Service Manual TD 76 2016
Service Manual TD 76 2016
Refrigerated Dryer
TD
No.: 9_5778 20 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
www.kaeser.com
Original instructions
/KKW/DTD 2.00 en Z1 SBA-TROCKNER
20190507 115552
Contents
13 Annex
13.1 Dimensional drawing ........................................................................................................ 51
13.2 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 54
13.3 Electrical Diagram ............................................................................................................ 57
Fig. 1 Three-phase star (wye system); 4 wire; center point solidly grounded ...................................... 7
Fig. 2 Three-phase star (wye system); 3 wire; grounded center point solidly grounded ...................... 7
Fig. 3 Location of safety signs .............................................................................................................. 16
Fig. 4 Enclosure overview .................................................................................................................... 19
Fig. 5 Machine overview ....................................................................................................................... 20
Fig. 6 SECOTEC CONTROL switches and indicators ......................................................................... 21
Fig. 7 Pressure dew point indicator ...................................................................................................... 22
Fig. 8 Machine Mountings .................................................................................................................... 23
Fig. 9 Recommended machine placement and dimensions [in.] .......................................................... 26
Fig. 10 Compressed air connection ........................................................................................................ 29
Fig. 11 Connecting the condensate drain ............................................................................................... 31
Fig. 12 Option K6: Connecting relay contacts to the condensate drain ................................................. 33
Fig. 13 Bypass line ................................................................................................................................. 33
Fig. 14 Switching on and off ................................................................................................................... 37
Fig. 15 Safety pressure switch ............................................................................................................... 38
Fig. 16 Cleaning the refrigerant condenser ............................................................................................ 42
Fig. 17 Check condensate drain ............................................................................................................. 43
Fig. 18 Option K5/K6: Removing the service unit ................................................................................... 44
Fig. 19 Transporting with a forklift truck ................................................................................................. 48
Fig. 20 Transport with a crane ................................................................................................................ 49
1.3 Copyright
This operator manual is copyright protected. Queries regarding use or duplication of the documen‐
tation should be referred to KAESER. Correct use of information will be fully supported.
1.4.1 Warnings
Warning notices indicate danger potentially resulting in personal injury, if the measures specified
are not taken.
Warning notices indicate three levels of danger identified by the corresponding signal term:
Signal term Meaning Consequences of non-compliance
DANGER Warns of imminent danger Will very likely result in death or severe injury
WARNING Warns of potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situa‐ May result in moderate physical injury
tion
Warning notices preceding a chapter apply to the entire chapter including all sub-sections.
Example:
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as a step.
Example:
1. The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The word "WARNING" indicates that death or severe injury may result from ignoring the warn‐
ing.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
Damage warnings have only one danger level, identified by this signal term:
Signal term Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Example:
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditional requirements relevant to safety shown here will help you to avoid dangerous situa‐
tions.
Option H1 ➤ This symbol is placed by 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 bolt-down machine feet). Option codes used in this
operating manual are explained in chapter 2.2.
Information referring to potential problems is identified by a question mark.
The cause is specified in the help text ...
➤ ... as is a solution.
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
2 Technical Data
2.1 Nameplate
Machine nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine.
Nameplates in various languages are provided with the machine.
➤ If required, attach a nameplate in the applicable language.
Feature Value
Model
Material no.
Serial No.
Year of manufacture
Max. gauge working pressure
Compressed air inlet temperature
Ambient temperature
Rated current
Largest motor FLA
Short circuit current
Supply fuse (field provided)
Rate power supply
Wiring diagram
Option
Refrigerant system
(Contains fluoridated global warming gas)
Refrigerant
Refrigerant charge
Global warming potential (GWP)
CO2 equivalent
Max. working pressure, HP*
Max. working pressure, LP**
Tightness checked
* High pressure
** Low pressure
2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference:
Tab. 4 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equip‐
ment fitted.
