KAESER ASD 25 Service Manual Download

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Service Manual

Screw Compressor

ASD T

Tri-Voltage

9_5721 06 USE

Summary of Contents for ASD 25

Page 1: ...Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 2: ...Original instructions KKW SASD 1 00 en 01 SBA SCHRAUBEN TRI VOLTAGE T SC...

Page 3: ...10 2 15 2 Internal heat recovery 11 2 16 Refrigeration dryer 12 3 Safety and Responsibility 3 1 Basic Information 14 3 2 Specified Use 14 3 3 Improper Use 14 3 4 User s Responsibilities 14 3 4 1 Obser...

Page 4: ...36 6 5 Making the Power Supply Connection 37 6 5 1 Changing main voltage connections 37 6 6 Refrigeration dryer Connecting the transformer according to the power supply 39 6 7 Options 39 6 7 1 Anchor...

Page 5: ...rizing 70 10 14 Topping up the Cooling Oil 72 10 14 1 Venting the Machine depressurizing 72 10 14 2 Top up with cooling oil and test run 73 10 15 Changing the Cooling Oil 74 10 16 Changing the Oil Fil...

Page 6: ...Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 98 13 3 Dimensional Drawing 104 13 4 Electrical Diagram 107 Contents iv Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06...

Page 7: ...e 48 Fig 22 Switching on and off with the clock 49 Fig 23 Acknowledging resetting messages 50 Fig 24 Filter mat for the air and oil cooler 63 Fig 25 Control cabinet ventilation grill 64 Fig 26 Cleanin...

Page 8: ...List of Illustrations vi Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 9: ...ab 27 Refrigeration dryer model 12 Tab 28 Refrigeration dryer compressed air system 13 Tab 29 Refrigeration dryer refrigeration circuit 13 Tab 30 Danger Areas 19 Tab 31 Safety Signs 20 Tab 32 Operatin...

Page 10: ...List of Tables viii Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 11: ...ocuments 1 3 Copyright This service manual is copyright protected Queries regarding use or duplication of the documentation should be referred to KAESER Correct use of information will be fully suppor...

Page 12: ...ists of actions comprising one stage of a task In lists of actions with several stages the sequence of actions is numbered Information that refers to only one option is marked with an indicator e g H1...

Page 13: ...l no psig cfm Voltage Hz RPM Package FLA Phase HP Wiring Diagram FOR SERVICE REFER TO EQUIPMENT NUMBER Tab 2 Nameplate 2 2 Options The table contains a list of possible options Enter options here as a...

Page 14: ...irend dis charge temperature auto matic safety shut down F 230 230 230 230 Tab 5 Temperature 2 5 Ambient Conditions ASD 25 ASD 30 ASD 40S ASD 40 Maximum elevation ft 3000 3000 3000 3000 Permissible am...

Page 15: ...at 0 4 in wc 5297 5886 7063 8240 Exhaust duct Dimensions in 25 5 8 x 25 5 8 25 5 8 x 25 5 8 25 5 8 x 25 5 8 25 5 8 x 25 5 8 Tab 7 Ventilation 2 7 Pressure Maximum working pressure see nameplate Safet...

Page 16: ...be stored in a protected location to prevent contamination Do not re use drums flush and send to reconditioner Although the KAESER synthetic is not highly flammable it will burn While KAESER synthetic...

Page 17: ...where incidental food contact may occur with the discharge air This lubricant meets the requirements of the FDA Regulation 21 CFR 178 3570 and is USDA H 1 approved and NSF certified FG 460 is approved...

Page 18: ...3545 3550 3550 175 1780 3545 3550 3550 217 1780 1780 3550 3550 Tab 15 Drive motor rated speed 2 11 2 Fan motor ASD 25 ASD 30 ASD 40S ASD 40 Rated power hp 0 75 0 75 0 75 0 75 Rated speed rpm 1080 1080...

Page 19: ...symmetrical three phase supply the phase angles and voltages are all the same Other power supplies are not suitable Fig 2 Three phase star wye 4 wire grounded neutral Fig 3 Three phase star wye 3 wir...

