KAESER ESD.2C Rotary Screw Compressor Manuals

Manuals and User Guides for KAESER ESD.2C Rotary Screw Compressor. We have 1 KAESER ESD.2C Rotary Screw Compressor manual available for free PDF download: Technical Documentation Manual

KAESER ESD.2C Technical Documentation Manual

KAESER ESD.2C Technical Documentation Manual (414 pages)

Brand: KAESER | Category: Air Compressor | Size: 13 MB

Table of Contents

Table of Contents
1
Technical Documentation
2
Wiring Diagram
5
General
7
Electrical Equipment Identification
8
General Components
8
Sensors/Actuators
8
Terminal Strips/Plug-In Connections
8
Compressor Control
9
Power Unit Frequency Converter
9
Performance-Related Components
10
Contents
39
List of Illustrations
43
Table of Contents
43
List of Tables
45
Symbols and Labels
47
Tab. 1 Danger Levels and Their Definition (Personal Injury)
47
- Warnings
  47
- Other Alerts and Their Symbols
  48
- Potential Damage Warnings
  48
- Tab. 2 Danger Levels and Their Definition (Damage to Property)
  48
- Tab. 3 Nameplate
  50
- Tab. 4 Options
  50
  - Technical Specifications
    50
  - Weight
    50
- Tab. 5 Machine Weight
  51
- Tab. 6 Temperature
  51
- Tab. 7 Ambient Conditions
  51
- Tab. 9 Ambient Conditions
  51
  - Ventilation
    51
  - Mass Flow Rate
    52
  - Pressure
    52
- Tab. 8 Ventilation
  52
- Cooling Oil
  53
- Fig. 1 Mass Flow Rate and Regulating Range
  53
- Tab. 10 Mass Flow Rate and Regulating Range
  53
- Tab. 11 Mass Flow Rate
  53
- Motors and Power
  54
- Tab. 12 Cooling Oil Recommendation
  54
- Tab. 13 Cooling Oil Charge
  54
- Tab. 14 Compressor Drive Motor
  54
  - Basic Requirements
    55
  - Power Supply
    55
- Tab. 15 Fan Motor (Option K1)
  55
- Tab. 16 Fan Motor (Option K2/K9)
  55
- Tab. 17 Noise Emission [Db(A)]
  55
- Fig. 2 Correct Use of RCD
  56
  - Further Requirements
    56
  - Grounded Conductor Specification
    56
  - Power Supply Specifications
    56
  - Closed Cooling System
    57
  - Open Cooling System
    57
- Tab. 18 Connection Data
  57
  - Water Cooling
    57
  - Cooling Water Quality
    58
  - Design Data
    58
- Tab. 19 Cooling Water Temperature (ΔT=10K)
  58
- Tab. 20 Specification: Heat Exchanger (Option K2)
  58
  - Water Cooling (Plate-Type Heat Exchanger)
    58
  - Cooling Water Temperature Rise 15 K
    59
- Tab. 21 Cooling Water Quality
  59
- Tab. 22 Cooling Water Temperature (ΔT=10K)
  59
- Water Cooling (Bundled Pipe Heat Exchanger)
  59
- Tab. 23 Specification: Heat Exchanger (Option K9)
  60
- Tab. 24 Cooling Water Quality
  60
  - Improper Use
    61
  - Safety and Responsibility
    61
  - Specified Use
    61
  - User's Responsibilities
    61
  - Adherence to Inspection Schedules and Accident Prevention Regulations
    62
  - Defining Personnel
    62
  - Dangers
    63
  - Electricity
    63
  - Forces of Compression
    63
  - Safely Dealing with Sources of Danger
    63
- Tab. 25 Inspection Intervals According to Ordinance on Industrial Safety and Health
  63
  - Operating Fluids/Materials
    64
  - Rotating Components
    64
  - Unsuitable Spare Parts
    64
  - Conversion or Modification of the Machine
    65
  - Personal Protective Equipment
    65
  - Safe Machine Operation
    65
  - Transporting
    65
  - Commissioning, Operation and Maintenance
    66
  - Decommissioning, Storage, Disposal
    67
  - Organisational Measures
    67
  - Safety Devices
    67
- Tab. 26 Danger Areas
  67
- Fig. 3 Location of Safety Signs
  68
  - Correct Fire Fighting
    69
  - In Emergency
    69
- Tab. 27 Safety Signs
  69
- Fig. 4 Enclosure Overview
  72
- Function Description
  72
- Fig. 5 Machine Layout
  73
  - Floating Relay Contacts
    73
  - Frequency Converter
    73
- Fig. 6 Machine Mountings
  74
- Fig. 7 Cooling Air Filter Mat (Option K3)
  74
  - Operating Modes
    75
  - Variable Speed with Frequency Converter (SFC)
    75
- Fig. 8 Keys - Overview
  76
- Operating Panel SIGMA CONTROL 2
  76
- Tab. 28 Keys
  76
- Indicators - Overview
  77
