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1. Gi g 8 10 50620 Connections SIGMA CONTROL BASIC Input I4 Pin 7 Supply 24 VDC Pin 9 1 Lay the cable a manner that it is not stressed when the control cabinet door is opened Strip 8 mm of insulation from the ends of the conductors 3 Use a screwdriver to open the spring loaded terminals and insert the ends of the conductors in the square openings above the corresponding terminals Secure the cable so there is no tension on the X2 plug 5 Sealthe cable gland against ingress of dirt or moisture Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 43 KAESER 6 Installation 67 Options 6 7 Options 6 7 1 Option H1 Anchoring the machine gt Use appropriate fixing bolts to anchor the machine Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13 3 6 7 2 Option W1 Connecting the external heat recovery system An unsuitable heat exchanger or incorrect installation may influence the cooling circuit Ii within the compressor Damage to the machine will follow gt Consult KAESER on suitable heat exchanger and have KAESER Service do the installation Service Manual Screw Compressor 44 ASK T SIGMA CONTROL BASIC 9 5717 20E KOMPRESSOREN T 1 Further information 9 5717 20E 7 initial Start up 7 1 Ensuring safety
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6. 10 Cooling oil charge Option 1 11 Mains supply 200V 3 50HZ nn 12 Mains 230 3 2 12 Mains supply 400 375 oot ane eee utere uda mettent rr edge c t edge edge 12 Supply conditions at 400 3 50 2 13 Mains supply 230 3 60 2 13 Mains supply 380 3 60 2 400 0000 13 440 3 oe tp eee o tp cit 13 M ins supply 460V 3 60Hz 2 oed eie nde Pet ee edis 13 Heat capacity option W1 14 Refrigeration dryer Model 14 Refrigeration dryer Compressed air system 14 Refrigeration dryer Refrigerant nnne 15 Inspection intervals according to 18 BENI EET 23 Safety obe ee qe reed ete ott a oet trc etna 24 Energy efficient control modes nnne nnn 31 Operating modes under MODULATING control 32 Refrigeration dryer control modes nennen nennen 32
7. 9792 abeyreq Jossesdwoy NINOS SIANO Ja Jp Joss sdwo 01490 4 passaiduo lt o lo Pipeline and instrument flow diagram diagram 13 Annex 13 1 O o o 5 9 5717 20E Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 94 Pipeline and instrument flow diagram diagram 13 Annex 13 1 KOMPRESSOREN Fe 20 1000 1XSV a 105 E series CTT sem T wea mg E 4 95 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 13 13 1 Pipeline and instrument flow diagram diagram O o o 5 es HE 01000 LS3S VJ Po ASV puaa wesbeig 134 yeusayxa waysks JaA028J jeay aJnssaJd uajs g 1 2 4 aJnssaJd 5 5 JaAQ0384 Bnjd mass uajs s 2 JeySou sayy aJnjeJaduia 10 4924915 aul 6l 0JjUO 9l BurjuaA 0Jju023 paulquio 1220 110 eso aJnssaJd N380SS 3440 aJs JV rues eme sess mes 9 5717 20E
8. Further information 9 5717 20E 5 3 5 3 Operating the machine in a compressed air network 3 Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely through the room 4 Ensure clean air in order to support the proper functioning of the machine Exhaust duct design The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by the duct design Any additional air resistance will reduce airflow and deteriorate machine cool ing gt Consult the KAESER service representative before deciding on m the design of the exhaust air ducting m the intersection between the machine and the exhaust air duct the length of the ducting m the number of duct bends design of flaps or shutters Use only motorised ventilation flaps and louvers on variable frequency drive SFC machines Flaps or shutters that are opened by the the action of airflow against the force of gravity do not open sufficiently at low cooling fan speeds Further information on installation of exhaust air ducts can be found in chapter 13 3 Operating the machine in a compressed air network If the machine is supplying an air network the network working pressure may not exceed 16 bar China 15 9 bar When charging a fully vented air system there is generally a very high rate of airflow through the air treatment devices These conditions are detrimental to correct a
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10. BIAS pajejnsui jeau rues eme sess esp 6007906 umen 0 248uJa8u 55 uesa z y pajoo2 jueJasDiJJay U34I s aJnssaJd JajllJ yuesaBbiujay J0jexipur aJnssaJd ajesuapuo 30 4145 Jojeuedas 4 435 jeau jueJaDiJjaJ jeau 0 9 5717 20E m Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 104 13 Ame 13 3 Dimensional drawing 13 3 Dimensional drawing Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 105 13 Ame 1 1441 13 3 Dimensional drawing KOMPRESSOREN T1041103 e Condensate drain G 1 4 Electrical connections Air discharge amp 1 1 4 ASK 27 35 Cooling air inlet Cooling air inlet Roblitz Schubart P 11012010 Freigeg 11012010 Gez Cooling air outlet Inlet air e 2 a 2 D a position marginally dependent on design CG Centre of gravity ATTENTION Pre
11. 9 5717 20E Tab 46 7 4 7 5 Material Precondition 7 4 Setting the overload protection cut out To be checked See Confirmed chapter gt 5 there sufficient cooling oil in the airend 7 5 gt 15 the machine firmly anchored to the floor 6 7 1 option H1 gt Are door interlock switches aligned and their function checked 7 7 gt all access doors closed and latched and all removable panels place and secured Installation conditions checklist Setting the overload protection cut out Electrical diagram 13 4 gives the location of the overload protection cut out With star delta starting the phase current is fed via the overload protection cut out This phase cur rent is 0 58 times the rated motor current To prevent the overload protection cut out from being triggered by voltage fluctuations tempera ture influences or component tolerances the setting can be higher than the arithmetical phase cur rent gt Check the overload protection cut out setting The overload protection cut out shuts the machine down despite being correctly set gt Contact KAESER Service Pouring cooling oil into the airend Before starting the compressor for the very first time and before re starting after a shutdown period of more than 3 months it is necessary to manually add a quantity of cooling oil into the airend In order to avoid that the cooling oil exceeds the permissible level drain the required qua
12. ESSERE 8 2 11 Cooling oil recommendation 8 2 12 Gooling Oil charge cea ned ede e up Diet 10 27193 Power SUpply iic n een td t pas EG uen eee tete 11 2 14 Power supply specifications 1 eene enne nenne 11 2 14 1 Mains frequency 50 2 2 4 1 0 1 1000000 nennen nnne nn nnne 12 2 14 2 Mains frequency 60 Hz 13 2 15 Avallable heat capacity ete eee ee Oe ete perdre 14 2 16 Refrigeration dryers 0 0 80000000 nnne nene nennen 14 Safety and Responsibility 9 1 16 3 2 Specified use Aedes eee ce eue ue uide 16 3 3 Improper use s nete s ett e ede ce oed eed pcd taps 16 3 4 User s Responsibilities 16 3 4 1 Observe statutory and universally accepted regulations 16 3 4 2 Qualified personnel enne nennen 17 3 4 8 Adhere to inspection schedules and accident prevention regulations 17 3 5 Dangets ete tene Hee re Ea ee dee 18 3 5 1 Safely dealing with sources of danger 18 3 5 2 Safe machine operation ssssssssssssssssssseeeeeeneeen nennen 20 3 5 8 Organisati
13. nennen 68 10 11 Checking the Excess Temperature Safety Shutdown Function 69 10 12 Checking the cooling oil nnne 69 10 13 Venting the machine de pressurising sese 70 10 14 Replenishing the cooling nennen 72 10 14 1 Venting the machine de pressurising 72 10 14 2 Topping up with cooling oil and trial 73 10 15 Changing the cooling 74 10 16 Changing the oll filter tees 77 10 17 Changing the separator cartridge 78 10 18 Refrigeration Dryer Maintenance 80 10 18 1 Cleaning the refrigerant condenser 80 10 18 2 Checking the condensate drain 80 10 18 3 Condensate drain maintenance 81 10 19 Documenting maintenance and service 83 Spares Operating Materials Service 11 1 Note the Nameplate 84 11 2 Ordering consumable parts and operating fluids materials 84 11 3 KAESER AIR SERVICE dee He 84 11 4 Service Addresses enne rennen
14. tare ee tee hae el tie lee rea ea 33 4 9 Keys and LEDs SIGMA CONTROL BASIC 33 4 10 Functional description SIGMA CONTROL BASIC 34 4 10 1 Display layout needed edere dee ee Pedo edet 34 4 10 2 Parameters Do ro ue ee oreet tp gente 35 4 10 3 Messages ned ede Deben e eesti deci ceeds 36 Installation and Operating Conditions 5 4 Ensuring eie 37 5 2 Installation conditions oi nece le Ee Ode teh eee 37 5 2 1 Determining location and clearances 37 5 2 2 Ensuring the machine room ventilation 38 5 2 8 Exhaust duct design ennt 39 5 3 Operating the machine in a compressed air network 39 Installation 0 1 Ensuring safety oue ea Ae cid I e GUERRE 40 6 2 Reporting Transport Damage 41 6 3 Connecting the machine with the compressed air network 41 6 4 Connecting the power supply 4 eene 41 6 4 1 Refrigeration dryer Connecting the transformer according to the mains 42 sus 6 5 Connecting the Condensate Drain 42 6 6 Connecting the remote LOAD IDLE control 43 0 4 Options e Eee ee eee des 44 6 7 1 Anchoring the machine 44 6 7 2 Connecti
15. Initial Start up Ensuring safety Here you will find instructions for a safe commissioning of the machine Warning instructions are located before a potentially dangerous task Disregard of warning instructions can cause serious injuries Complying with safety notes Disregard of safety notes can cause unforeseeable dangers gt Follow the instructions in chapter Safety and Responsibility gt Commissioning tasks may only be carried out by authorised personnel gt sure that no one is working on the machine gt Ensure that all service doors and panels are locked When working on live components Touching voltage carrying components can result in electric shocks burns or death gt Work on electrical equipment may only be carried out by authorised electricians gt Switch off and lock out the power supply isolating device and verify the absence of voltage gt Check that there is no voltage on floating relay contacts When working on the compressed air system Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death The following safety concerns relate to any work on components that could be under pressure gt Close shut off valves or otherwise isolate the machine from the compressed air network to en sure that no compressed air can flow back into the machine gt De pressurise all pressurised components and enclosures gt Check all hose coupli
16. KAESER KOMPRESSOREN 9 5717 20 E Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 110 13 4 Electrical Diagram 13 Annex KOMPRESSOREN 1 712511 3Jnp 242511 ysy savas Jossaidwo 101120145 jeJauab M ERE hp uworors Ja Jup uoijeJabiJjaJ uodo j Ja Jp soy Ajddns samod JaulJojsue J 71 404190 0 6 ujJea 31 2 SLOL 81546 10 OMVEL M ASOH 431014 2 Bulunseaw 5401294402 ul Bnjd 31 52 SLOL 81446 11 OMVIL 0 0 jeusayxa jeaJq Jo jou oq 31 52 SLOL 81545 11 9MV8L N ASOH aniq 10440 uoijejnsur Jayjaboy aq Ajuo fau 31 52 SLOL 81545 11 OMVEL M ASOH AGL abejjoA 104440 Duijeojj fau 3 paujJea pua ajBuis SPINI 104440 31 52 01 81545 11 DMY8L I ASOH 24060 abejjo 10440 Ayayes 8201 04 ISHNI 1011291049 x3ous pue saiddns 118 5 SJOJINPUOI 1 pJepuejs ijjnu iii NOLLN3LLV 51042 2 pajeubisap uou Joy jaulge3 10 4405 SUOILINILSUI eJauabD 111 Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 9 5717 20E 5 ENT 2020 248543 248543 UJoN
17. gt not direct the maintenance hose at persons while venting gt not inhale the oil mist Service Manual Screw Compressor 70 ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E Fig 25 o 10 Maintenance 10 13 Venting the machine de pressurising LN 10 50059 Venting the machine Hose coupling air cooler venting Shut off valve Pressure gauge Shut off valve open Hose coupling oil separator tank venting Shut off valve closed 6 Plug in nozzle Maintenance hose Isolating the machine from the air system gt Close the user s shut off valve between the machine and the air distribution network If no shut off valve is provided by the user the complete air network must be vented Venting the oil separator tank The oil circulation vents automatically as soon as the machine is stopped gt Check that the oil separator tank pressure gauge reads 0 bar The pressure gauge does not read 0 bar after automatic venting gt sure that the shut off valve is closed or that the complete air system is vented With the shut off valve closed insert the male hose fitting 6 into the hose coupling 3 Slowly open the shut off valve 7 to release pressure Disconnect the male hose fitting 6 and close the shut off valve 7 Y Y Y Y If manual venting does not bring the oil separator tank pressure gauge to zero Contact the KAESER Service Manually venting th
18. Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 749 433 3 Safety and Responsibility e u izklehid 38 Emergency situations Extinguishing substances gt Suitable extinguishing media Foam Carbon dioxide Sand or soil gt Unsuitable extinguishing media Strong jet of water 3 8 2 Treating injuries from handling cooling oil Eye contact Cooling oil can cause irritation gt Rinse open eyes thoroughly for a few minutes under running water Seek medical help if irritation persists Skin contact Cooling oil may irritate after prolonged contact gt Wash thoroughly with skin cleaner then with soap and water gt Contaminated clothing should be dry cleaned before reuse Inhalation Cooling oil mist may make breathing difficult gt Clear air passages of oil mist gt Seek medical help if difficulty with respiration continues Ingestion gt Wash out the mouth immediately gt Do not induce vomiting gt Seek medical aid 3 8 3 Injury from Handling Refrigerant Eye contact Severe eye irritation watering reddening and swelling of the eyelids Risk of caustic burns and frostbite gt Open eyelids wide to allow product to evaporate gt Hold the eyelid wide and rinse the eye with running water gt Consult an ophthalmologist if you experience lasting pains Skin contact Initially a sensation of chill skin may redden subsequently Risk of frostbite gt Allow the produ
19. A filter mat is placed behind every ventilation grille Filter mats protect the control cabinet from in gress of dirt If the filter mats are clogged adequate cooling of the components is no longer ensur ed In such a case clean or replace the filter mats Warm water and household detergent Spare parts as required The power supply isolating device is switched off the device is locked off the absence of any voltage has been verified The machine has cooled down Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 63 KAESER 10 Maintenance 10 5 Cooler maintenance 10 0057 Fig 20 Switching cabinet ventilation 1 Ventilation grille Filter mat 1 Carefully remove the ventilation grille and take out the filter mat 2 Beat the mat or use a vacuum cleaner to remove loose dirt If necessary wash with lukewarm water and household detergent 3 Change the filter mat if cleaning is not possible or if the change interval has expired 4 Insert the filter mat in the frame and latch in the ventilation grille 10 5 Cooler maintenance Regular cleaning of the cooler ensures reliable cooling of the machine and the compressed air The frequency is mainly dependent on local operating conditions A leaking cooler results in loss of cooling oil and compressed air Clogged coolers are indicative of unfavourable ambient conditions Such ambient conditions clog the cooling air ducts
20. List of Tables Danger levels and their definition personal injury 1 Danger levels and their definition damage to property 2 Nameplate EN 4 Optlons rd Hd nette tq tee ee 4 PEE 5 E 5 AMIDIGME COMGITIONS PE 5 Overview Ventilation 50 2 6 Overview Ventilation 60 2 2 2 6 0000 nnn nete 6 Pressure relief valve activating pressure 50 2 7 Pressure relief valve activating pressure 60 2 7 Delivery 50 Hz Re ee eec ette teet leet cese eee Tesco e Eee 7 Delivery 60 TAZ osa onde d ca tpe e etse eds 7 Noise emission dB A rre cite cct dine Pete rer De tec Dt pec vectes 8 T 8 Drive motor nominal speed at 50 2 4 22222222 1 0 000 0 8 Drive motor nominal speed at 60 Hz 8 Cooling oil recommendation 9 Cooling oil recommendation food processing 9 Cooling oil recommendation machines for snow CANNONS 10 Cooling oil charge Option K1
21. t tese dace tectus pauco 33 INGICALONS Me LEE 34 E E SEEE E 34 i um 35 Re commissioning after storage 4 nnne nennen nennen nnns 46 Installation conditions 46 MODULATING control Setting the Shut off valve 48 Switching off with without run on time 53 Alarm INGICAHONS PE 56 Warning MESSAGES EE 57 Other faults and 58 Regular Maintenance 60 Cooling Change intervals 62 62 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC vii KAESER List of Tables KOMPRESSOREN 55 Permissible cooling oil level under LOAD 69 Tab 56 Logged maintenance tasks 83 Tab 57 Consumable parts stesse deg 84 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KOMPRESSOREN 9 5717 20E 1 1 1 2 1 3 1 4 1 4 1 Tab 1 1 Regarding this document 1 1 Using this document Regarding this document Using this document The operating manual is a component of the product
22. 85 11 5 Spare Parts for Service and Repair 85 Decommissioning Storage and Transport 12 1 Putting Out of Operation ene 90 12 2 PACKING 5 ce USt 90 12 3 90 12 4 TANS POM uiuere DH 91 12 41 91 12 4 2 Transport with a forklift truck 91 124 3 Transport with a Crane 2 npn aaa 91 12 5 Disposal 92 13 1 Pipeline and instrument flow diagram 1 diagram 93 13 2 Pipeline and instrument flow diagram P amp I diagram MODULATING control 99 13 3 Dimensional drawing 105 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC KAESER Contents KOMPRESSOREN 13 4 Electrical Diagram ouod tede cm anaa 108 Service Manual Screw Compressor IV ASK T SIGMA CONTROL BASIC 9_5717 20 E KAESER KOMPRESSOREN 9 5717 20E Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig List of Illustrations Maximum relative humidity of intake air 6 Lo
23. Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER Contents KOMPRESSOREN 9_5717 20 E 10 11 12 13 9 2 Alarm messages machine shut down 56 9 3 Warning messages dec bd e Ere 57 9 42 Other Faults De MB 58 Maintenance 10 1 Ensuring safety x DESEE LN UU 59 10 2 Following the maintenance plan 60 10 2 1 Logging maintenance work 60 10 2 2 Resetting maintenance interval counters 60 10 2 3 Regular Maintenance 60 10 2 4 Cooling oil Change interval 084 61 10 2 5 Regular service tasks esee aet tae 62 10 3 Cooler Cleaning or Renewing the Filter Mats 62 10 4 Control cabinet Clean or renew the filter mat 63 10 5 Gooler 64 10 6 Maintaining the external heat recovery system 65 10 7 Air Filter Maintenance 20 000012 00000000000100000000000000 000 66 10 8 Compressor motor maintenance 4 eene nee 66 10 9 Maintaining the Drive Belts 67 10 10 Testing the pressure relief valve
24. o o m oc x 121 Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 9 5717 20E Kjddns TET Uy Num nen zer pua Treo ysy 591485 Jossajduo LL wow fi ueJBeip 1 5 15 4 lt 31219 4 19 31219 1 19 VA0IL al V 09 AI r V 09l 3 V 09 I 220 A005 2504 A005 Pi 204 A005 hive 2 04 A005 quu zxL Mojja A uaaJb Qus zx quus zxL Qus zx Je0L A005 Je0L A008 Je0L A005 Je0L A008 42219 42219 uug x 2219 2219 uug xi V S0 ADEZ VLIZ ASL 50 A0tZ _ _ 990 paysn pe _ _ VSS 0 _ _ 9970 _ _ VSS 0 5 71 9 0 5 0 71 90 60 71 90 570 71 ves o ss o 1 9 4 19 31219 34219 VAO09 VAO09 VAOSL NES 2 04 A005 LILL 2 01 A005 NINE 304 A005 zx Moja uaaub quus zx uaaub zx Je0L A008 Je0L A005 20 4 A008 2219 42219 uug x 2219 x VL9 ASL m lt lo lun gt 250 13 4 Electrical Diagram 13 Annex _ _ VSS 0 paysnfpe _ _ Vi pays
25. 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1926 1CD00 3RT1926 1CD00 3RT1926 1CD00 option T3 3RT1016 1AP01 3RT1016 1AP01 3RT1016 1AP01 3RT1016 1AP01 3RT1016 1AP01 Interference suppressor 7 3140 01760 7 3140 01760 7 3140 01760 Siemens 3RT1916 1CD00 3RT4916 1CD00 3RT1916 1CD00 3RT1916 1CD00 3RT1916 1CD00 Overload relay B25 7 6873 00220 7 6873 00220 7 6873 00200 7 6873 00200 7 6873 00200 3RB2046 1EBO 3RB2046 1EB0 3RB2036 1UBO 3RB2036 1UBO 3RB2036 1UB0 Equipment parts list Compressor ser KOMPRESSOREN Ursprung KAESER 25 100A 25 100A 12 5 50A 12 5 50A 12 5 50A setting 54 A 50Hz setting 47A 50Hz setting 30A setting 27A setting 25A Siemens setting 50A 60 Hz Overload protection switch F11 7 6860 00100 7 6860 00100 7 6860 00070 7 6860 00070 7 6860 00070 3RV1011 0K A10 3RV1011 0K A10 3RV1011 0GA10 3RV1011 0GA10 3RV1011 0GA10 0 9 125A 0 9 125A 0 45 0 63A 0 45 0 63 0 45 0 63 Siemens setting 1 setting 1 setting 0 55 setting 0 55 setting 0 55 i Overload protection switch F30 7 6860 00190 7 6860 00180 7 6860 00180 7 6860 00180 7 6860 00180 E option T3 3RV1011 1JA10 3RV1011 1HA10 3RV1011 1HA10 3RV1011 1HA10 3RV1011 1HA10 R 7 10 5 5 5 5 8 5 5 5 5 Siemens setting 8 8 setting 7 setting 7 setting 7 setting 7A Siemens 5