Page 20: ...C 4x AWG1 0 75 C 4x AWG2 0 75 C Consumption A 65 125 74 85 86 217 95 97 217 111 Tab 19 Supply 230V 3 60Hz Rated power supply 460V 10 3 ph 60Hz ASD 25 ASD 30 ASD 40S ASD 40 Pre fuse A 50 60 70 80 Suppl...

Page 21: ...l mg l 150 Free chlorine gas Cl2 mg l 1 Sulphite SO3 mg l 1 Dissolved iron Fe mg l 0 2 Hydrogen carbonat HCO3 mg l 70 300 Sulphate SO4 mg l 70 HCO3 SO4 1 Electrical conductivity S cm 10 500 Ammonia NH...

Page 22: ...MJ h 59 69 86 99 kcal h 14101 16578 20567 23732 Tab 24 Heat capacity option W2 W3 Flow rate for heating from 110 F to 160 F T 25K ASD 25 ASD 30 ASD 40S ASD 40 Flow rate gpm 2 51 2 95 3 70 4 62 Tab 25...

Page 23: ...57 Refrigerant R134a R134a Global warming potential GWP 1300 1300 Charge quantity lb Maximum permitted work ing pressure psig 305 305 Safety pressure switch shutdown pressure psig 305 305 Read off th...

Page 24: ...e manual Operate the machine only within its performance limits and under the permitted ambient condi tions Do not use compressed air for breathing purposes unless it is specifically treated for such...

Page 25: ...rs of electrical and compressed air devices and take appropriate measures to safeguard persons and property have received adequate training and authorization for the safe installation and maintenance...

Page 26: ...e shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine Vent all pressurized components and chambers completel...

Page 27: ...ubricants and chemical substances Avoid contact with skin and eyes Do not inhale oil mist or vapor Do not eat or drink while handling cooling and lubricating fluids Keep suitable fire extinguishing ag...

Page 28: ...nd humidity clean inlet air with no damaging contaminants inlet air free of explosive or chemically unstable gases or vapors inlet air free of acid alkaline forming substances particularly ammonia chl...

Page 29: ...ce personnel Tab 30 Danger Areas 3 6 Safety Devices Various safety devices ensure safe working with the machine Do not change bypass or disable safety devices Check safety devices for correct function...

Page 30: ...elt drive or fan blade Operate the machine only with fully closed safety guards access doors and pan els Isolate from the power supply and lock out before opening any machine enclosure or guard 11 Inj...

Page 31: ...sure De pressurize all pressurized components and enclosures Secure that machine keeps de pressurized Check that machine is de pressurized 25 Ear damage and burns can result from loud noise and or oi...

Page 32: ...and call for medical assistance 3 9 Warranty This service manual contains no independent warranty commitment Our general terms and condi tions of business apply with regard to warranty A condition of...

Page 33: ...protection regulations Observe relevant national regulations This applies particularly to parts contaminated with cooling oil Do not allow cooling oil to escape to the environment or into the sewage s...

Page 34: ...low control 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 wi...

Page 35: ...rator 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 within the machine keeps the oil circulating A separate pump...

Page 36: ...he 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 vo...

Page 37: ...ted at any time Internal heat recovery A plate type heat exchanger is installed for internal heat recovery Fig 10 Internal heat recovery option W2 W3 1 Plate type heat exchanger 4 5 4 Optional Filter...

Page 38: ...ulating valve is factory set Consult with authorized KAESER Service representative be fore making alterations 4 6 2 Control modes Using the selected control mode the controller switches the compressor...

Page 39: ...r MODULATING control 4 7 Refrigeration Dryer Control Modes The controller can operate in the following modes CONTINUOUS TIMER CONTINUOUS In this mode the refrigeration dryer runs continuously even if...