TD 51 TD 61 TD 76
Weight [lb.] 553 553 633
Tab. 5 Weight
TD 51 TD 61 TD 76
Flow rate 1)
[cfm] 200 240 285
Cooling air flow rate [cfm] 1950 1950 1880
Pressure dew point1) [°F] 38 38 38
Max. working pres‐ 232 232 232
sure [psig]
Min. compressed air inlet 37 37 37
temperature [°F]
Max. compressed air inlet 130 130 130
temperature [°F]
1)
According to ISO 7183 Option A2:
■ Reference point: 14.5 psia, 68 °F, 0 % relative humidity:
■ Operating state: Gauge working pressure 100 psig, compressed air inlet temperature 100 °F,
100 % relative humidity, cooling air inlet temperature 100 °F
TD 51 TD 61 TD 76
Refrigerant R 134a R 134a R 134a
Global warming potential 1430 1430 1430
(GWP)
Charge quantity1) [lb] 3.2 3.6 3.3
Charge quantity as CO2 2.1 2.3 2.1
equivalent [t]
Maximum working pres‐ 261 261 261
sure [psig] (high pressure
end)
Maximum working pres‐ 232 232 232
sure [psig] (low pressure
end)
Pressure control: 261 261 261
Cut-out pressure [psig]
1)
Volume of fluorinated greenhouse gases for which the refrigerant system was designed
The machine is designed for an electrical supply according to National Electric Code (NEC), edi‐
tion 2017, particularly article 670 and NFPA 79, edition 2015, particularly section 4.3. In the ab‐
sence of any user-specified alternatives, the limits given in these standards must be adhered to.
Consult manufacturer for any other specific power supply.
The incoming line within the control panel should be as short as possible.
If external sensors or communication lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC fittings into the control panel.
Three-phase
Do NOT operate package on any unsymmetrical power supply. Also do NOT operate package on
power supplies such as a three-phase WYE system with the center point not solidly grounded or
three-phase (open) delta.
The machine requires a symmetrical three-phase power supply transformer with a WYE configura‐
tion output as shown in Figure 1 and Figure 2. In a symmetrical three phase supply the phase an‐
gles and voltages are all the same.
Other power supplies are not suitable.
Fig. 1 Three-phase star (wye system); 4 wire; center point solidly grounded
Fig. 2 Three-phase star (wye system); 3 wire; grounded center point solidly grounded
Further information Please contact an authorized KAESER service representative for options.
The electrical diagram 13.3 contains further specifications for electrical connection.
Further information The electrical diagram in chapter 13.3 contains further specifications for electrical connection.
Performance Data
TD 51 TD 61 TD 76
Power consumption [hp]* 1.2 1.5 1.9
Maximum power con‐ 1.7 2.0 2.5
sumption [hp]
* Performance data for reference conditions; option A: ambient temperature 100° F, compressed
air inlet temperature 100° F, working pressure 100 psig.
TD 51 TD 61 TD 76
Mains fusing [A] 10 10 10
Supply cable 4xAWG14 4xAWG14 4xAWG14
Current drawn [A] 6.0 6.7 8.0
TD 51 TD 61 TD 76
Mains fusing [A] 10 10 10
Supply cable 4xAWG14 4xAWG14 4xAWG14
Current drawn [A] 3.3 4.2 5.2
TD 51 TD 61 TD 76
Mains fusing [A] 10 10 10
Supply cable 4xAWG14 4xAWG14 4xAWG14
TD 51 TD 61 TD 76
Current drawn [A] 2.6 3.3 4.1
TD 51 TD 61 TD 76
Mains fusing [A] 6 10 10
Supply cable 4xAWG14 4xAWG14 4xAWG14
Current drawn [A] 2.2 2.8 3.5
➤ 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.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety!
➤ Ensure that operating, installation, and maintenance personnel are qualified and authorized to
carry out their tasks.
3.5 Dangers
Basic information
Information concerning the various forms of danger that can arise during machine operation are
found here.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
Electricity
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.
➤ Close shut-off valves or otherwise isolate the machine from the distribution network to ensure
that no compressed air can flow back into the machine.
➤ Depressurize all pressurized components and enclosures.
➤ Do not carry out welding, heat treatment or mechanical modifications to pressurized 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.
Rotating components
Touching the fan while the machine is switched on can result in serious injury.
➤ Do not open the enclosure while the machine is switched on.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Ensure that all covers and safety guards are in place and secured before restarting.
Temperature
High temperatures are generated during compression. Touching hot components may cause inju‐
ries.
➤ Avoid contact with hot components.
These include, for example, the refrigerant condenser.
➤ Wear protective clothing.