26. 80 100 100 Supply cable mm 4x25 4x35 4x35 Current input A 69 83 91 Mains supply 200V 3 50Hz Rated voltage 230V 10 3 50Hz ASK 27 ASK 32 ASK 35 Backup fuse A 80 80 100 Supply cable mm 4x25 4x25 4x35 Current input A 61 72 79 Mains supply 230V 3 50Hz Rated voltage 400V 10 3 50Hz ASK 27 ASK 32 ASK 35 Backup fuse A 40 50 50 Supply cable mm 4x10 4x10 4x10 Current input A 35 38 45 Mains supply 400V 3 50Hz Network conditions The network conditions apply to machines connected to public mains supplies with the following characteristics Mains frequency 50 Hz Voltage between exterior and neutral lines 220 V 250 V Voltage between the exterior lines 380 V 440 V They do not apply to private power supplies within industrial areas isolated from the public mains Machines with current consumption gt 16 A lt 75 A comply fully with IEC 61000 3 12 The machines listed in table are intended for operation with a public power supply with a network impedance at the transfer point house connection of maximum Zmax Ohm Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20 E 42 14 42 9 5717 20E Tab 26 2 14 2 Tab 27 Tab 28 Tab 29 Technical Specifications 2 14 Power supply specifications The operator must ensure that the machines are only connected to a network that meets these re quirements If necessary ask the local electrici
27. ASK T SIGMA CONTROL BASIC Service Manual 100 13 2 Pipeline and instrument flow diagram P amp l diagram MODULATING control 13 Annex KOMPRESSOREN 3 20 2000 113SVJ 20007 bunvapuy e 4 6002906 unea 1 1 1 1 1 101 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 13 13 2 Pipeline and instrument flow diagram P amp l diagram MODULATING control O o o 5 20 2000 113S VJ ysy N380SS3UdWON 1 13d 3S 1VM Jeusayxa uajs s KJaA038J JeaH 9 155944 5 Ja3npsueJj aJnssaJd wajsks JaA028J 1 bnjd MaJ3g uajs s gt 1 4 jejsouJau aJnjeJaduis 10 0Jju02 jeuon2aJl Z 91270 apou Op4vA 40 paso 3 IMLA 440 4NYS 1044402 ui IMPA jjo jnug 48jj0 4u023 4924915 aul 440 4NYS 104440 el 0 4 02 3 ZZON dey jung eme sess hmm 9 5717 20E 0 Burdno3 5 48 002 x3aup eJnssaJd WNWIUI
28. Environment protection The operation of this machine may cause dangers for the environment gt not allow cooling oil to escape to the environment or into the sewage system gt Store and dispose of operating materials and replaced parts in accordance with local environ ment protection regulations gt Observe national regulations This applies particularly to parts contaminated with compressor cooling oil Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E ESER 4 Design and Function 9 5717 20E 4 1 Fig 3 4 1 Enclosure Design and Function Enclosure 04 0100 Enclosure overview 1 X Control cabinet door Sight glass Oil level indicator Latch Sight glass Condensate drain Panel removable When closed the enclosure serves various functions Sound insulation Protection against contact with components m Cooling air flow The enclosure is not suitable for the following uses m Walking on standing or sitting on 5 resting place or storage of any kind of load Safe and reliable operation is only assured with the enclosure closed Access doors are hinged to swing open and removable panels can be lifted off Latches are released by a key supplied with the machine Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 27 KAESER KOMPRESSOREN 4 2 Fig 4 28 4 J Design and Function 4 2 Machine function Machine f
29. Fill with cooling oil and test run as described in section 10 14 2 Venting the machine de pressurising Venting takes place in three stages Isolate the compressor from the air system Vent the oil separator tank Manually vent the air cooler CAUTION Escaping oil mist is damaging to health gt Do not direct the maintenance hose at persons while venting gt Do not inhale the oil mist Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20 E KAESER KOMPRESSOREN 9 5717 20E 10 14 2 10 10 14 Replenishing the cooling Isolating the machine from the air system gt Close the user s shut off valve between the machine and the air distribution network If no shut off valve is provided by the user the complete air network must be vented Venting the oil separator tank The oil circulation vents automatically as soon as the machine is stopped gt Check that the oil separator tank pressure gauge reads 0 bar The pressure gauge does not read 0 bar after automatic venting gt Make sure that the shut off valve is closed or that the complete air system is vented With the shut off valve closed insert the male hose fitting 6 into the hose coupling 3 Slowly open the shut off valve 7 to release pressure Disconnect the male hose fitting 6 and close the shut off valve 7 Y Y Y Y If manual venting does not bring the oil separator tank pressure
30. It describes the machine as it was at the time of first delivery after manufacture gt Keep the operating manual in a safe place throughout the life of the machine gt Supply any successive owner or user with this operating manual gt Please insert any amendment or revision of the operating manual sent to you gt Enter details from the machine nameplate and individual items of equipment in the table in chapter 2 Further documents Further documents included with this operating manual are Certificate of acceptance operating instructions for the pressure vessel Declaration of Conformity in accordance with the applicable directive Missing documents can be requested from KAESER gt sure all documents are complete and observe the instructions contained in them gt sure you provide the data from the nameplate when ordering documents Copyright This service manual is copyright protected Queries regarding use or duplication of the documenta tion should be referred to KAESER Correct use of information will be fully supported Symbols and labels gt Please note the symbols and labels used in this document Warnings Warning notices indicate dangers that may result in injury when disregarded Warning notices indicate three levels of danger identified by the corresponding signal word Signal term Meaning Consequences of disregard DANGER Warns of an imminent danger Will result in death or severe inj
31. Tab 52 Regular Maintenance Tasks 10 2 4 Cooling oil Change interval Duty cycles and ambient conditions are important factors influencing the number and length of the oil change intervals KAESER Service will support you in determining suitable intervals and provide information on il the possibilities of oil analysis gt Observe national regulations regarding the use of cooling oil in oil injected rotary screw com pressors Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 61 KAESER KOMPRESSOREN 62 Tab 53 10 2 5 Tab 54 10 3 Material Precondition 10 Maintenance 10 3 Cooler Cleaning or Renewing the Filter Mats gt Check operating conditions and adjust intervals as necessary log the results in table 53 for fu ture reference Maximum permissible oil change interval operating hours years SIGMA FLUID Favourable operating Unfavourable operat operating condi conditions ing conditions tions S 460 6 000 2 4 000 1 5 570 6 000 2 4 000 1 MOL 3 000 1 2 000 1 FG 460 3 000 1 2 000 1 FG 680 3 000 1 2 000 1 PANOLIN HLP SYNTH 3 000 1 2 000 1 46 Cool to moderate ambient temperatures low humidity high duty cycle Changing intervals of gt 6000 operating hours are not permissible without an oil analysis Cooling oil Change intervals Regular service tasks The table below lists necessary service tasks gt Only an authorised KAESER Service Technician s
32. compressed air opening partially Venting valve not closing Leaks in the pressure system Air consumption is greater than the capacity of the compressor Hose coupling or maintenance hose still plugged into the quick release coupling on the oil separator tank Cooling oil runs out of the air fil Oil level in the oil separator ter tank too high Inlet valve defective Compressor switches between Air receiver too small LOAD and IDLE more than R Airflow into the compressed air twice per minute network restricted The differential between cut in and cut out pressure too is small Cooling oil leaking into the floor Hose coupling or maintenance pan hose still plugged into the quick release coupling on the oil separator tank Oil cooler leaking Leaking joints Cooling oil consumption too Unsuitable oil is being used high Oil separator cartridge split Oil level in the oil separator tank too high return line clogged Other faults and actions Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC Remedy Call KAESER service represen tative Call KAESER service represen tative Check pipework and connec tions for leaks and tighten any loose fittings Check the air system for leaks Shut down the consumer s Remove coupling or mainte nance hose Drain off oil until the correct lev el is reached Call KAESER service represen tative Increase size of ai
33. dB A Noise emission dB A Mains frequency ASK 27 ASK 32 ASK 35 50 Hz 65 67 69 60 Hz 67 69 71 Noise pressure level as per ISO 2151 and the basic standard ISO 9614 2 tolerance 3 dB A at maximum machine working pressure Noise emission dB A Motors and Power Drive motor ASK 27 ASK 32 ASK 35 Rated power kW 15 0 18 5 22 0 Enclosure protection IP 55 IP 55 IP 55 Drive motor Rated speed min 50 Hz mains frequency Maximum working pres ASK 27 ASK 32 ASK 35 sure bar 8 0 2945 2950 2940 11 0 2945 2950 2940 15 0 2945 2950 2940 Drive motor nominal speed at 50 Hz Rated speed min 60 Hz mains frequency Maximum working pres ASK 27 ASK 32 ASK 35 sure bar 8 5 3555 3560 3555 11 0 3555 3560 3555 15 0 3555 3560 3555 Drive motor nominal speed at 60 Hz Cooling oil recommendation A sticker showing the type of oil filled is to be found near the oil separator filling port Information on ordering cooling oil is found in chapter 11 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 14 14 42 9 5717 20E Tab 18 Technical Specifications 2 11 Cooling oil recommendation Cooling oils for general applications Description Application Approval Viscosity at 40 Viscosity at 100 C Flash point Density at 15 Pour point Demulsibility at 54 C SIGMA FLUID MOL S 460 Mineral oil Silicone free synthetic oil Standard
34. preparation No personnel during transport Beneath the lifted machine No personnel Installation Within the machine Installation personnel Within 1 m radius of the machine and its sup ply cables Operation Within a 1 m radius of the machine Operating personnel Maintenance Within the machine Maintenance personnel Within a 1 m radius of the machine Tab 36 Danger Areas 3 6 Safety devices Various safety devices ensure safe working with the machine gt gt gt gt Do not change bypass or disable safety devices Regularly check safety devices for their correct function Do not remove or obliterate labels and notices Ensure that labels and notices are clearly legible Further information More information on safety devices is contained in chapter 4 section 4 8 3 7 Safety signs The diagram shows the positions of safety signs on the machine The table lists the various safety signs used and their meanings bh 03 1062 Fig 2 Location of safety signs Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 23 KAESER KOMPRESSOREN Tab 37 3 8 3 8 1 24 3 Safety and Responsibility 3 8 Emergency situations Item Symbol Meaning 1 Danger of fatal injury from electric shock gt Before starting any work on electrical equipment Switch off and lock out th
35. 10 Maintenance 10 15 Changing the cooling oil 2 Open the user s shut off valve between the machine and the air distribution network 3 After approx 10 minutes of operation Check the cooling oil level and top up if necessary 4 Switch off the machine and check visually for leaks Changing the cooling oil Drain the oil completely from the following components Oil separator tank Thermostatic valve Option W1 Always change the oil filter and oil separator cartridge when changing the oil Compressed air helps to expel the oil This compressed air can be taken either from the compres sor itself or from an external source An external source of compressed air is necessary in the following cases machine is not operational machine is to be restarted after a long period of standstill The machine must be isolated from the compressed air network and completely vented be fore undertaking any work on the pressure system Cooling oil Cooling oil receptacle The maintenance hose with hose coupling and shut off valve is stowed beneath the oil separator tank CAUTION There is risk of burns from hot components and oil gt Wear long sleeved clothing and gloves Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN Fig 27 9 5717 20E 10 Maintenance 10 15 Changing the cooling oil Changing the cooling oil oil separator tank Hose coupl
36. 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 an Interference suppressor 7 314 0 00920 7 3140 01400 7 3140 01400 7 3140 01400 7 3150 01400 t 2 option T3 3RT1016 1AP 01 3RT1016 1AP 01 3RT1016 1AP01 3RT1016 1AP01 3RT1016 1AP01 gt Interference suppressor 7 314 0 01760 7 3140 01760 Siemens 3RT1916 1CD00 3RT1916 1CD00 3RT1916 1CD00 3RT1916 1CD00 3RT1916 1CD00 TES Overload relay B25 7 6873 00200 7 6873 00200 7 6873 00200 7 6873 00190 7 6873 00190 WZ 3RB2036 1UB0 3RB2036 1UB0 3RB2036 1UB0 3RB2026 10B0 3RB2026 10B0 12 5 50 12 5 50 12 5 50 6 25 6 25 setting 20 50Hz setting 35 50 Hz setting 23 setting 20 setting 19 EX Siemens setting 37A 60Hz s 8 Overload protection switch F11 7 6860 00100 7 6860 00100 7 6860 00070 7 6860 00070 7 6860 00070 1011 0 10 3RV1011 0KA10 3RV1011 0GA10 3RV1011 0GA10 3RV1011 0GA10 0 9 1 25 0 9 1 25 0 45 0 63A 0 45 0 63 A 0 45 0 63 A Siemens setting 1 setting 1 setting 0 55A setting 0 55A setting 0 55A Overload protection switch F30 7 6860 00190 7 6860 00180 7 6860 00180 7 6860 00180 7 6860 00180 3RV1011 1JA10 3RV1011 1HA10 3RV1011 1HA10 3RV1011 1HA10 3RV1011 1HA10 7 10 5 5 BA 5 5 8 A 5 5 8 A 5 5 8 A E Siemens setting 8 8A setting 7A setting 7A setting 7A setting 7A R Siemens 55Y4105 7 0 5 55 4105 7 0 5 Transformer 11 7 6852 00010 7 6852 00010 7 6843 00010 7 6843 00010 7 6852 00010 B0609057 B0609057
37. 50Hz 440V 10 60Hz 200 10 60Hz 230V 210 60Hz 460V 210 60Hz Motor M1 18 5 kW 18 5 kW 18 5 kW 18 5 kW 18 5kW diagram 2 Sht 1 diagram 1 Sht 1 50Hz diagram 1 Sht 1 diagram 1 Sht 1 diagram 1 Sht 1 diagram 2 Sht 1 60 Hz Siemens 3RA1943 3L 3RV1935 5A 3RV1935 5A 3RV1935 5A 3RV1935 5A Terminal strips X1 option T3 X11 X31 3RT1044 1AL20 3RT1036 1AL20 3RT1034 1AL20 3RT1034 1AL20 3RT1034 1AL20 3RH1921 1XA20 0PA0 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 RT1936 1CD00 3RT1936 1CD00 3RT1044 1AL20 3RT1036 1AL20 3RT1034 1AL20 3RT1034 1AL20 3RT1034 1AL20 3RH1921 1DA11 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 Contactor 03 7 6867 0 7 6867 0 7 6865 0 7 6865 0 7 6865 0 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA 10 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1926 1CD00 3RT1926 1CD00 3RT1926 1CD00 option T3 3RT1016 1AP01 3RT1016 1AP01 3RT1016 1AP01 3RT1016 1AP01 3RT1016 1AP01 Interference suppressor 7 3140 01760 7 3140 01760 7 3140 01760 Siemens 3RT1916 1CD00 3RT1916 1CD00 3RT1916 1CD00 3RT1916 1CD00 3RT1916 1CD00 Overload relay B25 7 6873 00220 7 6873 00200 7 6873 00200 7 6873 00200 7 6873 00200 3RB2046 1EBO 3RB2036 1UB0 3RB2036 1UB0 3RB2036 1UB0 3RB2036 1UB0 25 100
38. 7 2292 10060 option T3 B0406058 USTE1600 B0312005 USTE1600 8 0A 7 0A 6 4 7 0 Block diagram 3 Sht 8 diagram 2 Sht 8 diagram 1 Sht 8 diagram 2 Sht 8 05 10 2011 connection W13 7 3140 03180 7 3140 02120 7 3140 02120 7 3140 02120 7 3140 02120 Siemens 3RA1943 3D 3 1935 1 3RV1935 1A 3RV1935 1A 3RV1935 1A Datum Bearbeiter Sitter connection W14 1 16 black 1 6 black 1 6 black 1x6mm black Siemens 500V 70 C 3RV1935 1A 500 V 70 C 500 V 70 C 500 V 70 C 500 V 90 C 500 V 90 C 500 V 90 C 500 V 90 500 V 90 C Siemens SIGMA CONTROL BASIC SIGMA CONTROL BASIC SIGMA CONTROL BASIC SIGMA CONTROL BASIC SIGMA CONTROL BASIC Switching element Schlegel 7 3218 0 MTHOO 3218 0 MTHOO 7 3218 0 MTHOO 7 3218 0 MTHOO 7 3218 0 MTHOO Control cabinet KAESER 212905 0 12905 0 212905 0 212905 0 212905 0 EMERGENCY STOP pushbutton S1 7 3217 0 QRUV 3217 0 QRUV 7 3217 0 7 3217 0 QRUV 7 3217 0 QRUV Mounting plate KAESER 209602 0 09602 0 209602 0 209602 0 209602 0 C nderung Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 13 4 13 Annex 134 Electrical Diagram Equipment parts list 5 35 5 35 machine power supply 200V 210 50Hz 230V 210 50Hz 380V 210 60Hz 400V 210 50Hz 10 60Hz 200V 210 60Hz 230V 210 60Hz 10 60Hz Motor 22kW 22kW 22kW 22k
39. ASK 32 ASK 35 Inlet aperture Z see fig 0 6 0 6 0 7 ure 9 m Forced ventilation with 8000 9000 10000 exhaust fan Flow rate m h at 100 Pa Tab 9 Overview Ventilation 60 2 2 7 Pressure Maximum working pressure see nameplate Service Manual Screw Compressor 6 ASK T SIGMA CONTROL BASIC 9 5717 20E 7744 11 2 Technical Specifications 28 Delivery Pressure relief valve activating pressure at 50Hz bar Maximum working over ASK 27 ASK 32 ASK 35 pressure bar 8 0 10 10 10 11 0 13 13 13 15 0 16 16 16 China 15 9 Tab 10 Pressure relief valve activating pressure 50Hz Pressure relief valve activating pressure at 60 Hz bar Maximum working over ASK 27 ASK 32 ASK 35 pressure bar 8 5 10 10 10 11 0 13 13 13 15 0 16 16 16 Tab 11 Pressure relief valve activating pressure 60Hz 2 8 Delivery Delivery m min at 50 Hz mains frequency Maximum working pres ASK 27 ASK 32 ASK 35 sure bar 8 0 2 60 3 15 3 50 11 0 2 17 2 65 2 95 15 0 1 68 2 03 2 35 Tab 12 Delivery 50 Hz Delivery m min at 60 Hz mains frequency Maximum working pres ASK 27 ASK 32 ASK 35 sure bar 8 5 2 60 3 15 3 50 11 0 2 17 2 65 2 95 15 0 1 68 2 03 2 35 Tab 13 Delivery 60 Hz Service Manual Screw Compressor 9 5717 20 E ASK T SIGMA CONTROL BASIC KAESER KOMPRESSOREN 2 9 Tab 14 2 10 2 10 1 Tab 15 Tab 16 Tab 17 2 11 2 Technical Specifications 2 9 Noise emission
40. B0609052 B0609052 B0609057 160 VA 160 VA 160 VA 160 V 160 VA diagram 1 Sht 7 diagram 2 Sht 7 diagram 3 Sht 7 diagram 4 Sht 7 diagram 6 7 Sht 7 Block 3 15 3 15A 250V 5 315A 250 _ 5 3 154 250 T3 15H 315A 250V _ 3 15A 250V b Transformer T30 7 3717 00260 7 2292 10060 7 3717 00240 7 2292 10060 80406058 USTE1600 B0312005 USTE1600 80 70A 6 4 70A Block diagram 3 Sht 8 diagram 2 Sht 8 diagram 1 Sht 8 diagram 2 Sht 8 Siemens 3RV1935 1A 3RV1935 1A 3RV1935 1A 3RT1926 4CC20 3RT1926 4CC20 a connection W14 1 6 black 1 6 black 5 Siemens 3RV1935 1A 500 V 70 C 500 V 70 3RA1923 3D 3RA1923 3D HE z cables W19 1 7 2 1 16 mm 1x16 mm 1x6 mm 1x6 mm 1x6 mm 88 els Compressor control K20 7 1005 7 1005 5 Siemens SIGMA CONTROL BASIC SIGMA CONTROL BASIC 516 CONTROL BASIC SIGMA CONTROL BASIC SIGMA CONTROL BASIC EMERGENCY STOP pushbutton S1 zo ___ 272 7 o raaro zoa ___ Switching element Schlegel 7 3218 0 MTHOO 7 3218 0 MTHOO Control cabinet KAESER Mounting plate KAESER 209602 0 209602 0 E H Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 13 Amex 13 4 Electrical Diagram 114 Equipment parts list ASK 32 ASK 32 T machine power supply 200V 10 50Hz 230V 210 50Hz 380V 210 60Hz 400V 10
41. Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 4 3 Fig 5 4 4 4 5 4 5 1 Fig 6 9 5717 20E 4 Design and Function 4 3 Refrigeration dryer Refrigeration dryer 04 50102 Refrigeration dryer 10 Refrigeration dryer Condensate drain The downstream refrigeration dryer removes moisture from the compressed air The condensate drain ejects the precipitate Floating relay contacts Floating relay contacts are provided for the transfer of signals messages Information on location loading capacity and type of message or signal is found in the electrical diagram If the floating relay contacts are connected to an external voltage source voltage may be present even when the machine is isolated from the power supply Options The options available for your machine are described below Option H1 Machine mountings These mountings allow the machine to be anchored firmly to the floor 04 50034 Machine mountings Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 29 KAESER KOMPRESSOREN 4 5 2 4 6 4 6 1 30 4 J Design and Function 4 6 Operating modes and control modes Option W1 Prepared for external heat recovery The cooling oil circuit includes 2 valves regulating the cooling oil temperature Combination valve Oil cooler temperature regulator Thermostatic valve Heat recovery system oil temperature regulato
42. any damaged belts immediately Changing the belts 1 Loosen the locking nut 2 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 67 KAESER KOMPRESSOREN 10 10 Precondition Precondition 68 10 Maintenance 10 10 Testing the pressure relief valve 2 Turn adjusting nut 1 to loosen the tension on the belts until they can be removed from the pul ley 3 Install the new set of belts and use the adjusting nut 1 to adjust tension until the marker pin reaches the lower end of the elongated hole 4 Tighten the locking nut 2 Testing the pressure relief valve In order to check the pressure relief valve the machine s working pressure is raised above the blowoff pressure of the valve The controller is switched to pressure relief valve checking mode to carry out this check This checking mode is intended for machines with maximum permissible working pressure less than 15 bar Pressure relief valves in machines with permissible working pressures higher than 15 bar must be removed from the machine and tested on a special rig Blow off protection and air system pressure monitoring are switched off during the test gt Never operate the machine without correctly functioning pressure relief valves gt Relief valves on machines with maximum permissible working pressure of 15 bar should be tested only by KAESER Service The machine must be isolated from the compressed air network and completely vent
