interval
68
Tab. 41 Regular Maintenance Tasks
68
Regular Service Tasks
69
Clean or Replace the Filter Mat
69
Tab. 42 Oil Change Intervals Lubricants
69
Tab. 43 Regular Service Tasks
69
Cooler Maintenance
70
Fig. 18 Filter Mat
70
Air Filter Maintenance
71
Fig. 19 Oil Cooler
71
Compressor Motor Maintenance
72
Maintaining the Drive Belt
72
Fig. 20 Air Filter Maintenance
72
Checking the Cooling Oil Level
73
Fig. 21 Changing the Belt
73
Venting the Machine (Depressurizing)
74
Fig. 22 Checking the Cooling Oil Level
74
Tab. 44 Permissible Cooling Oil Level under LOAD
74
Fig. 23 Venting the Machine
75
Replenishing Cooling Oil
76
Fig. 24 Replenishing the Cooling Oil
76
Venting the Machine (Depressurizing)
77
Topping off with Cooling Oil and Carrying out a Trial Run
78
Changing the Cooling Oil
78
Fig. 25 Changing the Cooling Oil, Oil Separator Tank
79
Changing the Oil Filter
81
Changing the Oil Separator Cartridge
82
Fig. 26 Changing the Oil Filter
82
Fig. 27 Changing the Oil Separator Cartridge
83
Checking the Safety Relief Valve Activating Pressure
84
Checking the Compressor Safety Relief Valve
84
Fig. 28 Compressor: Checking the Safety Relief Valve
84
Checking the Air Receiver Relief Valve
85
Performing the Test
85
Fig. 29 Air Receiver: Testing the Safety Relief Valve
85
Returning the Machine to Operational
86
Check the Safety Shut-Down Due to Excessive Airend Discharge Temperature
86
Testing the EMERGENCY STOP Push Button
86
Fig. 30 Testing the EMERGENCY STOP Push Button
86
Maintaining the Refrigerated Dryer
87
Cleaning the Refrigerant Condenser
87
Fig. 31 Refrigerated Dryer
87
Maintaining the Condensate Drain
88
Fig. 32 Checking the Condensate Drain
88
Fig. 33 Changing the Service Unit
89
Air Receiver Maintenance
90
Fig. 34 Air Receiver Maintenance
90
Documenting Maintenance and Service Work
92
Tab. 45 Logged Maintenance Tasks
92
11 Spares, Operating Materials, Service
93
Note the Nameplate
93
Ordering Consumable Parts and Operating Fluids/Materials
93
Kaeser Air Service
93
Tab. 46 Consumable Parts
93
Service Addresses
94
Replacement Parts for Service and Repair
94
12 Decommissioning, Storage and Transport
97
Decommissioning
97
Packing
97
Storage
97
Transport
98
Safety
98
Transport with a Forklift Truck
98
Transport with a Crane
98
Fig. 35 Transporting with a Forklift Truck
98
Disposal
99
Fig. 36 Transporting with a Crane
99
13 Annex
101
Pipeline and Instrument Flow Diagram (P+I Diagram)
101
Dimensional Drawing
107
Electrical Diagram
109

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KAESER AIRTOWER 4C Operator's Manual (124 pages)

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