➤ If welding is carried out on or near the machine take adequate measures to ensure that no
parts of the machine can ignite because of sparks or heat.
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.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the enclosure is closed.
➤ Operate the machine only with intact sound insulation.
➤ Wear hearing protection if necessary.
Modifications, additions to and conversions of the machine can result in unpredictable hazards.
➤ Do not convert or modify the machine!
➤ Obtain written approval by the manufacturer prior to any technical modification or expansion of
the machine, the controller, or the control programs.
Transport
The weight and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ 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 center of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.
Installation
A suitable installation location for the machine prevents accidents, faults, and damage.
➤ Install the machine in a suitable compressor room.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain, and
splashing water.
➤ Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ Ensure clean compressed air without damaging components.
Damaging contaminants are for instance: explosive or chemically instable gases and vapors,
acid or base forming substances such as ammonia, chlorine, or hydrogen sulfide.
➤ Do not position the machine in the warm exhaust air flow from other machines.
➤ Keep suitable fire extinguishing agents ready for use.
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 se‐
vere adverse effects for your health.
➤ Allow maintenance work to be carried out only by authorized personnel.
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
➤ Check that the floating relay contacts are voltage-free.
➤ 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.
➤ Depressurize all pressurized 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.
Improper handling of used or old operating fluids and components represent a danger for the envi‐
ronment.
➤ Drain all fluids from the machine, e.g. refrigerant,
and dispose of in accordance with local environmental regulations.
➤ Do not damage the refrigerant circuit.
➤ Give refrigerant only to authorized bodies for disposal.
➤ Dispose of the machine in accordance with local environmental regulations.
Further information More information on safety devices is contained in chapter 4, section 4.6.
3.8 Emergencies
3.8.1 Fire fighting
Suitable measures
Calm and prudent action can save lives in the event of a fire.
➤ Keep calm.
➤ Give the alarm.
Skin contact:
Inhalation:
3.9 Warranty
This operator manual contains no independent warranty commitment. Our general terms and con‐
ditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended un‐
der 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.
■ unauthorized modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of original spare parts and operating materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
Safe and reliable operation is only assured with the enclosure closed.
To open, undo the securing screws and take off panels.
Stage 1:
Warm compressed air entering the first section of the heat exchanger gives up some of its heat to
the chilled and dried compressed air leaving the dryer.
Stage 2:
Further air cooling takes place in the second part of the heat exchanger through which refrigerant
flows. The refrigerant gives up its heat to the surroundings in the condenser.
Stage 3:
A multi-stage, maintenance-free separation system removes the condensate precipitated out of the
compressed air as it is chilled. One or more automatic condensate drains, depending on dryer
model, eject the condensate from the separator.
Stage 4:
The dry, chilled air takes in some heat from the inflowing warm compressed air in the first part of
the heat exchanger through which it passes on the way out of the dryer. The relative humidity of
the compressed air has been reduced to about 21%.
At the heart of the machine is a thermal mass with high specific heat capacity. It is cooled down to
cut-out temperature by the refrigerant circuit and extracts the heat from the compressed air flowing
through the dryer. When heat extraction raises its temperature to the cut-in point, the refrigerant
compressors starts and reduces its temperature once more. The specific heat capacity of the ther‐
mal mass ensures that the pressure dew point remains stable long after the refrigerant compressor
has stopped on reaching the cut-out temperature.
Consequence:
Lower power consumption.
■ Temperature regulator:
The temperature regulator is fitted with a sensor. The red LED on the regulator flashes if a
short or broken circuit is detected.
The LED illuminates continuously if the dew point rises too high.
■ Enclosures and covers over moving parts and electrical connections:
These protect against accidental contact.
4.7 Options
The options available for your machine are described below.
4.7.1 Option H1
Machine Mountings
These mountings allow the machine to be anchored firmly to the floor.
Details of the fixing holes are contained in the dimensional drawing in chapter 13.1.
4.7.2 Option K6
Electronic condensate drain with floating relay contact
A sensor captures the filling level in the condensate drain. Condensate will be drained when the
condensate drain is filled. When the condensate drain is empty, the outlet line is closed in a timely
manner, to prevent unnecessary pressure drops.
In the event of a fault, the system may forward a message. The floating relay contact switches as
soon as the Fault/Alarm LED displays a fault.