43. are permanently greased Re greasing is not necessary gt Have the motor bearings checked by an authorised KAESER Service Service Manual Screw Compressor 66 ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E 10 9 Material Precondition A Fig 23 10 Maintenance 10 9 Maintaining the Drive Belts Maintaining the Drive Belts Spare parts if required The power supply disconnecting isolating device is switched off the disconnect device is locked in the off position a check has been made that no voltage is present The machine has cooled down WARNING Touching rotating drive belts may result in severe bruising or even loss of limb or extremi ties gt Switch off and lock out the power supply disconnecting isolating device and check that no voltage is present 10 50071 Drive Belt Maintenance Adjusting nut Locking nut Marker pin the illustration shows that belt tensioning is required Checking the belt tension and adjustment The tensioning device uses spring force to apply correct tension to the belts Adjust the tension when the marker pin reaches the top of the elongated hole 1 Loosen the locking nut 2 2 Use the adjusting nut 1 to adjust spring tension until the marker pin reaches the lower end of the elongated hole 3 Tighten the locking nut 2 Visual damage check 1 Turn the pulley by hand so that all of the belt can be inspected for damage 2 Change
44. author ised electrician 2 Carry out safety measures as stipulated in relevant regulations IEC 364 for example or DIN VDE 0100 and in national accident prevention regulations BGV A3 in Germany In addi tion observe the regulations of the local electricity supplier 3 Testthe overcurrent protection cut out to ensure that the time it takes to disconnect in re sponse to a fault is within the permitted limit 4 Select supply cable conductor diameters and fusing in accordance with local regulations 5 The user must provide the machine with a lockable power supply disconnecting device This could be for example a load disconnect switch with fused input If a circuit breaker is used it must be suitable for the motor starting characteristics 6 Check that the tappings on the control voltage transformer are connected according to the sup ply voltage If not change the tappings to suit the power supply voltage 7 DANGER Danger of fatal injury from electric shock gt Switch off and lock out the power supply disconnecting device and verify the absence of voltage 8 Connect the machine to the power supply 9 Ensure that the cabinet again complies with the requirements of degree of protection IP54 The electrical diagram in chapter 13 4 contains further details of the power supply connection Option T2 Refrigeration dryer Connecting the transformer according to the mains sup ply The refrigeration dryer transformer
45. conversant with and adhere to the safety instructions and sections of the service manual relevant to operation m have received adequate training and authorisation to operate electrical and compressed air de vices Additional qualifications for compressors with refrigeration dryers Adequate training and authorisation ton refrigeration devices Authorised installation and maintenance personnel have the following qualifications are legal age have read are conversant with and adhere to the safety instructions and sections of the ser vice manual applicable to installation and maintenance are fully conversant with the safety concepts and regulations of electrical and compressed air engineering are able to recognise the possible dangers of electrical and compressed air devices and take appropriate measures to safeguard persons and property have received adequate training and authorisation for the safe installation and maintenance on this equipment Additional qualifications for compressors with refrigeration dryers fully conversant with the safety concepts and regulations concerning refrigeration devices must be able to recognise the possible dangers of refrigeration devices and take appropri ate measures to safeguard persons and property gt Ensure that operating installation and maintenance personnel are qualified and authorised to carry out their tasks Adhere to inspection schedules and acci
46. drive motor runs under full load IDLE The inlet valve is closed The minimum pressure check valve shuts off the oil separator from the distribution network The venting valve is open A small volume of air circulates through the bleed hole in the inlet valve through the airend and back to the inlet valve via the venting valve The compressor motor runs without load and draws little current Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E ESER 4 Design and Function KA KOMPRESSOREN 9 5717 20 E Option C1 4 6 2 Option C1 Tab 38 4 6 Operating modes and control modes STANDSTILL The inlet valve is closed The minimum pressure check valve shuts off the oil separator from the distribution network The venting valve is open The compressor motor is stopped MODULATING CONTROL With the help of a control valve the proportional controller the degree of opening of the inlet valve is steplessly varied in response to the air demand The airend delivers compressed air to the distribution network The load and power consumption of the drive motor rises and falls with the air demand The regulating valve is factory set The setting should not be changed without consultation with KAESER SERVICE Control modes Using the selected control mode the controller switches the machine between its various opera tional states in order to compensate for air being drawn of by consumers and maintain system
47. dry 1 2 3 Screw the service module to the inlet pipe using sealing tape Carefully insert the control module sensor 3 in the opening 4 of the new service module Place the hook of the control module into the service module eye and press until the snap fas tener can be heard to click into place Fit the drain hose and open the shut off valve 9 upstream of the condensate drain Close all access doors replace and secure all removable panels Service Manual Screw Compressor 82 ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER 10 Maintenance 1 10 19 Documenting maintenance and service work 9_5717 20 E 10 19 Documenting maintenance and service work Machine number gt Enter maintenance and service work carried out in the list Date Maintenance task carried out Operating hours Tab 56 Logged maintenance tasks Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC Signature 83 KAESER KOMPRESSOREN 84 11 Tab 57 11 3 11 Spares Operating Materials Service 11 1 Note the Nameplate Spares Operating Materials Service Note the Nameplate The nameplate contains all information to identify your machine This information is essential to us in order to provide you with optimal service gt Please give the information from the nameplate with every enquiry and order for spares Ordering consumable parts and operating fluids materials KAESER consumable parts and operating materials a
48. hinten tren er sensn nnn 67 Checking the cooling 70 Mentirig the miachime s s e ee eed e excea ea et 71 Replenishing the cooling 72 Changing the cooling oil separator tank 75 Changing the cooling oil heat recovery system 76 Changing de ettet nua 77 Changing the oil separator cartridge 79 Refriger tion dryer eget 80 Checking condensate 81 Condensate drain maintenance 82 Transport with forklift truck 1 91 Transport with a 92 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC V KAESER List of Illustrations KOMPRESSOREN Service Manual Screw Compressor VI ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab
49. oil for all appli cations except in con nection with foodstuffs Particularly suitable for machines with a low du ty cycle 570 Synthetic oil Standard oil for all applications Standard oil for East except in connection with food South East Asian coun stuffs Particularly suitable for ma chines with a high duty cycle Not suitable for East South East Asian countries tries suitable for all ap plications except food processing Particularly suitable for machines with a high duty cycle 44 mm s 45 mm s 52 8 mm s DIN 51562 1 D 445 ASTM test D 445 ASTM test 6 8 mm s 7 2 mm s 8 0 mm s DIN 51562 1 D 445 ASTM test D 445 ASTM test 220 238 258 ISO 2592 D 92 ASTM test D 92 ASTM test 864 kg m 0 869 ISO 12185 D 1298 ASTM test 33 46 54 ISO 3016 D 97 ASTM test D 97 ASTM test 40 40 0 10 min 15 min Cooling oil recommendation D 1401 ASTM test Cooling oils for applications in food processing Description SIGMA FLUID FG 460 Synthetic oil Application Approval Viscosity at 40 Viscosity at 100 Service Manual Specifically for applications where the compressed air comes into contact with foodstuffs USDA H 1 NSF Approved for the manufacture of food packaging meat and poultry process ing and other food processing appli cations 50 7 mm s D 445 ASTM test 8 2 mm s D 4
50. on the compressed air system Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death The following safety concerns relate to any work on components that could be under pressure gt Close shut off valves or otherwise isolate the machine from the compressed air network to en sure that no compressed air can flow back into the machine gt De pressurise all pressurised components and enclosures gt Check all hose couplings in the compressed air system with a hand held pressure gauge to en sure that they all read 0 bar gt Do not open or dismantle any valves When working on the drive system Touching voltage carrying components can result in electric shocks burns or death Touching the fan wheel the coupling or the belt drive while the machine is switched on can result in serious injury gt Switch off and lock out the power supply isolating device and verify the absence of voltage gt Do not open the cabinet while the machine is switched on Details of authorised personnel are found in chapter 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 59 KAESER KOMPRESSOREN 10 2 10 2 1 Further information 10 2 2 10 2 3 60 10 Maintenance 10 2 Following the maintenance plan Following the maintenance plan Logging maintenance work The maintenance intervals given a
51. 12 5 50A 12 5 50A 12 5 50A 12 5 50A setting 49A 50Hz setting 42A 50Hz setting 27A setting 24 setting 22 Siemens setting 44 A 60Hz Overload protection switch F11 7 6860 00100 7 6860 00100 7 6860 00070 7 6860 00070 7 6860 00070 3RV1011 0KA10 3RV1011 0KA10 3RV1011 0GA10 3RV1011 0GA10 3RV1011 0GA10 0 9 1 25 0 9 1 25 0 45 0 63 0 45 0 63A 0 45 0 63A Siemens setting 1 setting 1A setting 0 55A setting 0 55A setting 0 55A Overload protection switch F30 7 6860 00190 7 6860 00180 7 6860 00180 7 6860 00180 7 6860 00180 option T3 3RV1011 1JA10 3RV1011 1HA10 3RV1011 1HA10 3RV1011 1HA 10 3RV1011 1HA10 7 10A 5 5 8A 5 5 8A 5 5 5 5 Siemens setting 8 8 setting 7A setting 7A setting 7A setting 7 Cut out F12 7 6862 0 7 6862 0 Siemens 55Y4105 7 0 5A 55 4105 7 0 5 Transformer 7 6852 00010 7 6852 00010 7 6843 00010 7 6843 00010 7 6852 00010 B0609057 B0609057 B0609052 B0609052 B0609057 160 VA 160 VA 160 VA 160 VA 160 VA diagram 1 Sht 7 diagram 2 Sht 7 diagram 3 Sht 7 diagram 4 Sht 7 diagram 6 7 Sht 7 Auxiliary switch 7 3140 02200 3RH1921 1DA11 Equipment parts list KAESER KOMPRESSOREN UASK B 03010 00 Compressor series ASK Ersatz f r Ersatz durch 7 6849 0 7 6849 0 7 6849 0 7 6849 0 7 6849 0 Block T3 15H 3 15A 250V T3 15H 3 45 250V T3 15H 3 15A 250V T3 15H 3 15A 250V T3 15H 3 15A 250V Transformer T30 7 3717 00260 7 2292 10060 7 3717 00240
52. 3ads japoul 30049 jin34i 104 42219 94 95 13 4 Electrical Diagram 13 Annex JV 0 O o o 5 x E 5 9 5717 20E Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 118 12 1405 33J 4 0A g 2 6 00 0 0E0 8 MS VS s4ndjno Aejay Ajddns Duniesum ysy Saluas sossasdwo 1 ny Sempre 5 jo dnour Buluuns 10 0 ou NO 104409 3104241 2504 A005 aBueJo VL JO Az JV xeu NO 1044407 gL 40140 Jakup uoije 1a614J81 24190 104224403 1816 101224102 13 4 Electrical Diagram 13 Annex OlSV8 10 1 02 VIADIS 2 oc o o oc ZLM gt Jeqiz 4015 2 3943 43 9t l0 ix 2 0 01 gt Tw 220 A008 Mojja 7uaaJB quus zx JVASL JV Screw Compressor Service Manual 19 1 ASK T SIGMA CONTROL BASIC 9 5717 20E 4 SV Saias 10558 Bee 10 imn
53. 45 ASTM test Screw Compressor ASK T SIGMA CONTROL BASIC D 1401 ASTM test FG 680 Synthetic oil Specifically for applications where the compressed air comes into contact with foodstuffs USDA H 1 NSF Approved for the manufacture of food packaging meat and poultry process ing and other food processing appli cations 70 0 mm s D 445 ASTM test 10 4 mm s D 445 ASTM test KAESER KOMPRESSOREN 10 Tab 19 Tab 20 2 12 Tab 21 2 _ Technical Specifications 2 12 Cooling oil charge SIGMA FLUID FG 460 FG 680 Flash point 245 C 245 C D 92 ASTM test D 92 ASTM test Density at 15 C Pour point Demulsibility at 54 Cooling oil recommendation food processing Cooling oils for the operation with snow cannons SIGMA FLUID PANOLIN HLP SYNTH 46 Description Saturated synthetic ester with additives mineral oil free Easily biologically degradable as per OECD criteria Application Specifically designed for machines intended for the operation with snow cannons Approval Viscosity at 40 47 mm s Viscosity at 8 1 mm s 100 C Flash point gt 210 Density at 15 0 92 g ml Pour point 35 Demulsibility at 54 Cooling oil recommendation machines for snow cannons Cooling oil charge For machines with the Option W1 the volume required additionally for the heat recovery must be added to the charge ASK 27
54. 5 a2JIAJag 40490 puaa wesbeig 134 N330S S 34dMWO 43S 1VM 214 10 949 0 gt juevabiyay J8suapuo3 pajoo2 jasuapuo2 uesa uzay U3JIMS aJnssaJd jajeg Ja Jp 18 4 uorj2efur jueJeBiJjas 40je3ipui aJnssaJd uleJp ajesuapuoj jjo jnus JojeJedas ajesuapuoj pajejnsu jeau Jasiunode jueJeDiJjaJ 04 of eme sess nd t 0 Screw Compressor Service Manual 9 5717 20E ASK T SIGMA CONTROL BASIC 98 KAESER KOMPRESSOREN 13 2 9 5717 20E 13 Annex 13 2 Pipeline and instrument flow diagram P amp l diagram MODULATING control Option C1 Pipeline and instrument flow diagram P amp l diagram MODULATING control Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 99 70 2000 1LSV4 10 000 1195 1 1 aanp unea AE Jossesdwoy NINOS SIANO Ja Jp Joss sdwo 01490 4 passaiduo lt o lo 13 2 Pipeline and instrument flow diagram P amp l diagram MODULATING control 13 Annex O o o 5 9 5717 20E Screw Compressor
55. 5Y4105 7 0 5 5SY4105 7 054A Transformer 11 7 6852 00010 7 6852 00010 7 6843 00010 7 6843 00010 7 6852 00010 B0609057 B0609057 B0609052 B0609052 B0609057 E 160 VA 160 VA 160 VA 160 VA 160 VA E diagram 1 Sht 7 diagram 2 Sht 7 diagram 3 Sht 7 diagram 4 Sht 7 diagram 6 7 Sht 7 Block T3 15H 3 15A 250V 15 3 15A 250V 315 35 250V T3 15H 3 15A 250 T3 15H 3 15A 250V Transformer T30 7 3717 00260 7 2292 10060 7 3717 0024 0 7 2292 10060 option T3 B0406058 USTE1600 B0312005 USTE1600 80 10 6 4 10 8 2 Block diagram 3 Sht 8 diagram 2 Sht 8 diagram 1 Sht 8 diagram 2 Sht 8 E Siemens 3RA1943 3D 3RA1943 3D 3RV1935 1A 3RV1935 1A 3RV1935 1A 5 2 W14 1 16 black 1 16 black 1 6 black 1 6 black 1x6mm black 88 sls Siemens 500 70 500 V 70 500 V 70 500 V 70 C 500 V 70 C Name Datum 500 V 90 C 500 V 90 500 V 90 500 V 90 500 V 90 Compressor control K20 7 1005 4 7 7005 4 Siemens SIGMA CONTROL BASIC SIGMA CONTROL BASIC SIGMA CONTROL BASIC SIGMA CONTROL BASIC SIGMA CONTROL BASIC EMERGENCY STOP pushbutton S1 7 3217 0 QRUV 7 3217 0 7 3217 0 3217 0 QRUV 7 3217 0 Switching element Schlegel 7 3218 0 MTHOO 7 3218 0 MTHOO 7 3218 0 MTHOO 3218 0 MTHOO 7 3218 0 MTHOO Control cabinet KAESER 212905 0 212905 0 212905 0 12905 0 212905 0 Mountin
56. ASK 32 ASK 35 Fluid volume litre 11 11 11 Topping up volume litres 2 2 2 minimum maximum Plus the oil volume of the heat recovery system Cooling oil charge Option K1 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 2 Technical Specifications Option W1 Tab 22 2 13 Further information 9 5717 20E 2 14 2 13 Power Supply Heat recovery The additional volume corresponds to the oil volume of the heat exchanger and the connecting lines ASK 27 ASK 32 ASK 35 Additional charge vol ume I Enter the volume required by your heat recovery system Cooling oil charge Option W1 Power Supply Basic requirements The machine is designed in accordance with the conditions for an electrical power supply specified by EN 60204 1 IEC 60204 1 section 4 3 In the absence of other user specified conditions the limits laid down in this standard must be ad hered to It is recommended that the user and the supplier reach an agreement on the basis of the EN 60204 1 ANNEX B The machine requires a symmetrical three phase power supply In a symmetrical three phase supply the phase displacement and voltages are equal for all phases The machine may only be operated from an earthed TN or TT three phase supply Connection to an IT supply is not permitted without taking further measures earth leak detection etc Further requirements Deman
57. C 15 16 ESER 3 Safety and Responsibility 3 1 3 2 3 3 3 4 3 4 1 3 1 Basic instructions Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula tions Nevertheless dangers can arise through its operation danger to life and limb of the operator or third parties damages to the machine and other material assets Disregard of warning or safety instructions can cause serious injuries gt Use this machine only if it is in a technically perfect condition and only for the purpose for which it is intended observe all safety measures and the instructions in the service manual gt mmediately rectify have rectified any faults that could be detrimental to safety Specified use The machine is intended solely for generating compressed air for industrial use Any other use is considered incorrect The manufacturer is not liable for any damages that may result from incorrect use The user alone is liable for any risks incurred gt Keep to the specifications listed in this service manual gt Operate the machine only within its performance limits and under the permitted ambient condi tions gt not use compressed air for breathing purposes unless it is specifically treated gt not use compressed for any application that will bring it into direct contact with foodstuffs unle
58. CONTROL BASIC 9 5717 20E 13 Annex 13 4 Electrical Diagram 2 oc o o m oc x DEL IeEEELT ELE MSV 591195 Jossa Jduio aBed ANVWYI9 6 190 05796 N34OSS3HdWO H3S3VM Waunyaeynuep Ajddns samod 1 11 2 09 01 0917 209 01 077 2 05 01 0017 2809 9 501 A08 2909 05 501 A0 amp 2 09 05 9 501 A00 JISV8 10 1 02 VWOIS MSV 591195 JossaJduio suieJDeip je31J 23 3 Erie BT Ss mew e ls we saijJed 04 ajgissa23e asiMJaujo Jo papJeMJoj suoinpoJda Jou sjeuibiuo JaujlaN asodind Jaujo Aue Joy apeu aq jou 5 5 5 21404428 pue juauljeaJ abesojs suoijanpouda Jayjo Aue Jo saidoj asodund au Ajuo paysnajua ase au juadojd aaisnjaxa ayy a3iAJas BuiKueduio33e au pue ayy ajejdaueu uo ave Jejn3ijJed Aue u3iuM Japun suoijipuo3 pue pue saiuanbaJj pue Ajddns samod UO 02 lt juaunaop 941 iii NOLLN3LLV 09 1 Sc
59. Display 1 2 Error code for alarm and warning messages see table 49 and table 50 Operating state LOAD gt Operating state IDLE 4 10 2 Parameters Parameters Meaning 0 Service Manual Operating hours counter Displays the total time the drive motor was switched on Only KAESER Service has the right to change this parameter Load hours counter Shows the total time the compressor drive motor has run under LOAD Only KAESER Service has the right to change this parameter Maintenance counters Displays the number of operating hours until the next scheduled maintenance is due SIGMA CONTROL BASIC counts down the operating hours from a default value The warning message 5 is displayed when the counter reaches zero Set the counter to its original value upon completion of the service activities The in terval starts anew A password is required to change this parameter Relief valve test mode This function switches the activating pressure check mode for the pressure relief valve on and off The warning message is displayed when the check mode is switched on A password is required to change this parameter For the inspection and the password see 10 10 Temperature display units The airend outlet temperature can be displayed in either or F Pressure display units The current working pressure can be displayed in bar psi or MPa Control modes Factory setting OFF This parameter c