- Tab. 29 Indicators
  77
- Typical Application
  78
Fig. 10 RFID Sensor Field
78
Fig. 11 Recommended Machine Placement and Dimensions [MM]
80
- Exhaust Duct Design
  81
- Gas Inlet Side
  81
- High Pressure Side
  81
- Operating the Machine in a Compressed Gas Network
  81
- Oil Return Line
  82
- Checking the Tightness
  84
Fig. 12 Gas Connection
84
Fig. 13 Connecting the Cooling Water
87
Filling with Cooling Oil
90
Fig. 14 Inlet Valve Oil Filling Port
91
Fig. 15 Coupling
91
Fig. 16 Switching on and off
94
Fig. 18 Switching on and off from a Remote Control Centre
96
Fig. 19 Switching on and off with the Clock
97
- Interpreting Operation Messages
  97
- Alarm Message
  98
Fig. 20 Acknowledging Messages
98
- Fault Recognition and Rectification
  99
- Other Faults
  99
- Tab. 36 Other Faults and Actions
  100
- Maintenance
  101
- Tab. 37 Advise Others that the Machine Is Being Serviced
  101
- Following the Maintenance Plan
  102
- Linde Regulations
  102
- Logging Maintenance Work
  102
- Regular Maintenance Tasks
  103
- Resetting Maintenance Interval Counters
  103
- Check the Oil Collecting Tank
  104
Fig. 21 Cooling Oil Collecting Tank
104
Fig. 22 Switching Cabinet Ventilation
105
Fig. 23 Cleaning the Cooler
106
- Water-Cooling Maintenance
  106
- Checking for Leaks
  107
- Cleaning or Renewing the Cooling Air Filter Mat
  107
Fig. 24 Cooling Air Filter Mat
107
Cleaning Cloths
108
Fig. 25 Compressor Motor Maintenance
108
- Checking the Coupling
  109
- Motor Running
  109
- Checking the Pressure Relief Valve
  110
Fig. 26 Checking the Coupling
110
- Checking the Cooling Oil Level
  111
- Checking the Overheating Safety Shutdown Function
  111
Fig. 27 Checking the Cooling Oil Level
112
Venting the Machine (De-Pressurising)
112
Fig. 28 Venting the Machine
113
- Vent Gas Manually from the Gas Cooler
  113
- Vent the Oil Separator Tank
  113
Fig. 29 Replenishing the Cooling Oil
114
Fig. 30 Changing the Cooling Oil, Oil Separator Tank
117
Draining the Oil from the Cooler
118
Fig. 31 Changing the Cooling Oil, Oil Cooler
118
Draining the Oil from the Airend
119
Fig. 32 Changing the Cooling Oil, Airend
119
Starting the Machine and Performing a Trial Run
119
Fig. 33 Changing the Oil Filter
120
Changing the Oil Separator Cartridge
121
Fig. 34 Open the Enclosure (Oil Separator Cartridge Changing)
122
Fig. 35 Changing the Oil Separator Cartridge
122
Opening the Machine Enclosure
122
Fig. 36 Open the Enclosure (Oil Separator Cartridge Changing)
123
Dimensions of the Flexible Pipe Connection
124
Fig. 37 Assembling Flexible Pipe Connections
124
- Documenting Maintenance and Service Work
  125
- Tab. 41 Logged Maintenance Tasks
  125
  - Note the Nameplate
    126
  - Ordering Consumable Parts and Operating Fluids/Materials
    126
- Tab. 42 Consumable Parts
  126
- Spares, Operating Materials, Service
  126
- Decommissioning, Storage and Transport
  128
- Packing
  128
- Putting out of Operation
  128
- Putting out of Operation for a Longer Period
  128
Fig. 38 Transport with a Forklift Truck
129
Disposal
130
Fig. 39 Transport with a Crane
130
- Pipeline and Instrument Flow Diagram (P&I Diagram)
  131
- Dimensional Drawing
  134
- Electrical Diagram
  142
- Important Settings
  176
- Optimizing the Brightness Settings
  177
- Optimizing the Contrast Settings
  177
- Setting the Contrast and the Brightness
  177
- KAESER Equipment Card
  179
- Log on with Equipment Card
  179
- Logging on with Equipment Card
  179
- RFID Reader
  180
- Adjusting the System Setpoint Pressure
  181
- Activating the «Clock» Key
  182
- Check Box Status
  182
- Entering Switching Points
  182
- Activating/Deactivating the Check Box
  185
- Changing the Control Mode
  188
- Assigning a Message to an Output
  189
- Maintenance Menu
  190
- Performing the Test
  192
- Safety Relief Valve Checking
  192
- Correct Conclusion of the Test
  193
- Interpreting Diagnostic Messages
  200
- Interpreting Fault Messages
  201
- Interpreting Warning Messages
  207