4.8 Accessories
4.8.1 Bypass line
The refrigerated dryer can be isolated from the air main with the bypass line.
The compressed air supply is maintained, however, no drying takes place.
Further information Further information on installation of a bypass line can be found in chapter 6.8.
4.8.2 Transformer
The transformer enables the connection of the machine to different power supply voltages.
Further information The wiring diagram shipped with the transformer contains further details of the power supply con‐
nection.
Precondition The floor must be level, firm and capable of bearing the weight of the machine.
➤ 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. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
3. Do not install the machine in the exhaust air flow from other machines.
4. Ensure clean air in order to support the proper functioning of the machine.
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.
Warning instructions are displayed prior to a potentially dangerous task.
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Check that there is no voltage on floating relay contacts.
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety instructions relate to any work on components that could be under
pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air system to en‐
sure that no compressed air can flow back into the machine.
➤ Vent all pressurized components and chambers immediately.
➤ Do not open or dismantle any valves.
Touching voltage carrying components can result in electric shocks, burns or death.
Touching the fan while the machine is switched on can result in serious injury.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Do not open the cabinet while the machine is switched on.
1. Serious injury or death can result from loosening or opening components under
pressure.
➤ Vent all pressurized components and enclosures.
2. The machine is not protected against air pressure exceeding 232 psi!
➤ The user must install a safety relief valve.
3. An excessive tightening torque may cause the tearing of the connections.
➤ Use a torque wrench to connect the machine to the compressed air network. Do not ex‐
ceed a tightening torque of 65 Nm.
4. Fit shut-off valves in the compressed air inlet and outlet lines.
Further information The dimensional drawing in chapter 13.1 gives the size and location of the connection ports.
Condensate line
Feature Value
Max. length [ft]
1) 49
Max. delivery head [ft] 16
Material Copper
(pressure-resistant, cor‐ Stainless steel
rosion-proof)
Plastics
Hose line
1)
For longer lengths, please contact the manufacturer before installation.
Feature Value
Gradient [%] >1
Max. length1) [ft] 65
Material Copper
(pressure-resistant, cor‐ Stainless steel
rosion-proof)
Plastics
Hose line
1)
For longer lengths, please contact KAESER before installation.
Depending on the machine model, you may have several condensate drains.
➤ Directly connect every condensate drain to the condensate collecting line.
➤ Collect the condensate in a suitable container and dispose of in accordance with environ‐
mental regulations.
Further information The dimensional drawing in chapter 13.1 provides the size and position of the connection port.
1. The power supply must only be connected by authorized installation personnel or an author‐
ized electrician.
2. Carry out safety measures as stipulated in relevant regulations and in national accident pre‐
vention regulations. In addition, observe the regulations of the local electricity supplier.
3. Test the overcurrent protection cut-out (backup fuse) to ensure that the time it takes to discon‐
nect in response to a fault is within the permitted limit.
4. Select supply cable conductor cross-sections 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 of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and check the absence of
any voltage.
8. Connect the machine to the power supply.
9. Ensure that the cabinet again complies with the requirements of degree of protection IP54.
Further information The electrical diagram in chapter 13.3 contains further details for the power supply connection.
6.6 Options
6.6.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.1.
6.7 Option K6
Connecting relay contacts to the condensate drain
Precondition The power supply disconnecting device is switched off,
the device is locked off,
the absence of voltage is verified.
Further information Connect the lines for external fault messages to the connection for relay contacts in accordance
with the circuit diagram in Chapter 13.3.
7 Initial Start-up
7.1 Ensuring safety
Instructions for Safe Initial Start-up of the Machine.
Warning instructions are found before a potentially dangerous task.
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Check that there is no voltage on potential-free contacts.
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety instructions relate to any work on components that could be under
pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air system to en‐
sure that no compressed air can flow back into the machine.
➤ Vent all pressurized components and chambers immediately.
➤ Do not open or dismantle any valves.
Touching voltage carrying components can result in electric shocks, burns or death.
Touching the fan while the machine is switched on can result in serious injury.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Do not open the cabinet while the machine is switched on.
➤ Commissioning may only be carried out by authorized installation and service personnel who
have been trained on this machine.