60. E ELT AC ETT i EAR A ___ Insulating jacket ORL TR x MAI ETUR EET _ Condens separator it insulation a dot an We AU Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual The replacement of the spare parts described requires an authorized and certified refrigerant technician Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 89 KAESER KOMPRESSOREN 90 12 12 1 Precondition Precondition 12 2 Material Precondition 12 3 12 Decommissioning Storage and Transport 12 1 Putting Out of Operation Decommissioning Storage and Transport Putting Out of Operation This is necessary under the following circumstances machine is temporarily not needed machine is to be moved to another location m machine is to be scrapped Temporarily putting out of operation The machine can be started at regular intervals gt Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec tion against corrosion Putting out of operation for a longer period Before putting out of operation the machine should be run under LOAD for at least 30 minutes Switch off the mains disconnecting dev
61. Escape Exits the edit mode without saving Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 33 KA KOMPRESSOREN 34 ESER 4 Design and Function Tab 41 Fig 8 Tab 42 4 10 4 10 1 4 10 Functional description SIGMA CONTROL BASIC Item Function 9 Enter Enters edit mode Exits the edit mode and saves Only affects the value in the third line of the display Keys 12 wen 13 15 19 16 CONTROL BASIC 19 04 S0036 Indicators Item Function 12 Indicator field or display Alphanumeric display with 4 lines 13 Fault Flashes red when an alarm occurs Lights continuously when acknowledged 15 Warning Lights yellow for m maintenance work due m warning messages 16 Control voltage Lights green when the power supply is switched on 19 Machine ON Lights green when the machine switched on Indicators Functional description SIGMA CONTROL BASIC Display layout Notae Der Line 1 yy Line 2 2 0000 Line 3 12345678SpTi Line 4 theline Display Meaning 1 XX X Current system pressure in bar psi or MPa 2 yy Current airend discharge temperature ADT in C or F 3 2 Display of parameters their settings see table 44 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E Design and Function KAESER 4 410 Functional description SIGMA CONTROL BASIC the line Display Meaning 4 Tab 43
62. Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E Manufacturer KAESER KOMPRESSOREN GmbH 96410 Coburg Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com Original instructions IKKW SASK 2 00 SBA SCHRAUBEN T SCB 20111103 144508 KAESER KOMPRESSOREN 9 5717 20E Contents Regarding this document 17 Using this document a eh ORE 1 12 Further documents eibi e qe 1 1 3 Copyright ERE e RR Rte eae 1 1 4 Symbols nd labels eo eee etc p e e pt ots 1 14 1 Wamings REOR URB IBN DEI DRE D e d E 1 1 4 2 Potential damage warnings eene 2 1 4 3 Other alerts and their symbols 2 Technical Specifications 21 oor EIER 4 2 2 Options ee eee de tesoro ele ee LL 4 23 4 2 4 ieiunii 5 2 5 Ambient 2 5 2 6 e 6 2 5 MEDI GRECI EA 6 2 6 7 2 9 Noise emission dB A 8 2 10 Motors and POwel e eei etie eee pedet 8 2 10 21 Driveitnotor s EE
63. Starting the machine for the first time No personnel are working on the machine All access doors are closed All removable panels are in place and secured 1 Open the shut off valve to the air network 2 Switch on the power supply isolating device After the controller has carried out a self test the green Contro voltage LED is lit continuously 3 Press the ON key The green Machine ONLED is lit continuously The drive motor runs up and after a short time the machine switches to LOAD and delivers compressed air gt Watch for any faults occurring in the first hour of operation gt After the first 50 operating hours check all electrical connections and tighten where nec essary Does the machine stop when the compressor motor rotates in the wrong direction gt Switch off and lock out the power supply isolating device and verify the absence of volt age gt Changeover phase lines L1 and L2 Setting the setpoint pressure The setpoint pressure cut out pressure is factory set at the maximum permissible working pres sure of the compressor Adjustment is necessary for individual operating conditions Do not set the setpoint pressure of the machine higher than the maximum working pressure of the compressed air system The machine may not toggle more than twice per minute between LOAD and IDLE To reduce the cycling toggling frequency gt Increase the difference between cut in and cut out pressure gt Add a larger air rec
64. W 10 asou jjo inug 491005 10 10 48 o 4uo3 JojeJedas 0 Jar aJ aJnssaJg JOJEIIPU 110 uieJp 4 asoy jjo 1nus pua asoy pue 10 Burjdno3 5 aunssaJq Screw Compressor Xue JojeJedas 0 Josuas 00L Ld 1 u3JI S aJnssaJd ASK SIGMA CONTROL BASIC Service Manual JOJOW 6njd maas DAJEA 102 13 2 Lu oc o o m oc 13 2 Pipeline and instrument flow diagram P amp l diagram MODULATING control eg HE 02000 11S V4 Po Ja KJp uoi4e Jabi JaM 10 2000 13s v3 01190 ue bei 84 1 passa duio jajjno passaJduio N380S S 3440 aJs JV zjesJ3 600906 umen 0 Screw Compressor Service Manual 03 1 ASK T SIGMA CONTROL BASIC 9 5717 20E 02000 113S V4 13 2 Pipeline and instrument flow diagram P amp l diagram MODULATING control 13 Annex O o o 5 JaKJp 2291253 N330S S 33 dMWO 23S 31V 40490 puaa wesbeig 134 pajejnsuir jeau adiq n3 ad d NI aui ssed g JojeJedas ssed q seb joy BAJA JApesyIS
65. W 22kW gt diagram 2 Sht 1 diagram 1 Sht 1 50Hz diagram 1 Sht 1 diagram 1 Sht 1 diagram 1 Sht 1 diagram 2 Sht 1 60Hz en supply terminals 0 3 7 3140 02100 7 3140 02100 7 3140 02090 7 3140 02090 7 3140 02090 Siemens 3RA1943 3L 3RA1943 3L 3RV1935 5A 3RV1935 5A 3RV1935 5A 5 11 31 7 6836 00070 Wieland 7 6836 00070 Wieland 7 6836 00070 Wieland 7 6836 00070 Wieland 6836 00070 Wieland terminal strips 11 7 6836 00060 Wieland 7 6836 00060 Wieland 7 6836 00060 Wieland 7 6836 00060 Wieland 7 6836 00060 Wieland Contactor Q1 7 6870 0 7 6870 0 7 6868 0 7 6867 0 7 6867 0 3RT1044 1AL20 3RT1044 1AL20 3RT1035 1AL20 3RT1034 1AL20 3RT1034 1AL20 3RH1921 1XA20 0PAO 3RH1921 1XA20 0PAO0 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 3RH1921 1DA11 3RH1921 1DA11 Interference suppressor 7 3140 00920 7 3140 00920 7 3140 00920 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 Contactor Q2 7 6870 0 7 6870 0 7 6868 0 3RT1044 1AL20 3RT1044 1AL20 3RT1035 1AL20 3RT1034 1AL20 3RT1034 1AL20 Auxiliary switch 7 3150 02200 7 314 0 02200 7 3140 02030 3RH1921 1DA11 3RH1921 1DA11 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 ies ASK Interference suppressor 7 314 0 00920 7 314 0 00920 7 3140 00920 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 Contactor 03 7 6867 0 7 6867 0 7 6866 0 7 6865 0 7 6865 0 X 3RT1034 1AL20 3RT1034 1AL20 3RT1026 1AL20 rd
66. al Start up 7 7 Checking the Door Interlock Switch bm eS 4 LI Ze f band S cnn LL EL IRN he 7 RA A W 4 7 WHED 1 07 1293 MODULATING control Setting the shut off valve Control valve proportional control Shut off valve gt close the control valve depending on the required control mode The control valve is factory set The setting should not be changed without consultation with KAESER Service Checking the Door Interlock Switch The interlock switch stops the machine as soon as the front access panel is opened Check the interlock switch function before every start up The door interlock switch is an important safety device The machine may only be operated with a correctly functioning interlock switch 07 50048 Location of the interlock switch Door interlock switch Access panel Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 49 KAESER KOMPRESSOREN 50 29 7 8 Precondition oem 7 9 initial Start up 7 8 Starting the machine for the first time 1 Open the access panel 2 while the machine is running The machine shuts down automatically The controller displays an alarm message 2 Close the panel and acknowledge the alarm The machine does not shut down gt Have the interlock switch checked by an authorised KAESER Service representative
67. amage without delay Connecting the machine with the compressed air network Condensate in the compressed air network can damage the pipework gt Install only corrosion resistant pipes gt Use fluoroelastomers as sealing material for seals gt Note the electro chemical voltage sequence gt Consult with KAESER for suitable materials for the compressed air network The compressed air system is vented completely to atmospheric pressure 06 50047 Compressed pipework Flexible pressure hose Shut off valve Do not induce any forces into the machine for which the compressive forces must be bal anced by bracing 1 WARNING Serious injury or death can result from loosening or opening components under pressure gt De pressurise all pressurised components and enclosures A shut off valve must be installed by the user in the connection line 3 Connecta flexible pressure hose The dimensional drawing in chapter 13 3 provides the size and position of the connection ports Connecting the power supply The supply isolating device is switched off the device is locked off the absence of any voltage has been verified Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 41 KAESER KOMPRESSOREN Further information 6 4 1 Further information 6 5 42 6 Installation 6 5 Connecting the Condensate Drain 1 The power supply must only be connected by authorised installation personnel or an
68. cation of safety Signs 2 2 22 epe dte eite a 23 Enclosure OVervieW et egeo Pub 27 Machine layout sie eta eee e E ee e ens 28 Refrigeration dryer c o etit et ettet 29 Machine MOuntingS 29 ebd dots 33 IridiCatOrs e e d Re 34 Recommended machine placement and dimensions 38 Compressed pipework 5 x egest Leo ede Le 41 Condensate drain dimensions MM 43 Connections SIGMA CONTROL BASIC sse eene nnne 43 Inlet valve filling Dort e e e et tette ate ct tas 48 MODULATING control Setting the shut off valve 49 Location of the interlock switch 49 Switching On and Off dede ed 52 Switching off in an emergency 53 Acknowledging messages 55 Filter mat for the air and oil cooler enne nennen 63 Switching cabinet ventilation 64 Filter mat for the air and oil cooler 65 Air filter maintenance diced 66 Drive Belt Maintenance 44 042280 nnn ninh
69. cient and suitable lighting such that the display can be read and work carried out comfortably and safely gt Keep suitable fire extinguishing agents ready for use gt Ensure that required ambient conditions are maintained Required ambient conditions may be Maintain ambient temperature and humidity Ensure the appropriate composition of the air within the machine room clean with no damaging contaminants e g dust fibres fine sand free of explosive or chemically unstable gases or vapours free of acid alkaline forming substances particularly ammonia chlorine or hydrogen sulfide Installation conditions Determining location and clearances The machine is intended for installation in an appropriate machine room Information on distances from walls and ventilation is given below The distances quoted are recommended distances and ensure unhindered access to all ma chine parts gt Please consult KAESER if you cannot comply with these recommendations The floor must be level firm and capable of bearing the weight of the machine Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 37 KAESER KOMPRESSOREN 38 Fig 9 5 2 2 5 Installation and Operating Conditions 5 2 Installation conditions 05 51170 Recommended machine placement and dimensions mm Exhaust fan Exhaust air duct Inlet air opening 1 NOTICE Ambient temperature too low Frozen con
70. ct to evaporate Service Manual Screw Compressor 9 5717 20 E ASK T SIGMA CONTROL BASIC 25 KAESER KOMPRESSOREN 3 9 3 10 26 3 Safety and Responsibility 3 9 Warranty gt Rinse with lukewarm water gt Consult a physician if experiencing lasting or reddened skin Inhalation At high concentrations risk of cardiac irregularity arrhythmia At very high concentration risk of asphyxia caused by oxygen deficiency gt Remove victim to the fresh air gt f necessary Respiration with respirator or administration of oxygen gt Consult a physician if experiencing breathing or nerve complaints Warranty This service manual contains no independent warranty commitment Our general terms and condi tions apply with regard to warranty A condition of our warranty is that the machine is used solely for the purpose for which it is inten ded and under the conditions specified Due to the multitude applications for which the machine is suitable the obligation lies with the user to determine its suitability for his specific application Furthermore we accept no warranty obligation for m use of unsuitable parts or operating materials un authorised modifications m incorrect maintenance m incorrect repair Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials gt Obtain confirmation from KAESER that your specific operating conditions are suitable
71. densate and highly viscous cooling oil can cause damage when starting the ma chine sure that the temperature of the machine is at least 3 before starting gt Heat the machine room adequately or install an auxiliary heater 2 Ensure adequate lighting so that all work on the machine can be carried out without danger or hindrance 3 Ensure that the indicators can be read without glare and that the controller display cannot be damaged by direct sunlight UV radiation 4 Ensure that all intake and exhaust apertures of the enclosure remain opened 5 If installed outdoors the machine must be protected from frost direct sunlight dust and rain Ensuring the machine room ventilation Adequate ventilation of the machine room has several tasks m jt prevents subatmospheric pressure the machine room m t evacuates the exhaust heat of the machine and thus ensures the required operating condi tions gt Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of the machine room 1 Ensure that the volume of air flowing into the machine room is at least equivalent to that being removed from it by the machine and exhaust fan 2 Make sure that the machine and exhaust fan can only operate when the inlet aperture is ac tually open Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 57354 5 Installation and Operating Conditions 5 2 3
72. dent prevention regulations The machine is subject to local inspection schedules Examples of German operation gt Carry out recurring inspections to BGR 500 chapter 2 11 The user must ensure that the machine s safety devices are checked for function as required or at least annually gt Carry out oil changes to BGR 500 chapter 2 11 The user must ensure that the cooling oil is changed as required or at least annually and the oil change must be documented Intervals may be varied if an analysis proves that the oil is still usable Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 17 KAESER 3 Safety and Responsibility 3 5 Dangers gt Keep to inspection intervals accordance with the Ordinance on Industrial Safety and Health with maximum intervals as laid down in 815 Inspection Inspection interval Inspecting authority Installation and equip Before commissioning Approved supervisory body ment inspection Internal inspection Every 5 years after installation or the Competent person last inspection e g KAESER Service Technician Strength test Every 10 years after installation or Competent person the last inspection e g KAESER Service Technician Tab 35 Inspection intervals according to regulations 3 5 Dangers Basic instructions The following describes the various forms of danger that can occur during machine operation Basic safety instructions are found in this service manual at the b
73. drain hose at the condensate drain 2 With your other hand push and hold the TEST key at the condensate drain for at least 2 seconds As soon as the condensate drain opens you will feel a short burst at the condensate drain hose Service the condensate drain if you do not experience a burst Condensate drain maintenance The condensate drain cannot be cleaned The service unit must be changed if condensate does not drain The power supply isolator is switched off all poles the device is secured to prevent switching back on the absence of voltage has been verified The Power LED is off see Fig 32 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 81 KAESER 10 Maintenance Aonidia 545 10 18 Refrigeration Dryer Maintenance 10 50115 Fig 33 Condensate drain maintenance 21 5 33 3 CJ Service module Control module Sensor Sensor opening Snap fastener Condensate drain hose fitting Contact springs Inlet Shut off valve 9 e3 C3 S3 Removing the service module px Close the shut off valve 9 upstream of the condensate drain Unscrew the drain hose fitting Press the snap fastener 5 and remove the control module carefully from the service module Carefully unscrew the service module from the inlet pipe Fitting the service module Precondition Use only genuine KAESER service modules Make sure the top of the service module and the contact spring are clean and
74. ds on a three phase supply for a machine with the following equipment Refrigeration dryer powered from a transformer This machine may only be supplied from an earthed TN or TT three phase supply in which the neutral point is earthed The machine may not be connected to a three phase supply in which one of the phases is earthed as this can lead to dangerous voltage surges Connection to an IT network is not permitted without further measures being taken earth leak de tection specially designed frequency converter etc The wiring diagram in chapter 13 4 contains further details of the power supply connection Power supply specifications The following supply cable conductor diameters copper multi core and fusing slow blow class gL 9G are selected according to the German DIN VDE 0100 430 IEC 60364 4 43 and IEC 60364 4 473 and DIN VDE 0298 4 standards for 30 ambient temperature and wiring type C Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 11 KAESER KOMPRESSOREN 12 2 14 1 Tab 23 Tab 24 Tab 25 2 14 1 1 2 Technical Specifications 2 14 Power supply specifications gt For other application conditions check conductor diameters and change accordingly Other conditions would include for example Higher temperature Other cable installation method Cable length gt 50 m Mains frequency 50 Hz Rated voltage 200V 10 3 50Hz ASK 27 ASK 32 ASK 35 Backup fuse A
75. e air cooler After shutting down the compressor and venting the oil separator tank the machine is still un der pressure from the air system or the section from the shut off valve to the minimum pres sure check valve 1 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 1 2 Slowly open the shut off valve 7 to release pressure 3 Disconnect the male hose fitting 6 and close the shut off valve 7 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 71 KAESER KOMPRESSOREN 10 14 A Material Precondition Fig 26 10 14 1 A 72 10 Maintenance 10 14 Replenishing the cooling Replenishing the cooling oil The machine must be isolated from the compressed air network and completely vented be fore undertaking any work on the pressure system The maintenance hose with hose coupling and shut off valve needed for venting is stowed beneath the oil separator tank The power supply isolating device is switched off the device is locked off the absence of any voltage has been verified A 6 10 50061 Replenishing the cooling oil 1 Hose coupling air cooler venting 6 Plug in nozzle 2 Pressure gauge Shut off valve 3 coupling oil separator tank venting Shut off valve open Oil filler port with plug Shut off valve closed Cooling oil level indicator 8 Maintenance hose 1 Ventthe machine as described in section 10 14 1 m
76. e power supply disconnecting device and verify the ab sence of any voltage Hot surface Risk of burns caused by contact with hot components gt Do not touch the surface gloves Risk of serious lacerations or even severing of extremities fingers from rotating components gt Operate the machine only with closed safety guards access doors and panels gt Switch off and lock out the mains isolating devices and verify the absence of any voltage before opening any machine enclosure or guard Risk of injury caused by an automatic machine start gt Wear long sleeved garments no synthetics such as polyester and protective gt Switch off and lock out the mains isolating devices and verify the absence of any voltage before opening any machine enclosure or guard 5 Risk of fatal injury caused by dismantling valves spring loaded or under pressure gt Do not open or dismantle valves gt Call an authorised Service Technician in the event of a fault Safety signs Emergency situations Correct fire fighting Suitable measures Calm and prudent action can safe lives in the event of a fire gt Keep calm gt Give the alarm gt Shut off supply lines if possible Mains disconnecting device all poles Cooling water if present Heat recovery if present Warn and move endangered personnel to safety Help incapacitated persons Close the doors When trained accordingly Attempt to extinguish the fire