- Interpreting System Messages
  211
- Fig. 9 Indicators - Overview
  216
Fig. 17 Switching off in an Emergency
216
- Tab. 33 Machine Identification
  218
- Tab. 35 Machine Identification
  218
  - SIGMA CONTROL 2 Controller
    223
  - Technical Data
    223
  - User Interface with Display, CPU and Interfaces
    223
  - Identification with RFID Equipment Card
    224
  - Input/Output Modules
    224
  - Cable Lengths
    226
  - Degree of Protection, IOM
    226
  - IOM Dimensions
    226
  - Maximum Cable Lengths
    226
  - Resistance Thermometer
    227
  - Basic Instructions
    228
  - Main Control System (MCS)
    229
  - System Structure
    229
  - The Controller
    229
  - Operating Panel
    230
  - Header
    233
  - Lines 7 and 8: Machine State
    233
  - Active Line
    234
  - Main Menu
    234
  - Setting Parameters
    234
  - Access Rights
    235
  - Activating Keys with Check Boxes
    235
  - Resetting Current Parameters
    235
  - Checking the Machine Status with KAESER CONNECT
    236
  - KAESER CONNECT for SIGMA CONTROL 2
    236
  - Secure Storage of the RFID Equipment Cards
    236
  - Menus – Overview
    237
  - Menu Structure
    238
  - Status Menu
    241
  - Menu: Power Switching
    249
  - Operating Modes and Control Modes
    249
  - Control Modes
    250
  - Continuous
    251
  - Frequency-Controlled Drive (SFC)
    251
  - Quadro
    251
  - Vario
    251
  - MODULATING Control
    252
  - Maintaining Ambient Conditions
    253
  - Configuring the Controller
    255
  - Selecting Menu Options
    255
  - Changing the Display Language
    256
  - Display Language
    256
  - Back of the KAESER Equipment Card
    257
  - Generating a Password for the SIGMA CONTROL 2
    257
  - Noting the Number of the KAESER Equipment Card
    257
- Controlling Access to the SIGMA CONTROL 2 Via Manual Input
  259
- Checking/Setting the Time and Date
  261
- Generating a Password for KAESER CONNECT
  261
- Checking/Setting the Date
  262
- Setting Display Formats
  263
  - Setting the Time Format
    263
  - Time Formats
    263
  - Units of Pressure
    264
  - Display Illumination
    265
  - Setting the Display Illumination
    265
- Setting and Activating Summer/Winter Time
  266
- Using KAESER CONNECT
  266
- Calling up KAESER CONNECT for SIGMA CONTROL 2
  267
- Displaying the System Status
  268
- Display Graphs
  270
  - Arrow Keys
    271
  - Pressure/Temperature Graphs
    271
  - Zoom and Arrow Key Functions
    271
  - Arrow Keys and Functions
    272
- Displaying Messages
  272
- Creating Additional User Accounts
  273
- Viewing the IO Modules Assigment
  273
  - "Log on for Write Access" Window
    274
  - User Administration Menu
    274
  - Creating a New User
    275
  - Updating User Accounts
    275
- Settings
  276
- Closing KAESER CONNECT
  277
- Performing a Data Backup
  277
- Adjusting the Pressure Parameters of the Machine
  278
- Displaying Pressure Parameters
  279
  - Opening the Menu for Pressure Parameters
    279
  - Adjusting the System Setpoint Pressure: Pa and Pb
    280
- Configuring the Pressure Parameters for Compressors
  280
- Automatic Start/Stop in Programmed Clock Mode
  284
- Configuring Machine Start and Stop
  284
- Setting up the Holiday Period
  287
- Starting the Machine Remotely (Remote ON/OFF)
  288
- Activating/Deactivating the Idle Phase (Venting Period Function)
  291
- Activating/Deactivating and Adjusting the "Automatic Restart after a Power
  292
- Activating and Adjusting the Control Modes
  293
- Selecting a Control Mode
  294
- Adjusting the Idle Time of DUAL Mode
  295
- Adjusting the Minimum Running and Unloaded Period in QUADRO Control
  295
- Activating the Settings for the Refrigerated Dryer
  296
- Setting the CLOCK Mode
  297
- Output Messages
  298
- Fault in the Refrigerated Dryer – Activate Fault Mode
  299
- Configuring the Machine for Local Mode
  301
- Configuring the System Pressure Setpoint Changeover Using the Clock Program
  301