8 Operation
8.1 Switching on and off
Always use the «main switch» to switch the machine on and off.
8.1.1 Switching on
Precondition No personnel are working on the machine.
All access doors and panels are closed and secure.
Result The Control voltage LED extinguishes. The machine is switched off (all poles) and disconnected
from the mains supply.
Result The machine is ready for operation again and will start as soon as pressure has equalized or oper‐
ating pressure is reached.
9.2 Faults
Fault Possible cause Remedy
Water in the compressed air Compressed air inlet and outlet Check the compressed air con‐
system reversed. nection.
The condensate is not draining Check and clean the conden‐
out of the system. sate drain and line.
Replace the service unit at the
condensate drain.
The safety pressure switch has Check operating conditions.
shut down the machine. Check the machine.
RESET the machine.
High pressure drop Dryer iced up on the air side. Switch off the machine and in‐
crease the ambient tempera‐
ture.
Continuous air loss from the Check the condensate drain.
condensate drain.
Pressure dew point too high Ambient or compressed air inlet Check installation conditions
temperature too high. are OK.
Low refrigerant level. Call an authorized KAESER
service representative.
Dirt collecting in the com‐ Call an authorized KAESER
pressed air system. service representative.
The safety pressure switch Ambient or compressed air inlet Check installation conditions
shuts down the machine temperature too high. are OK.
Refrigerant condenser dirty. Clean the refrigerant condens‐
er.
10 Maintenance
10.1 Ensuring safety
Follow the instructions below to ensure safe machine maintenance.
Warning instructions are found before a potentially dangerous task.
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Check that there is no voltage on potential-free contacts.
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety instructions relate to any work on components that could be under
pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air system to en‐
sure that no compressed air can flow back into the machine.
➤ Vent all pressurized components and chambers completely.
➤ Do not open or dismantle any valves.
Touching voltage carrying components can result in electric shocks, burns or death.
Touching the fan while the machine is switched on can result in serious injury.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Do not open the cabinet while the machine is switched on.
1. Use compressed air (<6 bar) to blow the refrigerant condenser clean at regular intervals.
2. Use a grease solvent detergent on heavy contamination.
10.5 Option K5 / K6
Electronic condensate drain
The condensate is removed by an electronic condensate drain.
If there is a condensate drainage malfunction, the valve opens at intervals (about every 3 seconds)
to rectify the fault.
Check the condensate drain regularly and replace the service unit as necessary.
1. With one hand, lightly touch the condensate 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.
Result As soon as the condensate drain opens, you will feel a short burst at the condensate drain hose.
Replace the service unit if you do not experience a burst during manual test.
1. Serious injury or death can result from loosening or opening components under
pressure!
➤ Fully vent all pressurized components and enclosures.
2. Close the shut-off valve 9 upstream of the condensate drain.
3. Unscrew the fitting 6 at the condensate line.
4. Press the snap fastener 5 and carefully remove the control module 2 from the service unit 1 .
5. Carefully loosen the union nut 13 at the shut-off valve 9 until remaining residual air has esca‐
ped through the vent holes.
6. Unscrew the screw-in part 11 from the service unit 1 and place aside.
7. Remove the insulation 14 (if available) from the service unit 1 .
Use only KAESER service units to ensure correct function of the condensate drain.
Precondition Ensure that the top of the service unit 1 and the contact springs are clean and dry.
2. Carefully insert the control module sensor 3 in the opening 2 of the service unit 1 .
3. Place the snap fastener 5 of the control module 1 into the service unit eyes.
4. Press the control module 2 against the service unit until the snap fastener audibly clicks into
place.
5. At the screw-in part 11 , replace old sealing material with new sealing tape.
6. Install the screw-in part 11 in the service unit 1 .
7. Tighten the union nut 13 at the shut-off valve 9 .
8. Attach the condensate line.
9. Open the shut-off valve 9 upstream of the condensate drain.
10. Close all access doors, replace and secure all removable panels.
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spare parts or operating materials.
➤ Use only original KAESER parts and operating materials.
➤ Have an authorized KAESER service representative carry out regular maintenance.
Name Number
Service Unit condensate drain 9602
Temporarily decommissioning
Permanent decommissioning
12.2 Storage
Moisture can lead to corrosion, particularly on the surfaces of the machine.