77. ed be fore undertaking any work on the pressure system Preparation for the test The machine is switched off 1 Close the user s shut off valve between the machine and the air distribution network 2 Read off the activating pressure on the valve the activating pressure is usually to be found at the end of the part identification 3 Scroll to parameter 3 Pressure relief valve check mode with the arrow keys and confirm by depressing the Enter key for at least three seconds 4 Enter the password BASIC and confirm with the Enter key 5 Use the arrow keys to select parameter on and confirm Carrying out the check The machine starts in IDLE as soon as it is switched on As long as the ON key is depressed and held the machine will run in LOAD operating mode and pressure builds up in the oil separator tank As soon as the ON key is released the machine Switches back to IDLE and switches automatically to STANDSTILL when the idling period has elapsed The machine is switched off Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E 10 Maintenance 10 11 Checking the Excess Temperature Safety Shutdown Function 1 WARNING The pressure relief valve may blow off at any time 10 11 10 12 Tab 55 Precondition Excessive noise is caused when the pressure relief valve blows off There is danger of scalding from hot oil There is dang
78. eginning of each chapter in the section entitled Safety Warning instructions are found before a potentially dangerous task 3 5 1 Safely dealing with sources of danger The following describes the various forms of danger that can occur during machine operation Electricity Touching voltage carrying components can result in electric shocks burns or death gt Allow only qualified and authorised electricians or trained personnel under the supervision of a qualified and authorised electrician to carry out work on electrical equipment according to elec trical engineering regulations gt Before commissioning or re commissioning the machine the user must ensure adequate pro tection against electric shock from direct or indirect contact gt Before starting any work on electrical equipment Switch off and lock out the power supply isolator and verify the absence of any voltage gt Switch off any external power sources These could be connections to floating relay contacts or the electrical machine heating for ex ample gt Use fuses corresponding to machine power gt Check regularly that all electrical connections are tight and in proper condition Forces of compression Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death The following information concerns work on components that could be under pressure gt Close shut off valves or otherwise isolate the machine fr
79. eiver downstream to increase buffer capacity Setpoint pressure switching point 1 Scroll with the arrow keys until the parameter D setpoint pressure switch point is displayed in line 3 2 Press and hold enter for at least 3 seconds until the cursor flashes 3 Use the arrow keys to set the desired switching point and confirm with enter Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E Te VNaya y 7 Initial Start up Mel izizklehid 70 Setting the setpoint pressure Setpoint pressure switching differential This switching differential is factory set Adjust this parameter if the motor starting frequency is too high 1 Scroll with the arrow keys until the parameter C setpoint pressure switching differential is dis played in line 3 Press and hold enter for at least 3 seconds until the cursor flashes 3 Use the arrow keys to set the desired differential and confirm with enter Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 51 KAESER KOMPRESSOREN 8 1 Fig 16 8 1 1 Precondition Result 8 1 2 52 8 Operation 8 1 Switching On and Off Operation Switching On and Off Always switch the machine on with the ON key and off with the OFF key A power supply disconnecting device has been installed by the user KY NESTS wen keeser com IN FN 8 2 3 08 S0050 Switching On and Off 1 Machine ON LED
80. er of injury from bursting components and compressed air gt Close all access doors and replace and secure all removable panels gt Wear ear and eye protection gt Abort the test if the working pressure reaches 10 above the blowoff pressure of the valve 2 Press the ON key for short time The machine starts in IDLE 3 Observe the pressure indication on the SIGMA CONTROL BASIC keep the ON key press ed 4 Stopthe test as soon as the pressure relief valve blows off or working pressure rises to 10 96 above the activating pressure of the pressure relief valve 5 f necessary vent the machine and replace the defective pressure relief valve Returning the machine to operational 1 Call up the edit mode again and enter the password BASIC 2 Use the arrow keys to set the parameter to off and confirm with the enter key 3 Open the user s shut off valve between the machine and the air distribution network Checking the Excess Temperature Safety Shutdown Function The machine should shut down if the airend discharge temperature reaches a maximum of 110 C gt Have the safety shutdown function checked by an authorized KAESER service representative Checking the cooling oil level The sight glass allows a risk free reading of the cooling oil level The oil indicator should be fully filled with oil when the machine is at standstill The correct oil level cannot be seen The ideal situation is with the oil level around
81. ermissible pressure loss in the cooling air circuit 0 6 bar Maximum heat capacity ASK 27 ASK 32 ASK 35 available kW 13 0 15 8 17 8 MJ h 47 57 64 kcal h 11188 13598 15319 With the combination valve set to open at 80 C Heat capacity option W1 Refrigeration dryers Model ASK 27 ASK 32 ASK 35 Model Read off the dryer model from the dryer nameplate and enter it in the table Refrigeration dryer Model Compressed air system ABT 27 ABT 32 Pressure drop bar 0 2 0 2 referred to 7 bar working pressure Maximum permissible 16 16 working pressure bar Refrigeration dryer Compressed air system Refrigerant circuit The refrigeration dryer contains a refrigerant that is classified by the Kyoto Protocol as a fluorinated global warming gas Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20 E 77 53 14 2 Technical Specifications 2 16 Refrigeration dryers 9 5717 20E ABT 27 Refrigerant R 134a Global warming potential 1300 GWP Charge quantity kg Maximum permitted 21 working pressure bar high pressure end Maximum permitted 16 working pressure bar low pressure end Safety pressure switch 21 Cut out pressure bar ABT 32 R 134a 1300 21 16 21 Read off the charge quantity from the dryer nameplate and enter it in the table Tab 34 Refrigeration dryer Refrigerant circuit Service Manual Screw Compressor ASK T SIGMA CONTROL BASI
82. etwork Switch on the power supply and reset the maintenance interval counter After approx 10 minutes of operation Check the cooling oil level and top up if necessary Qro p N a Switch off the machine and check visually for leaks Changing the oil separator cartridge The oil separator cartridge cannot be cleaned The life of the oil separator cartridge is influenced by m contamination in the air drawn into the compressor andadherence to the changing intervals for Cooling oil Oil filter Air filter The machine must be isolated from the compressed air network and completely vented be fore undertaking any work on the pressure system Spares Cleaning cloth The power supply isolating device is switched off the device is locked off the absence of any voltage has been verified The machine is fully vented the pressure gauge on the oil separator tank reads 0 bar Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER 10 Maintenance 10 17 Changing the oil separator cartridge 10 50065 Fig 30 Changing the oil separator cartridge Cover 19 Self locking nut Dirt trap Screw fitting 16 Air pipe Gasket Fixing screw Oil separator cartridge Changing the oil separator cartridge 1 WARNING Compressed air Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly gt De pressurise all pressurised c
83. event ingress of moisture and formation of condensation gt Maintain a storage temperature of gt 0 C 2 Store the machine in a dry frost proof room Transport Safety Weight and centre of gravity determine the most suitable method of transportation The centre of gravity is shown in the drawing in chapter 13 3 gt Please consult with KAESER if you intend to transport the machine in freezing tempera tures Transport only using a forklift truck or lifting gear and only by personnel trained in the safe trans portation of loads gt sure the danger area is clear of personnel Transport with a forklift truck The forks are fully under the machine 12 50069 Transport with forklift truck gt Drive the forks completely under the machine or pallet and lift carefully Transport with a crane Suitable lifting gear ensures correct transportation The lifting slings must be fed under the machine The slings may not bear on the side of the machine enclosure Examples of unsuitable fixing points Pipe sockets Flanges Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 91 KAESER KOMPRESSOREN 92 Precondition Fig 35 12 5 Precondition x 12 Decommissioning Storage and Transport 12 5 Disposal Attached components such as cyclone separators condensate drains or filters m Rain protection covers gt Please consult with KAESER if you have questions to the a
84. fore undertaking any work on the pressure system Spares Cooling oil receptacle The power supply isolating device is switched off the device is locked off the absence of any voltage has been verified The machine is fully vented the pressure gauge on the oil separator tank reads 0 bar CAUTION There is risk of burns from hot components and oil gt Wear long sleeved clothing and gloves 10 50064 Changing the oil filter 1 Oil filter Direction to unscrew Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 77 KAESER KOMPRESSOREN 78 A 10 17 A Material Precondition 10 Maintenance 10 17 Changing the oil separator cartridge Changing the oil filter 1 WARNING Compressed air Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly gt De pressurise all pressurised components and enclosures 2 Unscrew the oil filter anti clockwise catch oil spillage and dispose of in accordance with envi ronmental protection regulations 3 Lightly oil the new filter s gasket 4 Turn the oil filter clockwise by hand to tighten gt Dispose of parts and materials contaminated with oil in accordance with environmental protection regulations Starting the machine and carrying out a trial run Close all access doors replace and secure all removable panels Open the user s shut off valve between the machine and the air distribution n
85. g plate KAESER 209602 0 209602 0 209602 0 09602 0 209602 0 i t Anderung Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC Sm 24543 zes _ SunseevvTa 00 0 0E0 8S VS JaMOd umm oes Y ysy 9425 jossauduo ume uorws Buiu24IMS J MOd 5 JaMod 5 jo dno 1040 JossaJduioj uoij2unj pue uoij3as ssoJ3 940 rsg Kjddns a3i Jas 385 lt rm 2 TTo DO S i T 40 9 lt 78 Jasn kq paljddns asnj 5 88 lt 0 JojeJedas 10 3ue4j pun 3 04 A005 46 0 UP 3 0 A005 Mojja K uaa JB quwyx ce 201 A008 uug x 13 4 Electrical Diagram 13 Annex O o o 5 x E 5 9 5717 20E Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 116 13 Annex 13 4 Electrical Diagram 2 Lu oc o o m oc Nsuosssuanon 9149 soss sdwo ueJbeip jn24r 3637WVM MEE E Tex E 9e
86. gauge to zero Contact the KAESER Service Manually venting the air cooler After shutting down the compressor and venting the oil separator tank the machine is still un der pressure from the air system or the section from the shut off valve to the minimum pres sure check valve 1 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 1 2 Slowly open the shut off valve 7 to release pressure 3 Disconnect the male hose fitting 6 and close the shut off valve 7 Topping up with cooling oil and trial run Replenishing the cooling oil A sticker on the oil separator tank specifies the type of oil used 1 WARNING Compressed air Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly gt De pressurise all pressurised components and enclosures 2 NOTICE The machine could be damaged by unsuitable oil gt Never mix different types of oil gt Never top up with a different type of oil to that already used in the machine Slowly unscrew the filler plug 4 Top up to bring the oil to the correct level 5 Renew the filler plug s gasket if necessary and screw the plug into the filler port Starting the machine and carrying out a trial run 1 Close all access doors replace and secure all removable panels Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 73 KAESER KOMPRESSOREN 74 10 15 A Material A
87. green OFF key ON key Controller ON LED green Switching on No personnel are working on the machine All access doors and panels are closed and secure 1 Switch on the power supply disconnecting device After the controller has carried out a self test the green Power ON LED lights continuously 2 Press the ON key The green Machine ON LED lights continuously If a power failure occurs the machine is not prevented from automatic re starting It can start automatically again as soon as power is restored The compressor motor starts as soon as system pressure is lower than the setpoint pressure cut out pressure Switching off Depending on current operating condition the machine shuts down after a protective run on peri od Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E ESER 8 Operation KA KOMPRESSOREN 9 5717 20 E Tab 48 8 2 Fig 17 Result Precondition Result 8 2 Switching off in an emergency and switching on again LOAD IDLE The machine switches to IDLE The motor stops immediately The Machine ON LED flashes The Machine ON LED extinguishes The drive motor comes to a stop after about 15 seconds The Machine ON LED extinguishes Switching off with without run on time 1 Press the OFF key The machine is ready to operate as soon as the Machine ON LED is extinguished The ma chine can be started again 2 Switch off and lock out the p
88. hanges the control mode OFF QUADRO ON DUAL Refrigeration dryer control mode Factory setting OFF This parameter changes the dryer control mode OFF TIMER m ON CONTINUOUS Screw Compressor 9 5717 20 E ASK T SIGMA CONTROL BASIC 35 77 444 4 Design and Function 210 Functional description SIGMA CONTROL BASIC Parameters Meaning 8 Switching the refrigeration dryer on and off Factory setting ON Option T3 This parameter switches the dryer permanently on or off OFF refrigeration dryer off refrigeration dryer on A password is required to change this parameter In machines without a refrigeration dryer the parameter is factory set to OFF System setpoint pressure Switching differential The switching differential determines the distance between cut in and cut out pres sure system setpoint pressure switching point and thus the switching frequency from LOAD to IDLE Setting range bar 0 1 5 0 D System setpoint pressure Switching point The switching point corresponds to the working pressure of the air system and the cut out pressure of the machine Setting range bar 5 5 maximum operating overpressure E maximum possible setpoint pressure setting Only KAESER Service has the right to change this parameter F Options The displayed value informs KAESER Service concerning the controller s internal machine configuration Tab 44 Parameters Further information Means
89. has tappings for various mains voltages 1 Check that the correct connections are made for the supply voltage provided for the machine 2 If necessary re connect the transformer to match the mains supply voltage The electrical diagram in chapter 13 4 contains further details of the power supply connection Connecting the Condensate Drain A threaded hose connection is provided to connect a condensate drain hose to the condensate drain outlet Condensate must be able to drain freely The illustration shows typical installations Condensate flows downward in the collecting line This prevents condensate flowing back to the compressor Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN Fig 11 x Further information 6 6 Material Fig 12 9 5717 20E 6 Installation 6 6 Connecting the remote LOAD IDLE control 196 5000 06 50110 Condensate dimensions mm Threaded connection Condensate collecting line gt Connect the condensate hose gt Collect the condensate in a suitable container and dispose of in accordance with environ mental regulations The dimensional drawing in chapter 13 3 gives the size and position of the condensate drainage connection ports Connecting the remote LOAD IDLE control Screwdriver DIN 5264 A 0 4x2 5 mm Flexible conductor 0 5 1 5 mm maximum length 100 m recommended NYSLY 2x1 0 mm
90. hen ordering Before and during all work be sure to read and follow the safety and service instructions in the machine s service manual See cooling fluid recommendations Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 11 ESER KOMPRESSOREN 10 0872 9035 O SSSL uondo Screw Compressor Service Manual 9 5717 20E ASK T SIGMA CONTROL BASIC 88 KAESER 11 Spares Operating Materials Service 1 11 5 Spare Parts for Service and Repair 9 5717 20E Legend KAESER Refrigeration dryer ABT SEL 2321 01 Teter dryer a a E E no ETC eee FPEM Refrigerant I IE ___ Hot gas bypass regulator _ 5 21 2 51 s Refrigerant filling port ted rude MEER E mE Starter talay a Circuit breaker refr compe Temperature re gauge rcp PERIERE Thermostat UNI mc IQ REPRINT _ Refrigerant compressor M OPI MEC V et Crank case heater unit i dA td iss a a loa V UL Heat excnanger _ ree tnl E Refrigerant condenser cpl Res Refrigerant separator AP ANC ER MN iT DM Ie ESI store M tel phar C
91. hine is activated gt Switch off and lock out the power supply disconnecting device and verify the absence of any voltage gt Wear close fitting clothes and a hair net if necessary gt sure all covers and safety guards are in place and secured before re starting Temperature High temperatures are generated during compression Touching hot components may cause inju ries gt Avoid contact with hot components These include for example compressor airends or blocks oil and compressed air lines cool ers oil separator tanks motors and machine heaters gt Wear protective clothing gt f welding is carried out on or near the machine take adequate measures to prevent sparks or heat from igniting oil vapours or parts of the machine Noise The enclosure absorbs the machine noise to a tolerable level This function will be effective only if the enclosure is closed gt Operate the machine only with intact sound insulation gt Wear hearing protection if necessary The blowing off of the pressure relief valve can be particularly loud Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 19 20 ESER 3 Safety and Responsibility 3 5 2 3 5 Dangers Operating fluids materials The used operating fluids and materials can cause adverse health effects Suitable safety meas ures must be taken in order to prevent injuries Strictly forbid fire open flame and sm
92. hould carry out service work gt Have service tasks carried out punctually taking ambient and operating conditions into ac count Interval Service task Up to 12 000 h Have the valves checked up to 12 000 h every Check the drive motor bearings three years at the latest up to 36 000 h every six Have hose lines replaced years at the latest Pressure pipes Control air lines h operating hours Regular service tasks Cooler Cleaning or Renewing the Filter Mats The filter mats help to keep the cooler clean If the filter mats are clogged adequate cooling of the components is no longer ensured Filter mats Warm water and household detergent Spare parts as required The machine is switched off Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20 E KAESER KOMPRESSOREN 9 5717 20E Fig 19 10 4 Material Precondition 10 Maintenance 10 4 Control cabinet Clean or renew the filter mat 10 0056 Filter mat for the air and cooler 1 Filter mat No tools are needed to remove the filter mat 1 Carefully remove the filter mat from the retaining frame 2 Beatthe mat or use a vacuum cleaner to remove loose dirt If necessary wash with lukewarm water and household detergent 3 Change the filter mat if cleaning is not possible or if the change interval has expired Carefully insert the filter mat in the retaining frame Control cabinet Clean or renew the filter mat
93. ice the disconnect device is locked in the off position check that no voltage is present Machine fully vented no pressure 1 Allow the machine to cool down completely 2 Disconnect all air and electrical connections Packing A wooden crate is required for overland transport to protect the machine from mechanical damage Other measures must be taken for the transport of machines by sea or air Please contact KAESER SERVICE for more information Desiccant Plastic sheeting Wooden crate The machine is decommissioned The machine is dry and cooled down 1 Place sufficient desiccant silica gel or desiccant clay in the machine 2 Wrap the machine fully in plastic sheeting 3 Protect the machine in a wooden crate against mechanical damages Storage Moisture can lead to corrosion particularly on the surfaces of the airend and in the oil separator tank Frozen moisture can damage components valve diaphragms and gaskets Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E I 12 4 12 4 1 Precondition 12 4 2 Precondition Fig 34 12 4 3 12 Decommissioning Storage and Transport 12 4 Transport The following measures also apply to machines not yet commissioned Please consult with KAESER if you have questions to the appropriate storage and commis sioning 1 NOTICE Moisture and frost can damage the machine gt Pr