- Local Operating Mode (Local Mode)
  301
- Selecting the < Configuration ➙ Pressure Control ➙ Load Control > Menu
  301
  - Example of System Pressure Changeover Switching Points
    302
  - Deleting the Existing Clock Program
    303
- Configuring the System Pressure Setpoint Changeover Using the Clock
  304
  - Selecting the Operating Mode
    304
  - Setting Clock Periods Pa and Pb
    304
  - Selecting Local Mode
    305
  - Setting Starting Time for Pa or Pb
    305
- Configuring the Machine for Master Control
  306
- List of the Various Master Controllers
  306
- Configuring Profibus Mode (SIGMA AIR MANAGER or VESIS)
  307
- Configuring the Profibus Interface Without SIGMA AIR MANAGER or VESIS
  316
- Selecting the Profibus Interface
  316
- (Ethernet Interface)
  317
- Assigning the Slave Address
  317
- Configuring for Master Control of Two Machines in Master/Slave Operation
  317
- Configuring for Master Control Using the LOAD Remote Contact
  323
- Sigma Air Manager Basic)
  323
- Configuring for Master Control with Local/Load Remote Contact
  326
- Configuring Setpoint Pressure Pre-Selection Via Remote Contact
  329
- Configuring Master Control of Compressors Regulated by Pressure Switch
  331
- Examples of Time Settings for Equal Overall Load
  339
- Configuring Email
  340
- Configuring Input and Output Signals
  342
- Assigned Output Signals
  343
- Outputting Important Operational States of the Machine
  343
- Displaying Analog Input Values
  344
- Displaying Additional Binary Input Signals
  348
  - Assign and Activate the Input
    349
  - Entering the Message Text
    349
  - Setting the Time Delay
    350
  - Assign and Activate the Output
    351
  - Setting the Logic
    351
- Activating Remote Acknowledgement
  352
- Selecting the Message Type (Operational, Alarm, Warning)
  352
- Activating the "Remote Control" Key
  353
- Selecting the < Configuration ➙ Acknowledgement > Menu
  353
- Setting the Remote Acknowledgement Function
  353
- Assigning an Input
  354
- Linking to an External Pressure Transducer
  355
- Transmission of Sensor Value
  355
- Assigning an Input to an External Sensor
  356
- Selecting the < Configuration ➙ Pressure Control > Menu
  356
- Checklist of Installation Conditions
  357
- Commissioning the Machine
  357
- Operation
  359
- Switching off
  359
- Switching on
  359
- Switching on and off
  359
- Acknowledging Alarm and Warning Messages
  360
- Switching off in an Emergency and Switching on Again
  360
- Displaying Messages
  362
  - Information of a Message
    362
  - Message Type and Status Abbreviations
    362
  - Displaying the Last Fault/Warning
    363
  - Displaying the Message History
    363
- Selecting the Status Menu
  363
- Displaying the Current Operating Mode
  364
  - Operating Mode Display
    364
  - Abbreviation of Operating Modes
    365
- Adjusting Working Pressure
  365
- Possible Operating Modes
  365
- Displaying Analog Data
  366
- Displaying Operating Data
  367
- Interpreting Operation Messages
  368
- Setting the Maintenance Interval
  370
- Preparing the Test
  371
- Safety Relief Valve Checking
  371
- Checking the Temperature Sensor and Overheating Shutdown Function
  373
- Basic Instructions
  376
- Fault Recognition and Rectification
  376
- Interpreting Alarm Messages
  376
- Interpreting Diagnostic Messages
  381
- Interpreting System Messages
  381
- Interpreting Warning Messages
  381
- 10 Maintenance
  386
- Maintenance Work
  386
- 11 Spares, Operating Materials, Service
  387
- Displaying the Version Number, Machine Model, Part Number and Serial Number
  387
- Kaeser Air Service
  387
- Note the Nameplate
  387
- Service Addresses
  387
- 12 Decommissioning, Storage and Transport
  389
- Commissioning
  389
- Disposal
  389
- Packing
  389
- Storage
  389
- Transporting
  389
- Spare Parts
  391
- Machine Data
  401
- Spares for Service and Repair
  401
- ESD 442 SFC / 14 Bar
  403

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