Frozen moisture can damage components such as diaphragms, valves, and gaskets.
Please consult with KAESER if you have questions about appropriate storage and commis‐
sioning.
12.3 Transport
12.3.1 Safety
Weight and center of gravity determine the most suitable method of transportation. The center of
gravity is shown in the drawing in chapter 13.1.
➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.
Precondition Transport only by forklift truck or suitable lifting gear and only by personnel trained in the safe
transportation of loads.
➤ Consult KAESER if you require suitable load-carrying and attachment devices or have
questions regarding the correct use.
Precondition Load-carrying and attachment devices meet the local safety regulations.
The crane, load-carrying and attachment devices or the lifted machine do not endanger personnel.
1. Risk of accident caused by incorrect use of lifting gear and attachment devices!
➤ Comply with permissible load limits.
➤ Comply with specific safety information of used load-carrying and attachment devices.
2. Properly use load-carrying and attachment devices:
■ Ensure proper distribution of the fastening points relative to the centre of gravity position
(symmetrical load distribution).
■ Ensure equal slope angles of 15° to 45° for attachment devices with multiple strands.
─ Slope angles between 45° and 60° may be unsuitable.
─ Slope angles larger than 60° are prohibited.
■ Ensure the maximum incline of 6° of the machine to the horizontal.
■ Ensure sufficient distance of the attachment devices to the machine.
■ Ensure a positive stability height: Dimension B > Dimension A
■ Do not attach the attachment devices to any machine component.
3. Carry out a lifting test:
Slightly lift the machine to check whether machine remains in horizontal position and does not
teeter.
4. Transport the machine only after a successful lifting test.
12.4 Disposal
The sealed refrigerant circuit still contains both refrigerant and oil.
13 Annex
13.1 Dimensional drawing
outlet
considered
Y
Machine mountings
Condesate drain
24 5/8
Z
(e) 48 1/4 46 3/4
Compressed air
internal thread ASA B2.1
15 1/8
20 1/4
TD 76 2x internal thread ASA B2.1 NPT 2
17 1/8
passages and doorways - Crating has not been
TD 51/61 2x internal thread ASA B2.1 NPT 1 1/2
4 1/2
6 7/8
8 1/8
20 3/4
H1
inlet
Code:
Electrical
2 x dia. 1/2
Compressed air
46 3/4 (e)
1 1/2
5 1/4
23 5/8
45 1/2
35 5/8
43 7/8
33 1/2
Cooling air
Instrument panel
outlet
CG
TD 76
5 7/8 18
4 5/8
45 5/8
TD 51/61 45 1/2
Cooling air inlet
31525
Status
Released
10247848 D 00
Dokument TZD
Dokument TZM
10247848 USE 00
21 5/8
4 1/8
139 5 1/2
A3
TD
1:20
H1
Original
Änderungs-Nr. Projektion Maßstab
di
a.
15
Bezeichnung
3
3 7/8
7/
Gez.
10
8
18 7/8
Bearb.
29 7/8
21 5/8
CG
Z
24 3/8 18 7/8
H1
18.06.2018 HUEBNER1
17.05.2013 HUEBNER1
Name
1/8
1 1/2
dia. 1
USE
3 7/8 3 7/8 /2
Sprache
Blatt
1 von 1
Stand
Dimensional drawing 13.1
Annex 13
13 Annex
13.1 Dimensional drawing
1 2 3
vormontiert / pre-assembled
A
--> lose mitgeliefert /
loosely delivered 20
70
vormontiert / pre-assembled
31
B 10 42
41
30 50
20 40
31 Alle vormontierten
Gewinde verklebt mit /
C
42 all pre-assembled
threads glued with
Loctite 9466 (896887.0)
41 60
50
40
D
60
Für die silikonfreie Version 896383L1
sind die Arbeitsanweisungen
Reinigen/Verpacken gem. AW-09030026-CG und
PS = 16 bar Reinigen von Kugelhähnen gem. AW-10040009-CG
E 232 psig zu beachten
----------------------------------------
------------------ For silicone-free version 896383L1
TS = -5°C / +65°C take notice of the work instructions
Cleaning/Packaging acc. to AW-09030026-CG and
23°F / 149°F Cleaning of ball valves acc. to AW-10040009-CG
1 2 3