94. il level Y gt Ensure that the permissible room temperature is not exceeded gt Change the oil filter 5 Fault in the refrigeration dryer gt Clean the refrigerant condenser Ensure adequate ventilation gt Install an extractor fan 6 Defective analog input pressure or gt Check lines and connections temperature sensor We Y 7 Maximum permissible temperature Ensure adequate ventilation of the controller housing exceeded gt Ensure that the permissible room temperature is not exceeded 8 Reserve Tab 49 Alarm indications 9 3 Warning messages The fault code appears in the 4th line of the display field An adhesive label at the machine explains the fault code using symbols Fault Symbol Meaning Remedy code S Maintenance counter has elapsed gt Carry out maintenance p Back pressure present gt Check direction of drive motor p Oe tation Machine below minimum permissi gt Increase room temperature ble starting temperature i Pressure relief valve check mode gt Check pressure relief valve switched on gt Deactivate check mode Tab 50 Warning messages Service Manual Screw Compressor 9 5717 20 E ASK T SIGMA CONTROL BASIC 57 58 57 3 9 Fault Recognition and Rectification 9 4 Tab 51 9 4 Other Faults Other Faults Fault Possible cause Machine runs but produces no Inlet valve not opening or only
95. ined in chapter 2 2 2 Information referring to potential problems are identified by a question mark o The cause is named in the help text gt aSis solution e This symbol identifies important information or measures regarding the protection of the envi ronment Further information Further subjects are introduced here Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 3 KAESER KOMPRESSOREN 2 1 Tab 3 2 2 Tab 4 2 3 2 Technical Specifications 2 1 Nameplate Technical Specifications Nameplate The machine s nameplate provides the model designation and important technical information The nameplate is located on the outside of the machine above the cooler or m on the rear of the machine gt Enter here the nameplate data as a reference Feature Value Rotary Screw Compressor Part No Serial No Year of manufacture Rated power Rated motor speed Maximum working pressure Ambient temperature Nameplate Options The table contains a list of possible options gt Enter options here as a reference Option Option code Exists Modulating control C1 Adjustable machine feet H1 Air cooling K1 Transformer power supply for refrigeration dryer 2 Refrigeration dryer T3 Prepared for heat recovery W1 Options Weight The weight given is the maximum Actual weights of individual machines are dependent on equip ment fitted Service Manual Screw Compresso
96. ing air cooler venting Pressure gauge Hose coupling oil separator tank venting Oil filler port with plug Cooling oil level indicator Plug in nozzle Shut off valve 73 93 97 5 9 S 5 Oil changing with help from internal pressure The machine has been running for at least 5 mi nutes under LOAD The machine is fully vented the pressure gauge on the oil separator tank reads 0 bar 1 Close the shut off valve in the venting line 2 Startthe machine and watch the oil separa tor tank pressure gauge 2 until it reads 3 5 bar Switch off the machine Wait at least 2 minutes to allow the oil to flow back to the separator tank Draining the oil from the separator tank 10 0062 Shut off valve open Shut off valve closed Maintenance hose Hose coupling oil drain 10 Shut off valve venting line 11 Shut off valve oil drain Changing the oil using an external compressed air source The supply disconnecting device is switched off the device is locked off the absence of voltage has been verified The machine is fully vented the pressure gauge on the oil separator tank reads 0 bar An external source of compressed air is availa ble 1 Close the shut off valve in the venting line 2 With the shut off valve closed insert the male hose fitting 6 into the hose cou pling 3 3 Connect the maintenance hose to the exter nal air supply 4 Openthe shut off valve 7 until the pre
97. into account Interval Maintenance task see chapter weekly Check belt tension 10 9 Check the cooling oil level 10 12 Cooler 10 3 Check the filter mat Control cabinet 10 4 Check the filter mat Check the condensate drain 10 18 2 h operating hours Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER 10 Maintenance 10 2 Following the maintenance plan Interval Maintenance task see chapter Up to 1 000 h Maintain the drive belt 10 9 Check the air filter 10 7 Clean the cooler 10 5 Cooler 10 3 Clean the filter mat Control cabinet 10 4 Clean the filter mat Clean the refrigerant condenser 10 18 1 Display Change the air filter element 10 7 SIGMA CONTROL BASIC Cooler Change the filter mat 10 5 Control cabinet Change the filter mat 10 4 Display Change the oil filter 10 16 SIGMA CONTROL BASIC Change the oil separator cartridge 10 17 At least annually Variable see table 53 Change the cooling oil 10 15 Annually Check the pressure relief valve 10 10 Check the overheating safety shutdown function 10 11 Check the cooler for leaks 10 5 Maintain the heat recovery system 10 6 Check that all electrical connections are tight Have the refrigerant circuit checked and documented an authorised KAESER Service Technician Have the safety pressure switch checked by an author ised KAESER Service Technician Up to 12 000 h Replace the drive belt 10 9 h operating hours
98. ion Dryer Control Modes QUADRO In contrast to the the DUAL regulating mode the machine will switch from LOAD to STANDSTILL in QUADRO mode after periods with low compressed air consumption After periods with a high compressed air consumption the machine will switch from LOAD to STANDSTILL after passing through IDLE In this control mode the controller requires two specified times The running time and the idle standstill time The shorter these times are set the sooner and more frequently the motor is stopped MODULATING control The MODULATING control completes the aforementioned control types It continuously changes the delivery volume within the machine s control range Compressed air demand Operating modes rises MODULATING LOAD falls MODULATING IDLE STANDSTILL Operating modes under MODULATING control Refrigeration Dryer Control Modes The controller can operate in the following modes CONTINUOUS TIMER CONTINUOUS The refrigeration dryer will remain activated even when the machine is in standby TIMER The refrigeration dryer is switched on and off by a timer when the machine is in standby In this mode the operating temperature is held within tight limits This mode of control is set up at the factory Which control mode is the most practical and when Control mode Advantage Disadvantage CONTINUOUS Constant dew point Higher power consumption when the machine is in standby mode TIMER L
99. ion the machine in warm cooling outlet air from other machines gt Keep suitable fire extinguishing agents ready for use Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 21 22 3 14 3 Safety and Responsibility 3 5 3 3 5 4 3 5 Dangers Commissioning operation and maintenance During commissioning operation and maintenance you may be exposed to dangers resulting from e g electricity pressure and temperature Careless actions can cause accidents with severe ad verse effects for your health gt Allow maintenance work to be carried out only by authorised personnel Wear close fitting flame resistant clothing Wear protective clothing as necessary Switch off and lock out the power supply isolating device and verify the absence of voltage Check that there is no voltage on floating relay contacts Close shut off valves or otherwise isolate the machine from the compressed air network to sure that no compressed air can flow back into the machine De pressurise all pressurised components and enclosures Allow the machine to cool down Do not open the cabinet while the machine is switched on Do not open or dismantle any valves Use only spare parts approved by KAESER for use in this machine Y Y Carry out regular inspections for visible damages of safety installations of the EMERGENCY STOP command device of any components requiring
100. ir treatment Air quality suffers To ensure the desired air quality when charging a vented air network we recommend the installa tion of an air main charging system gt Consult KAESER for advice on this subject Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 39 40 ESER 6 Installation 6 1 Further information 6 1 Ensuring safety Installation Ensuring safety Follow the instructions below for safe installation Warning instructions are located before a potentially dangerous task Disregard of warning instructions can cause serious injuries Complying with safety notes Disregard of safety notes can cause unforeseeable dangers gt Follow the instructions in chapter 3 Safety and Responsibility gt Installation work may only be carried out by authorised personnel gt Make sure that no one is working on the machine gt Ensure that all service doors and panels are locked When working on live components Touching voltage carrying components can result in electric shocks burns or death gt Work on electrical equipment may only be carried out by authorised electricians gt Switch off and lock out the power supply isolating device and verify the absence of voltage gt Check that there is no voltage on floating relay contacts When working on the compressed air system Compressed air is contained energy Uncontrolled release of this energy can cause seri
101. l heat recover system is de pressurised 10 80319 Changing the cooling oil heat recovery system Thermostatic valve Screw plug 1 Have receptacle ready 2 Remove the drain plug 3 and allow the oil to drain completely 3 Replace the plug 3 Filling with cooling oil 1 WARNING Compressed air Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly gt all pressurised components and enclosures 2 Slowly unscrew the filler plug 4 see illustration 27 3 Fill with cooling oil 4 Check the filler plug and ring seal for damage and screw the plug back in again Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E 10 16 A Material Precondition A Fig 29 10 Maintenance 10 16 Changing the oil filter Starting the machine and carrying out a trial run Close all access doors replace and secure all removable panels Open the user s shut off valve between the machine and the air distribution network Switch on the power supply and reset the maintenance interval counter Start the machine and check the oil level again after about 10 minutes topping up if necessary Switch off the machine and check visually for leaks Changing the oil filter The machine must be isolated from the compressed air network and completely vented be
102. monitoring gt particular attention to cleanliness during all maintenance and repair work Cover compo nents and openings with clean cloths paper or tape to keep them clean gt not leave any loose components tools or cleaning rags on or in the machine gt Components removed from the machine can still be dangerous Do not attempt to open or destroy any components taken from the machine De commissioning storage and disposal Improper handling of old operating fluids and components represent a danger for the environment gt Drain off fluids and dispose of them according to environmental regulations These include for example compressor oil and cooling water gt Have refrigerant disposed of by authorised bodies only gt Dispose of the machine in accordance with local environmental regulations Organisational Measures gt Designate personnel and their responsibilities gt Give clear instructions on reporting faults and damage to the machine gt Give instructions on fire reporting and fire fighting measures Danger Areas The table gives information on the areas dangerous to personnel Only authorised personnel may enter these areas Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E Safety and Responsibility KAESER 3 3 6 Safety devices Activity Danger area Authorised personnel Transport Within a 3 m radius of the machine Installation personnel for transport
103. nfpe _ _ NL paysn pe 71 9 0 570 71 ysz l 6 0 71 vsz1 6 0 A002 ueJbeip Lu tc O o o 5 x 9 5717 20E Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 122 EP turds NMJ zjesJ3 248543 unjeg Bunsapuy 0 00 0 0 0 8 lS VS sweJbeip Jawsojsued supog 10553 aS e eS js we ueJBeip 1 2 15 3 04 A005 Mojja uaaJb uui zx 4 pue YLEX uaaM aq uoij3auuo3 ue NOILN3LIV 2809 08 0 097 Jadwnf 0 1 Z gt JaMog 7 MOEZ SO0Ed MOEZ SOE 13 4 Electrical Diagram 13 Annex ZHOS A004 oel e oel JaMOd 9 lt lt uoij3auuo2 JaMOq ueJbeip KAESER KOMPRESSOREN 123 Screw Compressor ASK T SIGMA CONTROL BASIC Service Manual 9 5717 20E 0 9144 euiuJa Am 249543 1248543 xsv salas 1055 t EF q panddns 2245 Buluuns 4040u Z sasodind 5 404 7 ou NO 1044497 01 285 550 2 ajqe3 99 c 5 1851 Sj3e4u02 38JJ 4 0A jenueu 3 19 e
104. ng the edit mode 1 Scroll with the UP DOWN keys until the desired parameter appears in line 3 2 Depress the enter key for at least 3 seconds Depending on the parameter either the displayed value or the the first character of the required password flashes Changing a parameter that is not password protected The current parameter setting flashes gt Use the UP DOWN keys to change the value of the parameter and confirm with enter Changing a password protected parameter Some parameters can only be edited after a password has been entered Password BASIC This password will be automatically reset if no key is pressed within 5 minutes The first character flashes 1 Select the first character with the UP DOWN key and confirm with enter The next character flashes 2 Repeatuntil all characters have been entered When the correct password is entered the parameters are displayed 3 Use the UP DOWN keys to change the value of the parameter and confirm with enter Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E TITT Operation 84 Acknowledging alarm and warning messages 8 4 Acknowledging alarm and warning messages kaeser com 222 7S 11 08 50052 Fig 18 Acknowledging messages 10 Warning LED yellow 11 A arm LED red Acknowledge key Alarm message Messages are displayed on the new value princi
105. ng the external heat recovery system 44 Initial Start up feds Ensuringisatelyr 6 D Leo int 45 7 2 Instructions to be observed before commissioning or re commissioning 46 7 3 Checking installation and operating conditions 46 7 4 Setting the overload protection cut out eene 47 7 5 Pouring cooling oil into the airend 47 7 6 Activating and deactivating the MODULATING control 48 7 7 Checking the Door Interlock Switch 49 7 8 Starting the machine for the first time 50 7 9 Setting the setpoint pressure nnne 50 Operation 8 1 Switching On and 52 8 1 4 Switching ee o de e A TR eret 52 827222 SSWITCHING Off db teet ettet tct ttd 52 8 2 Switching off in an emergency and switching on again 53 8 3 Setting parameters n nennen 54 8 4 Acknowledging alarm and warning messages 55 Fault Recognition and Rectification 94 e ee ceo crie vex Die 56
106. ngs in the compressed air system with a hand held pressure gauge to en sure that they all read 0 bar gt not open dismantle any valves When working on the drive system Touching voltage carrying components can result in electric shocks burns or death Touching the fan wheel the coupling or the belt drive while the machine is switched on can result in serious injury gt Switch off and lock out the power supply isolating device and verify the absence of voltage gt Do not open the cabinet while the machine is switched on Details of authorised personnel are found in chapter 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 45 46 ESER 7 2 Tab 45 7 3 Initial Start up 7 2 Instructions to be observed before commissioning or re commissioning Instructions to be observed before commissioning or re commis sioning Incorrect or improper commissioning can cause injury to persons and damage to the machine gt Commissioning may only be carried out by authorised installation and service personnel who have been trained on this machine Special measures for re commissioning after storage Storage period Remedy longer than 3 months gt Manually fill the airend with cooling oil 12 months gt Change the oil filter gt Change the oil separator cartridge gt Change the cooling g
107. ntity from the de pressurised oil separator tank Chapter 10 15 provides detailed information on how to drain cooling oil from the oil separator tank 11 cooling oil The supply disconnecting device is switched off the device is locked off the absence of voltage has been verified Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 47 KAESER KOMPRESSOREN 48 Fig 13 7 6 Tab 47 Precondition 7 initial Start up 7 6 Activating and deactivating the MODULATING control 07 S0048 Inlet valve filling port Screw plug Inlet valve 1 Unscrew the filler plug from the inlet valve 2 Pour the stipulated amount of cooling oil into the airend and replace the filler plug 3 Turn the airend manually by means of the belt pulley to distribute the oil Option C1 Activating and deactivating the MODULATING control Use a shut off valve to activate and deactivate the MODULATING control If the MODULATING control is deactivated the machine always delivers the maximum possible compressed air quantity in LOAD mode MODULATING control Shut off valve switch on open switch off close MODULATING control Setting the shut off valve The supply disconnecting device is switched off the device is locked off the absence of voltage has been verified Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20 E KOMPRESSOREN Fig 14 7 7 I Fig 15 9 5717 20 E 7 Initi
108. of changing or adjusting parameters are given in chapter 8 3 4 10 3 Messages Alarm message An alarm shuts the machine down automatically The red LED flashes Fig 8 Warning message The yellow LED lights to indicate a warning figure 8 Service Manual Screw Compressor 36 ASK T SIGMA CONTROL BASIC 9 5717 20E 343 4 5 Installation and Operating Conditions 9 5717 20E 5 1 5 2 5 2 1 Precondition 5 1 Ensuring safety Installation and Operating Conditions Ensuring safety The conditions in which the machine is installed and operated have a decisive effect on safety Warning instructions are located before a potentially dangerous task Disregard of warning instructions can cause serious injuries Complying with safety notes Disregard of safety notes can cause unforeseeable dangers gt Strictly forbid fire open flame and smoking gt f welding is carried out on or near the machine take adequate measures to prevent sparks or heat from igniting oil vapours or parts of the machine gt not store inflammable material in the vicinity of the machine gt machine is not explosion proof Do not operate in areas in which specific requirements with regard to explosion protection are in force For instance the requirements of ATEX directive 94 9 EC Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres gt Ensure suffi
109. oking Follow safety regulations when dealing with oils lubricants and chemical substances Avoid contact with skin and eyes Do not inhale oil mist or vapour Do not eat or drink while handling cooling and lubricating fluids Keep suitable fire extinguishing agents ready for use Y vY Y Y Use only KAESER approved operating materials Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine gt Use only spare parts approved by the manufacturer for use in this machine gt Useonly genuine KAESER replacement parts on pressure bearing parts Conversion or modification of the machine Modifications additions to and conversions of the machine or the controller can result in unpredict able dangers gt Do not convert or modify the machine gt Obtain written approval by the manufacturer prior to any technical modification or expansion of the machine the controller or the control programs Extending or modifying the compressor station If dimensioned appropriately pressure relief valves reliably prevent an impermissible rise in pres sure New dangers may arise if you modify or extend the compressed air station gt When extending or modifying the compressed air system Check the blow off capacity of pressure relief valves on air receivers and compressed air lines before installing a new machine gt blow off capacity is insufficient Install pressure relief valves with la