Page 40: ...nst accidental contact 4 9 SIGMA CONTROL Keys and Indicators Fig 11 Keys Item Description Function 1 ON Switches on the machine The programmed operating mode is active 2 OFF Switches the machine off 3...

Page 41: ...ights red if communication via the Profibus interface is interrupted 15 Warning Flashes yellow for maintenance work due warning messages Lights continuously when acknowledged 16 Controller power Light...

Page 42: ...n inlet air with no damaging contaminants inlet air free of explosive or chemically unstable gases or vapors inlet air free of acid alkaline forming substances particularly ammonia chlorine or hydroge...

Page 43: ...the ventilation is insufficient a dangerous vacuum can build up in the machine room Ensure that the volume of air flowing into the machine room is at least equivalent to that being removed from it by...

Page 44: ...can be found in chapter 13 3 5 3 Using the Compressor to Supply A Compressed Air System When the machine is connected to a compressed air system the system operating pressure must not exceed 232 psig...

Page 45: ...se isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine 2 Vent all pressurized components and chambers completely 3 Check all machine hose...

Page 46: ...or hose 6 4 Connecting the condensate drain A threaded hose connection is provided to connect the drain hose to the condensate drain outlet Condensate must drain freely The illustration shows typical...

Page 47: ...e 4 Use supply conductors and fuses in accordance with local regulations 5 The user must provide the machine with a lockable supply disconnecting device This could be for example a switch disconnector...

Page 48: ...ome cases depends on the maximum working pressure of the machine The maximum working pressure psig is shown in brackets Check the overload protection relay setting ASD 25 ASD 30 ASD 40S ASD 40 208V 3...

Page 49: ...cting the transformer according to the power supply The refrigeration dryer transformer has tappings for various power supply voltages 1 Check that the correct connections are made for the supply volt...

Page 50: ...elay contacts Working on pressure systems 1 Close shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine 2 Vent...

Page 51: ...e power supply disconnecting device installed 6 5 Does the power supply conform to the specifications on the nameplate 2 1 Are the power supply cable conductor cross sections and fuse ratings adequate...

Page 52: ...temper ature influences or component tolerances the setting can be higher than the motor rated current see motor nameplate Check the motor overload protection switch setting The overload switch shuts...

Page 53: ...ion is incorrect reverse the supply phases L1 and L2 You have no phase sequence meter Switch the machine on and off again the moment the drive motor begins to turn Compare the direction of rotation of...

Page 54: ...ent is necessary for individual operating conditions Do not set the setpoint pressure of the machine higher than the maximum working pressure of the air system The machine may not toggle more than twi...

Page 55: ...y 8 times 5 Press Enter to enter language selection 6 Press the UP or DOWN keys as often as necessary to reach the required language 7 Press enter to select the language 8 Depress the escape key for 5...

Page 56: ...ED Power ON lights 2 Press the ON key The green LED Machine ON lights If a power failure occurs the machine is not prevented from automatic re starting It can re start automatically as soon as power i...

Page 57: ...ushbutton The pushbutton remains latched in The compressor s pressure system is vented and the machine is prevented from automatically re starting Switching on Precondition The fault has been rectifie...

Page 58: ...tarting device in the remote control center as follows DANGER Before starting make sure that no one is working on the machine and that it can be safely started Tab 42 Remote control identification 3 P...

Page 59: ...The clock LED lights The machine is switched on and off by the clock 8 5 Acknowledging Alarm and Warning Messages Messages are displayed on the new value principle Message received LED flashes Message...

Page 60: ...acknowledge reset key alarm LED extinguishes The machine is now ready to start again Warning message Precondition The danger of an alarm is eliminated Maintenance has been carried out Reset the messa...

Page 61: ...onnections AI1 short cct AI2 short cct The connection between the sensor and the analog input is shorted Check line and connections AI3 AI4 error Line break between the analog input and the sensor Sho...

Page 62: ...k the machine for leaks Check coupling V belts Call authorized KAESER Service representative condensatedrain The condensate drain is defective Check the condensate drain coolingwater low Cooling water...