110. om the distribution network to ensure that no compressed air can flow back into the machine Service Manual Screw Compressor 18 ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E 3 Safety and Responsibility 3 5 Dangers gt De pressurise all pressurised components and enclosures gt not carry out welding heat treatment or mechanical modifications on pressurised compo nents e g pipes and vessels as this influences the component s resistance to pressure The safety of the machine is then no longer ensured Compressed air quality The composition of the compressed air must be suitable for the actual application in order to pre clude health and life threatening dangers gt Use appropriate systems for air treatment before using the compressed air from this machine as breathing air and or for the processing of foodstuffs gt Use foodstuff compatible cooling oil whenever compressed air is to come into contact with foodstuffs Spring forces Springs under tension or compression store energy Uncontrolled release of this energy can cause serious injury or death Minimum pressure check valves pressure relief valves and inlet valves are powerfully spring loa ded gt not open or dismantle any valves Rotating components Touching the fan wheel the coupling or the belt drive while the machine is switched on can result in serious injury gt not open the enclosure while the mac
111. omponents and enclosures 2 Unscrew the fitting and carefully put the parts to one side then pull out the copper pipe at item 15 3 Unscrew the nut 19 and turn the air pipe 16 to one side Remove the cover fixing screws and carefully remove the cover 14 Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of ac cording to environmental protection regulations Clean all sealing faces Insert the new oil separator cartridge with gaskets and screw down the cover Renew the O ring and strainer in the dirt trap 15 Attach the air pipe to the cover 14 with a new self locking nut 0 Replace and tighten all fittings 2o 0o gt Dispose of parts and materials contaminated with oil in accordance with environmental protection regulations Starting the machine and carrying out a trial run 1 Close all access doors replace and secure all removable panels 2 Open the user s shut off valve between the machine and the air distribution network Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 79 KAESER KOMPRESSOREN 80 10 18 Material Fig 31 10 18 1 Precondition 10 18 2 10 Maintenance 10 18 Refrigeration Dryer Maintenance 3 Switch on the power supply and reset the maintenance interval counter 4 After approx 10 minutes of operation Switch off the machine and check visually for leaks Refrigeration Dryer Maintenance The refrigerati
112. on circuit is fully hermetically sealed and needs no maintenance Repairs may only be carried out by certified personnel Compressed air for blowing out Cleaning cloth Vacuum cleaner Spare parts as required 10 S0112 Refrigeration dryer Access panel Refrigerant condenser Sight glass Condensate drain Screws Condensate drain gt Check and clean the refrigerant condenser and condensate drain regularly as described below Cleaning the refrigerant condenser The supply disconnecting device is switched off the device is locked off the absence of voltage has been verified 1 Undo the latch 5 and remove the panel 1 2 Use compressed air 5 bar to blow the condenser 4 through from outside to inside and then vacuum up the dirt 3 Replace the panel again Checking the condensate drain The condensate drain opens automatically when enough condensate has collected One of the illustrated condensate drains is fitted according to compressor model Fig 32 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 9 5717 20E Precondition Fig 32 Result 10 18 3 Precondition 10 Maintenance 10 18 Refrigeration Dryer Maintenance The machine is shut down The Power LED lights Taat ECO Drain 30 10 50114 Checking condensate drainage 1 PowerLED TEST key 3 Alarm LED 1 With one hand lightly touch the condensate
113. onal Measures 22 354 Danger Areas o Rte a Re IR ERR ees 22 3 6 Safety deV ES degentes 23 3 7 Safety SIQNS e 23 3 8 Emergency Situations e paea ea 24 3871 Correct fire fighting esie Leere ecu eee eee 24 3 8 2 Treating injuries from handling cooling oil 25 3 8 3 Injury from Handling Refrigerant 25 3 9 Warranty ic oae EH ee apt ett patei ted e dte dte tents 26 3 10 Environment protection 4 26 Design and Function Enclosure 27 4 27 Machine T hctlon RUE Ue Bib eels tliat ie 28 4 3 Refrigeration dryer 29 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC KAESER KOMPRESSOREN Contents 44 Eloatirigirelay Contacts iie i dol ehe 29 4 5 ODptlors n EE RR REIR pee e OR Pe qe ERE EC 29 4 5 1 Machine mountings 44 29 4 5 2 Prepared for external heat recovery 30 4 6 Operating modes and control 30 46 1 Operating modes cies eee e deett 30 462 Control modes o c dd Ad gilet let 31 4 7 Refrigeration Dryer Control Modes 32 48 Safety Hae
114. ous injury or death The following safety concerns relate to any work on components that could be under pressure gt Close shut off valves or otherwise isolate the machine from the compressed air network to en sure that no compressed air can flow back into the machine gt all pressurised components and enclosures gt Check all hose couplings in the compressed air system with a hand held pressure gauge to en sure that they all read 0 bar gt not open or dismantle any valves When working on the drive system Touching voltage carrying components can result in electric shocks burns or death Touching the fan wheel the coupling or the belt drive while the machine is switched on can result in serious injury gt Switch off and lock out the power supply isolating device and verify the absence of voltage gt Do not open the cabinet while the machine is switched on Details of authorised personnel are found in chapter 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E ESER 6 Installation KA KOMPRESSOREN 6 2 Precondition Fig 10 it AN Further information 9 5717 20E 6 4 Precondition 6 2 Reporting Transport Damage Reporting Transport Damage 1 Checkthe machine for visible and hidden transport damage 2 Inform the carrier and the manufacturer in writing of any d
115. ower power consumption when Brief increase in dew point when the compres the machine is in standby mode sor re starts Refrigeration dryer control modes Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 1 4 Design and Function 25 Safety devices 4 8 Safety devices The following safety devices are provided and may not be modified in any way EMERGENCY STOP control device The EMERGENCY STOP button shuts down the compressor immediately The motor remains stopped The pressure system is vented Pressure relief valve The pressure relief valve protects the system against excessive pressure It is factory set Safety pressure switch machine with refrigeration dryer The safety pressure switch protects the refrigerant circuit against excessive pressure It cannot be set Door interlock switches The machine will stop automatically if a safety interlocked door or panel is opened or removed m Enclosures and guards for moving parts and electrical connections Protect against accidental contact 4 9 Keys and LEDs SIGMA CONTROL BASIC 04 0035 Fig 7 Keys overview Item Function 1 ON Switch on the machine 2 OFF Switch off the machine Resets alarms acknowledge Resets the maintenance interval counter 6 DOWN Scrolls down the parameter list Reduces a parameter value 7 UP Scrolls up the parameter list Increases a parameter value 8
116. ower supply disconnecting device The machine is switched off and isolated from the mains supply The Controller Power LED ex tinguishes Switching off in an emergency and switching on again The EMERGENCY STOP push button is located below the control panel 9 08 50051 Switching in an emergency 9 EMERGENCY STOP control device Switching off gt Press the EMERGENCY STOP control device The EMERGENCY STOP button remains latched after actuation The compressor s pressure system is vented and the machine is prevented from automatically re starting Switching on The fault has been rectified 1 Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it 2 Acknowledge any existing alarm messages The machine can now be started again Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 53 KAESER KOMPRESSOREN 54 8 3 Result Precondition Precondition 8 Operation 8 3 Setting parameters Setting parameters If a password is needed it is requested automatically Every action can be cancelled with the escape key If no key is pressed for ten seconds in the edit mode the display automatically returns to the previous mode Restarting the controller is not necessary Edited parameters are immediately effective Network pressure and airend discharge temperature are neither updated nor displayed whilst in the edit mode Enteri
117. pared for heat recovery Machine mountings Air cooling UapJa JyIDWEB uanbupDnz asia 46115405 ui usjJnp U3ou PUBO 1 nz JNU uajJnp Jaustuo pyera DunpuaJaA Jajun DunjjaJqJaA Japo BunjraqmoJaA Gunsaysiads 5 5 Japo Jedoy UapJaA Japua JaA UIJ PUD WAU JJapupab 1 1 nu uapbuaq oA uabunuapuy ajBupansbunppiqu3 NZ UALIDGUIBIAA JNU unjua6r3 sauprsjenunssno Jasun 41319 Dunuuaraz 210 Service Manual Screw Compressor 106 ASK T SIGMA CONTROL BASIC 9 5717 20E 13 13 3 Dimensional drawing KAESER KOMPRESSOREN KOMPRESSOREN Schubart P huebner 055 for installed ducting Total permissible pressure 2 400 m h 2 900 m h 3400 22 07 2011 Cooling air inlet Freigeg 22 07 2011 Bez ASK 27 V ASK 32 V ASK 35 V ASK 27 32 35 Original Bezeichnung Anderungs Nr Ookument Nr 10200660 D 00 Techn Dienst Nr 111485 00 Cooling air outlet ASK 27 V 3 000 m h ASK 32 V 3500 m h ASK 35 V 4 000 m h with fil
118. ple Message received LED flashes Message acknowledged LED lights Message gone LED extinguished or Message received LED flashes Message gone LED flashes Message reset LED extinguished gt the fault and acknowledge the message with the acknowledge key alarm LED extinguishes The machine is now ready to start again Warning message m Message coming LED flashes Message gone LED extinguished gt Rectify fault or carry out maintenance The Warning LED extinguishes as soon as the cause of the warning is rectified Service Manual Screw Compressor 9 5717 20 E ASK T SIGMA CONTROL BASIC 55 KAESER KOMPRESSOREN 9 1 9 2 56 9 Fault Recognition and Rectification 9 1 Basic instructions Fault Recognition and Rectification Basic instructions The following tables are intended to assist in locating faults There are 3 types of fault Alarm red LED flashes see chapter 9 2 Warning yellow LED lights see chapter 9 3 Other faults no indication see chapter 9 4 The messages valid for your machine are dependent on the controller and individual equipment 1 Do not attempt fault rectification measures other than those given in this manual 2 other cases Have the fault rectified by an authorized KAESER service representative Alarm messages machine shut down The fault code appears in the 4th line of the display field A sticker with symbols on the machine e
119. potential personal in jury Warning notices for damages are identified by their signal term Signal term Meaning Consequences of disregard NOTICE Warns of a potentially dangerous situation Damage to property is possible Danger levels and their definition damage to property Example NOTICE The type and source of the imminent danger is shown here Potential effects when ignoring the warning are indicated here gt protective measures against the damages are shown here gt Carefully read and fully comply with warnings against damages Other alerts and their symbols This symbol identifies particularly important information Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 77 3331 1 Regarding this document KOMPRESSOREN 1 4 Symbols and labels Material you will find details on special tools operating materials or spare parts Precondition you will find conditional requirements necessary to carry out the task The conditions relevant to safety shown here will help you to avoid dangerous situations Option H1 This symbol denotes lists of actions comprising one stage of a task Operating instructions with several steps are numbered in the sequence of the operating steps Information relating to one option only are marked with an option code e g H1 indicates that this section applies only to machines with screw in machine feet Option codes used in this service manual are expla
120. ppropriate lifting gear The lifting gear complies with local safety regulations No pressure should bear on the sides of the machine cabinet 12 0070 Transport with crane Lifting gear Slings 1 NOTICE The machine can be damaged by incorrect attachment of the lifting gear gt Do not attach the lifting gear to any of the machine components 2 Use the lifting gear correctly and lift the machine carefully Disposal When disposing of a machine drain out all liquids and remove dirty filters The machine is decommissioned 1 Completely drain the cooling oil from the machine 2 Remove used filters and the oil separator cartridge 3 Hand the machine over to an authorized disposal expert gt Components contaminated with cooling oil must be disposed of in accordance with local environment protection regulations Machines with refrigeration dryers The sealed refrigerant circuit still contains both refrigerant and oil gt Refrigerant and oil must be drained and disposed of by an authorized body Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 13 13 1 9 5717 20E 13 Annex 13 1 Pipeline and instrument flow diagram diagram Annex Pipeline and instrument flow diagram diagram Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 93 701000 16459 101000 1535 2 aanp son PEE
121. pressure between the set minimum and maximum values The control mode also rules the degree of energy efficiency of the machine The machine dependant venting phase between the LOAD and STANDSTILL operating modes en sures load changes at minimum material stresses The controller SIGMA CONTROL BASIC can operate in the following modes DUAL QUADRO MODULATING control Energy efficient control modes for various applications Application Recommended control mode Compressed air station with one machine or several machines with com QUADRO parable delivery Machine for peak load in a compressed air station DUAL Machine for intermediate load in a compressed air station QUADRO Machine for basic load in a compressed air station QUADRO Energy efficient control modes The SIGMA CONTROL BASIC controller is factory set to QUADRO control mode unless specifi cally ordered otherwise DUAL In the DUAL control mode the machine is switched back and forth between LOAD and IDLEto maintain the machine working pressure between the preset minimum and maximum values When maximum pressure is reached the machine switches to IDLE When the preset dling time has elapsed the machine is STOPPED The time is permanently set in SIGMA CONTROL BASIC Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 31 32 ESER 4 Design and Function Option C1 Tab 39 4 7 Tab 40 4 7 Refrigerat
122. r The oil temperature regulators ensure that the cooling oil is kept at the ideal temperature for ma chine operation The thermostatic valve opens first so that surplus heat is released into the heat recovery system If the heat recovery system cannot remove sufficient heat the combination valve opens to additional ly release the cooling circuit via the oil cooler Condition Combination valve opening temperature thermostatic valve opening temperature The heat available for recovery depends on the individual operating conditions of the machine Connections are provided for an external system to recover surplus heat The thermostatic valve is deactivated when the machine is delivered The necessary operating ele ment must be installed when installing the heat recovery system If necessary the operating element in the combination valve can be exchanged for one with higher opening temperature The opening temperature depends on operating and ambient conditions Operating elements are marked with their opening temperature If the cooling oil temperature is too low condensate can form and damage the machine gt Consult KAESER Service on components and layout to ensure proper functioning of the cooling and heat recovery systems Operating modes and control modes Operating modes The machine operates in the following modes LOAD The inlet valve is open The airend delivers compressed air to the distribution network The
123. r ASK T SIGMA CONTROL BASIC 9 5717 20E 4 14d 14 2 9 5717 20E Tab 5 24 Tab 6 2 5 Tab 7 Technical Specifications 24 Temperature Weight kg Machine weight Temperature Minimum cut in tempera ture Typical airend discharge temperature during oper ation C Maximum airend dis charge temperature au tomatic safety shut down Temperature Ambient conditions Maximum elevation amsl m Permissible ambient tem perature Cooling air temperature Intake air temperature Higher altitudes are permissible only after consultation with the manufacturer Ambient conditions Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC ASK 27 465 ASK 27 65 100 110 ASK 32 480 ASK 32 65 100 110 ASK 35 495 ASK 35 65 100 110 T9 X1333 2 Technical Specifications 15 578 26 Ventilation 100 80 70 60 0 3 31 34 36 38 41 45 T Fig 1 Maximum relative humidity of intake air Intake air temperature Maximum relative humidity of intake air 96 2 6 Ventilation The values given are minimum guide values Mains frequency 50 Hz ASK 27 ASK 32 ASK 35 Inlet aperture Z see fig 0 5 0 6 0 7 ure 9 m Forced ventilation with 7500 8500 9500 exhaust fan Flow rate m3 h at 100 Pa Tab 8 Overview Ventilation 50 2 Mains frequency 60 Hz ASK 27
124. r receiver Increase air pipe diameters Check filter elements Check switching differential Remove coupling or mainte nance hose Call KAESER service represen tative Tighten joints Replace seals Use SIGMA FLUID cooling oil Change the oil separator car tridge Drain off oil until the correct lev el is reached Check dirt trap in the return line 9 5717 20E KAESER KOMPRESSOREN 10 10 1 Further information 9 5717 20E 10 Maintenance 10 4 Ensuring safety Maintenance Ensuring safety Follow the instructions below for safe installation Warning instructions are located before a potentially dangerous task Disregard of warning instructions can cause serious injuries Complying with safety notes Disregard of safety notes can cause unforeseeable dangers gt Follow the instructions in chapter 3 Safety and Responsibility gt Allow maintenance work to be performed by authorised personnel only gt sure that one is working on the machine gt Ensure that all service doors and panels are locked When working on live components Touching voltage carrying components can result in electric shocks burns or death gt Work on electrical equipment may only be carried out by authorised electricians gt Switch off and lock out the power supply isolating device and verify the absence of voltage gt Check that there is no voltage on floating relay contacts When working
125. ram amp Equipment parts list ASK 27 ASK 27 T machine power supply 200V 10 50Hz 230V 110 50Hz 380V 110 60Hz 400V 210 50Hz 110 60Hz 200V 110 60Hz 230V 10 60Hz 310 60Hz Motor 15kW 15kW 15kW 15kW 15kW gt diagram 2 Sht 1 diagram 1 Sht 1 50Hz diagram 1 Sht 1 diagram 1 Sht 1 diagram 1 Sht 1 diagram 2 Sht 1 60Hz en Siemens 3RV1935 5A 3RV1935 5A 3RV1935 5A 3RV1915 5A 3RV1915 5A 5 terminal strips X1 option T3 X11 X31 3RT1036 1AL20 3RT1036 1AL20 3RT1034 1AL20 3RT1026 1AL20 3RT1026 1AL20 Auxiliary switch 7 3140 04050 7 3140 04050 7 3140 04050 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 3RH1921 1XA31 0MA3 Interference suppressor 7 3140 00920 7 3140 00920 7 3140 00920 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1926 1CD00 3RT1926 1CD00 Contactor Q2 7 6869 0 7 6869 0 7 6867 0 3RT1036 1AL20 3RT1036 1AL20 3RT1034 1AL20 3RT1026 1AL20 3RT1026 1AL20 Auxiliary switch 7 3140 02030 7 314 0 02030 7 311 0 02030 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 3RH1921 1CA01 Interference suppressor 7 3140 00920 7 3140 00920 7 3140 00920 Siemens 3RT1936 1CD00 3RT1936 1CD00 3RT1936 1CD00 3RT1926 1CD00 3RT1926 1CD00 o Contactor 03 7 6867 0 7 6866 0 7 6865 0 3RT1034 1AL20 3RT1026 1AL 20 3RT1025 1AL20 3RT1025 1AL20 3RT1025 1AL20 a 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921 1CA10 3RH1921
126. re original Kaeser products They are specifi cally selected for use in KAESER machines Unsuitable or poor quality consumable parts and operating fluids materials may damage the ma chine or impair its proper function Personal injury may result from machine damage WARNING There is risk of personal injury or damage to the machine resulting from the use of unsuita ble spares or operating fluids materials gt Use only original KAESER parts and operating fluids materials gt Have an authorised KAESER Service Technician carry out regular maintenance Machine Name Quantity Number Air filter cartridge 1 1250 Filter mat cooler 1 1050 Filter mat control cabinet 2 1100 Oil filter 1 1200 Oil separator cartridge 1 1450 Cooling oil 1 1600 Drive belt 1 1801 Consumable parts KAESER AIR SERVICE KAESER AIR SERVICE offers m authorised service technicians with KAESER factory training increased operational reliability ensured by preventive maintenance m energy savings achieved by avoidance of pressure losses optimum conditions for operation of the compressed air system security of genuine KAESER spare parts increased legal certainty as all regulations are kept to gt Why not sign a KAESER AIR SERVICE maintenance agreement Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 11 Spares Operating Materials Service similes 11 4 Service Addresses Result Your advan