Page 63: ...monitor Fault in mains power supply Have the mains power supply checked Emergency stop EMERGENCY STOP push button pressed Unlatch the push button OS dp Oil separator cartridge clogged Change the oil...

Page 64: ...t The activating pressure of the safety relief valve will soon be reached Change the oil separator cartridge Open the shut off valve in the venting line bus alarm The bus link from the Profibus DP int...

Page 65: ...ding maintenance inter val counter no press buildup The compressor cannot build up to working pressure Check for air leaks Check the value for internal pressure given in the analog data menu against t...

Page 66: ...presen tative motor starts h The permissible number of motor starts was exceeded in the last 60 minutes Extend the idle period Increase the capacity of air receiver Increase the cross section of pipin...

Page 67: ...AM Internal RAM defective Call authorized KAESER Service represen tative oil content The oil content limit for pure air will soon be reached Check the scavenge tube in the oil separator cartridge Chec...

Page 68: ...for leaks and tighten any loose fittings Air consumption is greater than the capacity of the compressor Check the air system for leaks Shut down the consumer s Hose coupling or maintenance hose still...

Page 69: ...Tighten joints Replace seals Cooling oil consumption too high Unsuitable oil is being used Use SIGMA FLUID cooling oil Oil separator cartridge split Change the oil separator car tridge Oil level in th...

Page 70: ...ensure that no com pressed air can flow back into the machine 2 Vent all pressurized components and chambers completely 3 Check all machine hose connectors with a handheld pressure gauge to ensure th...

Page 71: ...enu 2 Select reset and y and confirm with the enter key Further information Detailed information can be found in the SIGMA CONTROL operating instructions 10 2 3 Regular maintenance tasks The table bel...

Page 72: ...etermining appropriate inter vals and provide information on the possibilities of oil analysis Please observe national regulations regarding the use of cooling oil in oil injected screw com pressors C...

Page 73: ...no longer ensured Material Filter mats Warm water and household detergent Spare parts as required Precondition The machine is switched off Fig 24 Filter mat for the air and oil cooler 1 Filter mat No...

Page 74: ...entilation grill 2 Filter mat 1 Carefully remove the ventilation grill 1 and take out the filter mat 2 2 Beat the mat or use a vacuum cleaner to remove loose dirt If necessary wash with lukewarm water...

Page 75: ...cleaned Heavy and stubborn contamination should be removed by a KAESER Service representa tive Check the cooler for leaks Can cooling oil be seen to be leaking Is a cooler leaking Have the defective...

Page 76: ...tive check the heat exchanger for internal leaks at least once a year Contamination Have an authorized KAESER Service representative clean the heat exchanger as soon as a pressure drop in the heat tra...

Page 77: ...osing the air filter housing 1 Clean all parts and sealing surfaces 2 Insert the element 4 in the cover 5 and lay on the backplate 3 3 Use the screw and nut 2 to hold the housing together 4 Insert the...

Page 78: ...The machine is running Check the coupling for noisy or uneven running Make a visual check for damage Precondition The power supply disconnecting device is switched off The disconnecting device is loc...

Page 79: ...between the machine and the compressed air system 2 Read the blowoff pressure on the valve the blowoff pressure is usually to be found at the end of the part identification 3 Observe the pressure indi...

Page 80: ...the compressed air system Vent air from the oil separator tank Vent air manually from the air cooler Material The hose coupling shut off valve and maintenance hose lie beneath the oil separator tank P...

Page 81: ...e does not read zero Make sure that the shut off valve is closed or that the compressed air system is vented to atmospheric With the shut off valve closed insert the male hose fitting 6 into the hose...

Page 82: ...he Cooling Oil 1 Hose coupling air cooler venting 2 Pressure gauge 3 Hose coupling oil separator tank venting 4 Oil filler with plug 5 Cooling oil level indicator 6 Male hose coupling fitting 7 Shut o...