127. re those recommended for average operating conditions gt n adverse conditions perform maintenance work at shorter intervals Adverse conditions are e g m high temperatures much dust m high number of load changes low load gt Adjust the maintenance intervals with regard to local installation and operating condi tions gt Documenting all maintenance and service work This enables the frequency of individual maintenance tasks and deviations from our recom mendations to be determined A prepared list is provided in chapter 10 19 Resetting maintenance interval counters SIGMA CONTROL BASIC is equipped with a maintenance interval counter The maintenance in terval counter counts down the operating hours to the next maintenance task The counting down of the maintenance interval indicator shows when the next maintenance action is due Reset the counter to the original value once the task has been carried out 1 Select parameter 2 maintenance interval counter with the UP DOWN keys 2 Depress the Enter key for at least 3 seconds 3 When the cursor flashes confirm the offered value with the Enter key Regular Maintenance Tasks The table below lists maintenance tasks required The refrigeration circuit is a closed unit Repairs may only be carried out by certified personnel Take note of the controller s service messages and carry out tasks punctually taking ambient and operating conditions
128. rew Compressor ASK T SIGMA CONTROL BASIC Service Manual 9 5717 20E ysy sais soss sdwo n E Sjua4u023 0 1511 t EF P 000 0 0 8 SVV ajejd noke rol 000 0 0 85IS Vl LEXZ LEXL LEX EL uoido ampaps 4 00 0L0 0 8 IS V3 0 9144 25 00701060 8 3S VS sweJbeip JauJojsueJJ 410341 _ 00 0 0 0 8 3S VS Ajddns 1014403 ueJBeip gt gt 00 010 amp 0 yeusayxa lt 41039415 021750 000L0 0 8 9S VS euJajur syndur ueJBelp 120 00 0L0 0 8 S VS sjndjno Aejay Ajddns 00 0 0 0 8 S VS Buiddey jo 1juoj o 00 0 0 0 8 S VS JaMog Ip 411219 6 00 0 0 0 8 4S VS ueJBelp 2117 098 0070 060 8 ASYN 151 sjJed juaudinb3 EE 00 0 0 0 8 ASYN 151 sjJed jueudinb3 9 00 0 0 0 8 ASYN 451 syed juaudinb3 s 000 0 0 8 IS v juaudinba jei4428 a 00 0 0 0 8 3S v Ssuoij3nJ4sui jeJauat gt e 0070 060 8 35 2 JO 1511 00 010 0 8 SVG pun 43 BurMeuq 1au04sn23 Bulmesg awen uaupazuuayuabejuy 481184s 8p 7 apuny 7 Bunuuauag E amp 5 2 13 Annex
129. rger blow off capacity Safe machine operation The following is information supporting you in the safe handling of the machine during individual product life phases Personal protective equipment When working on the machine you may be exposed to dangers that can result in accidents with severe adverse health effects gt Wear protective clothing as necessary Suitable protective clothing examples Safety workwear Protective gloves Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20 E KAESER KOMPRESSOREN 9 5717 20E 3 Safety and Responsibility 3 5 Dangers Safety boots Eye protection m Ear protection Transporting The weight and size of the machine require safety measures during its transport to prevent acci dents gt Use suitable lifting gear that conforms to local safety regulations Allow transportation only by personnel trained in the safe movement of loads Attach lifting gear only to suitable lifting points Be aware of the centre of gravity to avoid tipping Make sure the danger zone is clear of personnel Y Y Y Do not step onto machine components to climb up the machine Assembly gt Only use only electrical cables that are suitable and approved for the surroundings and electri cal loads applied gt Never dismantle compressed air pipes until they are fully vented gt Only use pressure lines that are suitable and approved for the maximum working pre
130. sg pa Wal dd LW 00 005 ZOLM 21423 juauoduio Jaquinu uoij3auuoj jeuJ84xa 520 Jaquinu um juauoduioj 01445 jeuiu Ja Screw Compressor Jaquinu uoij3auuoj uo jeuijsag 13 4 Electrical Diagram 13 Annex 18104 4 FEE EEE Kddns 34 24214 B aueJj z1 13d S euiuJg 40 0 45 euiuJa KAESER KOMPRESSOREN 9 5717 20 E ASK T SIGMA CONTROL BASIC Service Manual 124 LEXZ LEXL LEX E1 Um ziesug 2515 ysy Saluas sossasdwo jeuiuiJa 2609 A09 7 ZH09 A0 ZHO9 A097 ZH09 077 ZHOS A007 ZH09 ZH09 A08 sanddns samod ZH09 002 ZHOS 002 senddns juo uo 4014284403 21 uodo EERE EEEE 1029 Lh Il m A 301 005 uus 9s 022 ER a qej LEX LEX juauoduio LEX V023 Jaquinu uoij3auuoj 5 7 uo jeuijsag L OVLX 7 Jaquinu
131. ss it is specifically treated Improper use Improper usage can cause damage to property and or severe injuries gt Only use the machine as intended gt Never direct compressed air at persons or animals gt Use hot cooling air for heating purposes only if there is no risk to the health of humans or ani mals If necessary hot cooling air should be treated by suitable means gt not allow the machine to take in toxic acidic flammable of explosive gases or vapours gt Do not operate the machine in areas in which specific requirements with regard to explosion protection are in force User s Responsibilities Observe statutory and universally accepted regulations This is for example nationally applied European directives and or valid national legislation safety and accident prevention regulations Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN 3 4 2 3 4 3 9 5717 20E 3 Safety and Responsibility 3 4 User s Responsibilities gt Observe relevant statutory and accepted regulations during installation operation and mainte nance of the machine Qualified personnel These are people who by virtue of their training knowledge and experience as well as their knowl edge of relevant regulations can assess the work to be done and recognise the possible dangers involved Authorised operators possess the following qualifications are legal age m are
132. ssure gauge on the oil separator tank reads 3 5 bar 5 Close the shut off valve 7 and remove the male hose fitting from the coupling Contact KAESER Service if condensate is detected in the cooling oil It is necessary to adapt the airend discharge temperature to individual ambient conditions Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC T5 KAESER KOMPRESSOREN 76 Precondition x Option W1 Precondition Fig 28 10 Maintenance 10 15 Changing the cooling oil The supply disconnecting device is switched off the device is locked off the absence of voltage has been verified Have an oil receptacle ready With the shut off valve closed insert the male hose fitting 6 into the hose coupling 9 Place the other end of the maintenance hose in the oil receptacle and secure it in place Open the shut off valve 11 Slowly open the shut off valve 7 in the maintenance hose and allow oil and air to drain com pletely co qe qox Pressure gauge on the oil separator tank indicates O bar 6 Close the shut off valve and unplug the male hose fitting gt Dispose of used oil in accordance with environment protection regulations Draining the oil from the thermostatic valve A drain plug is provided to drain oil from the thermostatic valve If the machine is connected to an external heat recovery system oil should also be drained from the heat exchanger at a suitable point The externa
133. ssure and the intended medium gt Do not allow connection pipes to be placed under mechanical stress gt Do not induce any forces into the machine via the connections so that the compressive forces must be balanced by bracing Positioning A suitable installation location for the machine prevents accidents and faults gt Install the machine in a suitable compressor room gt Ensure sufficient and suitable lighting such that the display can be read and work carried out comfortably and safely gt Ensure accessibility so that all work on the machine can be carried out without danger or hin drance gt If installed outdoors the machine must be protected from frost direct sunlight dust rain and splashing water gt Do not operate in areas in which specific requirements regarding explosion protection are in force For instance the requirements of ATEX directive 94 9 EC Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres gt Ensure adequate ventilation gt Place the machine in such a manner that the working conditions in its environment are not im paired gt Comply with limit values for ambient temperature and humidity gt intake air must not contain any damaging contaminants Damaging contaminants are for instance explosive or chemically instable gases and vapours acid or base forming substances such as ammonia chlorine or hydrogen sulfide gt not posit
134. t Have the motor bearings checked by an authorised KAESER Service Tech nician 36 months gt Have the overall technical condition checked by an authorised KAESER Service Technician Re commissioning after storage Checking installation and operating conditions gt Check and confirm all the items in the checklist before starting the machine To be checked See chapter Confirmed gt Are the operators fully conversant with safety regulations gt Have all the positioning conditions been fulfilled 5 gt Is user s lockable power supply disconnecting device installed 6 4 gt Does the power supply conform to the specifications on the name 2 1 plate gt Are the power supply cable conductor cross sections and fuse rat 2 14 ings adequate gt Drive motor overload protection switch set according to the mains 7 4 voltage gt Option T2 Do the connections to the transformer correspond with 6 4 1 the mains supply gt Have all electrical connections been checked for tightness gt shut off valve fitted to compressed air outlet 6 3 gt Has the connection to the air system been made with a hose or axial 6 3 compensator gt 15 the condensate drain connected 6 5 gt Hasthe drive belt tension been checked 10 9 gt Is there sufficient cooling oil in the separator tank 10 12 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20E 7 Initial Start up
135. tage lower costs and higher compressed air availability 11 4 Service Addresses Addresses of KAESER agents are given at the end of this manual 11 5 Spare Parts for Service and Repair Use this parts list to plan your material requirement according to operating conditions and to order the required spare parts gt sure that any service or repair tasks not described in this manual are carried out by an authorised KAESER Service Technician Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 85 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 11 KOMPRESSOREN KAESER 0 9821 O3S uondo 968 Screw Compressor Service Manual 9 5717 20E ASK T SIGMA CONTROL BASIC 86 77 53 14 11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair Legend KAESER ASK 2 T SEL 1438 05E Maintenance kit combi valve Overhaul kit combinati Maintenance kit thermostatic valve Maintenance kit VC valve Pneumatic valve Mains contactor Contactor dryer Protective cap Actuator interlock switch Crankshaft pulley Drive motor pulley Fan spacer ring Cooler OST pressure relief valve Please quote the part number and serial number of the machine together with the item number and the description of the part w
136. termats 60 Pa 6 mm water column 40 Pa 4 mm water column Total permissible pressure loss for installed ducting Ap ASK 27 32 ASK 35 325 pa zoo 0 Jenn anu o aq suoipnpoura Jou sipuliuo sodund paas au unu Aun aq jou swapsks Jo asn Aq uoypuiwassip nz nu wafun apuy ajfupagstumppuqu pun sayjo fun 20 sardo asodund au 10 papsmujua aun 24494044 ano fapuanvan pun inoJ ioAUm mua Rz ats UNUL Jai jsuos sapo taou ya nquiaat Dunpua a sapo Bunvaysreds aftjsuos Jasun Service Manual Screw Compressor 9 5717 20E ASK T SIGMA CONTROL BASIC 107 13 Amex 13 4 Electrical Diagram 13 4 Electrical Diagram Service Manual Screw Compressor 108 ASK T SIGMA
137. the machine s interior and the engines resulting in increased wear and tear gt Have the authorised KAESER Service clean the cooling air ducts Material Brush and vacuum cleaner Face mask as required Precondition The power supply isolating device is switched off the device is locked off the absence of any voltage has been verified The machine has cooled down Service Manual Screw Compressor 64 ASK T SIGMA CONTROL BASIC 9 5717 20E KAESER KOMPRESSOREN Fig 21 10 6 9 5717 20E 10 Maintenance 10 6 Maintaining the external heat recovery system 10 0056 Filter mat for the air and cooler 1 Filter mat Cleaning the cooler A filter mat helps to keep the cooler clean Despite this fact the cooler will clog over a period of time Do not use sharp objects to clean the cooler It could be damaged Avoid creating clouds of dust 1 Carefully remove the filter mat from the retaining frame 2 Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt 3 Carefully insert the filter mat in the retaining frame The air and oil coolers can no longer be properly cleaned gt Have severe clogging removed by an authorised KAESER Service Technician Checking the cooler for leaks gt Visual inspection Did cooling oil escape Is a cooler leaking gt Have the defective cooler repaired immediately by KAESER Service Option W1 Maintaining the external heat recovery system Deposi
138. the optimum mark when the machine is running Operating state Minimum oil level Maximum oil level LOAD Permissible cooling oil level under LOAD In frequency controlled compressors SFC the oil level indicator sis only accurate when the machine is running at or near maximum speed The lower the pressure at the compressed air outlet the higher the speed The machine has been running at least 5 minutes under LOAD Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 69 KAESER 10 Maintenance Kolnie 10 13 Venting the machine de pressurising 10 50060 Fig 24 Checking the cooling oil level Minimum oil level Maximum oil level Optimum oil level Y Check the oil level with machine running under LOAD Result As soon as the minimum level is reached Replenish the cooling oil 10 13 Venting the machine de pressurising Venting takes place in three stages m Isolate the compressor from the air system Vent the oil separator tank Manually vent the air cooler The machine must be isolated from the compressed air network and completely vented be fore undertaking any work on the pressure system Material The maintenance hose with hose coupling and shut off valve needed for venting is stowed beneath the oil separator tank Precondition The power supply isolating device is switched off the device is locked off the absence of any voltage has been verified CAUTION Escaping oil mist is damaging to health
139. ts in the heat exchanger can significantly reduce its capacity to transfer heat Check the heat exchanger regularly for leaks and contamination Frequency of checking is depend ant on the characteristics of the heat transfer medium gt Have the external heat recovery system checked annually by KAESER Service Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 65 KAESER 10 Maintenance 15 378 107 Filter Maintenance 10 7 Air Filter Maintenance Check that all sealing surfaces match each other The use of an unsuitable air filter element If can permit dirt to ingress the pressure system and cause damage to the machine The air filter element cannot be cleaned Material Replacement part Precondition The power supply disconnecting isolating device is switched off the disconnect device is locked in the off position a check has been made that no voltage is present The machine has cooled down _ 10 50058 Fig 22 Air filter maintenance 1 Snap fastener Air filter element Air filter housing Release the spring clips and remove the element Clean all parts and sealing surfaces Insert the new element in the housing d aS Clip the air filter housing onto the inlet valve 10 8 Compressor motor maintenance The drive motor bearings
140. ty company for the value of the network impedance ASK 27 Anticipated number of 15 start stop cycles per hour Highest permissible sys 0 049 tem impedance 7 Ohm Specification related to the sum of impedances in external and neutral lines Supply conditions at 400V 3 50Hz Mains frequency 60 Hz Rated voltage 230V 10 3 60Hz ASK 27 Backup fuse A 80 Supply cable mm 4x25 Current input A 64 Mains supply 230V 3 60Hz Rated voltage 380V 10 3 60Hz ASK 27 Backup fuse A 50 Supply cable mm 4x10 Current input A 39 Mains supply 380V 3 60Hz Rated voltage 440V 10 3 60Hz ASK 27 Backup fuse A 40 Supply cable mm 4 6 Current input A 32 Mains supply 440V 3 60Hz Rated voltage 460V 10 3 60Hz ASK 27 Backup fuse A 40 Supply cable mm 4x6 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC ASK 32 15 0 028 ASK 32 80 4x25 74 ASK 32 50 4x10 45 ASK 32 50 4x10 38 ASK 32 50 4x10 ASK 35 15 0 021 ASK 35 100 4x35 84 ASK 35 63 4x16 51 ASK 35 50 4x10 43 ASK 35 50 4x10 13 KAESER KOMPRESSOREN 14 Tab 30 2 15 Tab 31 2 16 Tab 32 Tab 33 2 Technical Specifications 2 15 Available heat capacity ASK 27 ASK 32 ASK 35 Current input A 32 37 42 Mains supply 460V 3 60Hz Option W1 Available heat capacity The quality of the heat transfer medium and its required flow rate depend on the type of heat exchanger used Maximum p
141. unction 04 0101 Machine layout 1 Inlet valve 6 Control cabinet Minimum pressure check valve separator tank Compressor motor Air filter filter 9 cooler Airend Add on cabinet for refrigeration dryer Ambient air is cleaned as it is drawn in through the filter 8 The air is then compressed in the airend 5 The airend is driven by an electric motor 3 Cooling oil is injected into the airend It lubricates moving parts and forms a seal between the ro tors themselves and between them and the airend casing This direct cooling in the compression chamber ensures a very low airend discharge temperature Cooling oil recovered from the compressed air in the oil separator tank 7 gives up its heat in the oil cooler 9 The oil then flows through the oil filter 4 and back to the point of injection Pressure with in the machine keeps the oil circulating A separate pump is not necessary A thermostatic valve maintains optimum cooling oil temperature Compressed air freed of cooling oil in the oil separator tank 7 flows through the minimum pres sure check valve 2 into the air cooler 9 The minimum pressure check valve ensures that there is always a minimum internal pressure sufficient to maintain cooling oil circulation in the machine The aftercooler brings down the compressed air temperature to 5K to 10K above ambient Most of the moisture carried in the air is removed in the aftercooler Service
142. ury WARNING Warns of a potentially imminent danger May result in death or severe injury CAUTION Warns of a potentially dangerous situation result in a moderate physical injury Danger levels and their definition personal injury Warning notices preceding a chapter apply to the entire chapter including all sub sections Example Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 1 KAESER KOMPRESSOREN 1 4 2 2 1 4 3 1 Regarding this document 1 4 Symbols and labels DANGER The type and source of the imminent danger is shown here The possible consequences of ignoring a warning are shown here If you ignore the warning notice the DANGER signal word indicates a lethal or severe in jury will occur gt measures required to protect yourself from danger are shown here Warning notes referring to a sub section or the subsequent action are integrated into the procedure and numbered as an action Example 1 WARNING The type and source of the imminent danger is shown here The possible consequences of ignoring a warning are shown here If you ignore the warning notice the WARNING signal word indicates that a lethal or severe injury may occur gt measures required to protect yourself from danger are shown here 2 Always read and comply with warning instructions Potential damage warnings Contrary to the warnings shown above damage warnings do not indicate a
143. xplains the fault code Fault Symbol Meaning Remedy code 1 EMERGENCY STOP push button gt Unlatch the EMERGENCY STOP FS pressed push button Interlocked access door open or gt Close the access door or fit the panel panel if present removed 2 Motor alarm gt Check the setting of the overload pro Overload protection of drive or fan tection cut out motor overload pro motor if fitted tection switch On machine with frequency control gt Change the oil separator cartridge led drive gt Check minimum pressure check Alarm in the frequency converter valve gt Have the frequency converter checked by an authorised KAESER service representative 3 ncs There is build up of back pressure gt Changeover phase lines L1 and L2 m incorrect direction of motor rota gt Replace drive belts tion gt Have the frequency converter m drive belts parted checked by an authorised Compressor not venting correct KAESER Service Technician ly at STANDSTILL Back pressure switch defective Brief interruption of power supply Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9 5717 20 E 79 433 9 Fault Recognition and Rectification 9 3 Warning messages Fault Symbol Meaning Remedy code 4 Maximum permissible airend dis Clean the radiator charge temperature exceeded Maintain sufficient distance between the cooling air inlet and exhaust openings and any wall Check the cooling o

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