Page 83: ...open the shut off valve 7 to release pressure Withdraw the male hose fitting 6 and close the shut off valve 7 If manual venting does not bring the oil separator tank pressure gauge to 0 psig call an...

Page 84: ...ystem option W1 W2 W3 Always change the oil filter and oil separator cartridge when changing the oil Contact KAESER Service representative if condensate is detected in the cooling oil It is necessary...

Page 85: ...heck that no voltage is present 4 Wait at least 2 minutes to allow the oil to flow back to the separator tank The power supply disconnecting device is switch ed off The disconnecting device is locked...

Page 86: ...l drainage 3 Shut off valve 6 Male hose fitting 7 Shut off valve 1 Have an oil receptacle ready 2 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 2 3 Place the end...

Page 87: ...has run out 6 Fit the safety screen again 7 Close the shut off valve 3 and unplug the male hose fitting Result The cooling oil is drained from the airend A small amount of cooling oil may flow back in...

Page 88: ...ser s shut off valve between the machine and the compressed air network 3 Switch on the power supply and reset the maintenance interval counter 4 Start the machine and check the oil level again after...

Page 89: ...machine and carry out a test 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 compressed air system 3 Switch on the pow...

Page 90: ...cking 20 Fitting 21 Gasket 23 Oil separator cartridge Changing the Oil Separator Cartridge 1 Unscrew the fitting 20 and carefully put the parts to one side then pull out the copper pipe at item 15 2 U...

Page 91: ...The refrigeration circuit is permanently sealed and needs no maintenance Repairs may only be carried out by certified personnel Material Compressed air for blowing out Cleaning rags Vacuum cleaner Sp...

Page 92: ...e drain manual check Press the TEST button and hold for at least 2 seconds Carry out maintenance on the condensate drain if condensate still does not flow Collect condensate in a suitable container an...

Page 93: ...steners Precondition The service unit matches the control module Make sure the top of the service unit and the contact spring are clean and dry 1 Screw the service unit to the inlet pipe using sealing...

Page 94: ...ntenance and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 50 Logged maintenance tasks 10 Maintenance 10 19 Document maintenance and service work...

Page 95: ...ay result Use only genuine KAESER parts and operating materials Have an authorized KAESER Service Technician carry out regular maintenance Machine Name Quantity Number Air filter element 1 1250 Filter...

Page 96: ...ou can plan your material requirement according to operating conditions and order the spare parts you need Make sure that any service or repair tasks not described in this manual are carried out by an...

Page 97: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 87...

Page 98: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 88 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 99: ...t Machine fully vented no pressure 1 Allow the machine to cool down completely 2 Disconnect all air and electrical connections 12 2 Packing A wooden crate is required for ground transport to protect t...

Page 100: ...le machine must be over the forks Fig 41 Transporting with a forklift Drive the forks completely under the machine or palette and lift carefully 12 4 3 Transporting with a crane A suitable lifting cra...

Page 101: ...achine 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 Parts contam...

Page 102: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 92 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 103: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 93...

Page 104: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 94 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 105: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 95...

Page 106: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 96 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 107: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 97...

Page 108: ...pe and Instrument Flow Diagram P I diagram MODULATING control mode 13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 98 Service Manual Screw Compressor ASD T Tri Volta...

Page 109: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 99...

Page 110: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 100 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 111: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 101...

Page 112: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 102 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 113: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 103...

Page 114: ...13 3 Dimensional Drawing 13 Annex 13 3 Dimensional Drawing 104 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 115: ...13 Annex 13 3 Dimensional Drawing 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 105...

Page 116: ...13 Annex 13 3 Dimensional Drawing 106 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

Page 117: ...13 4 Electrical Diagram 13 Annex 13 4 Electrical Diagram 9_5721 06 USE Service Manual Screw Compressor ASD T Tri Voltage 107...

Page 118: ...13 Annex 13 4 Electrical Diagram 108 Service Manual Screw Compressor ASD T Tri Voltage 9_5721 06 USE...

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KAESER ASD 25, Service Manual

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Summary of Contents for ASD 25

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