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Summary of Contents for KAESER KOMPRESSOREN i.Comp 3
- Page 1 Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 www.kaeser.com...
- Page 2 Original instructions /KKW/PWPC 2.04 en SBA-KOLBEN-ANLAGE M 20200310 081012...
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Page 3: Table Of Contents
Machine operating points ..................4.3.2 Control mode ...................... i.Comp CONTROLLER ....................Control panel ........................Installation and Operating Conditions Ensuring safety ........................ Installation conditions ....................... 5.2.1 Risk of falling due to vibrations or negligence ............ Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... - Page 4 11.2 Ordering consumable parts ....................11.3 KAESER AIR SERVICE ....................11.4 Replacement parts for service and repair ................ Decommissioning, Storage and Transport 12.1 De-commissioning ......................12.2 Packing ..........................12.3 Storage ..........................12.4 Transport .......................... Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 5 Contents 12.4.1 Safety ........................12.5 Disposal ........................... Annex 13.1 Dimensional Drawing ....................... 13.2 Pipeline and instrument flow diagram (P&I diagram) ............13.3 Electrical Diagram ......................Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 6 Contents Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 7 Fig. 11 Acknowledging messages ......................Fig. 12 Replace the air filter ........................Fig. 13 Check the safety valve ....................... Fig. 14 Venting the machine ........................Fig. 15 Venting the crankcase ........................ Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 8 List of Illustrations Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 9 Check list of installation conditions ..................... Tab. 20 Fault messages .......................... Tab. 21 Warning display .......................... Tab. 22 Maintenance and service work ....................Tab. 23 Logged maintenance tasks ......................Tab. 24 Consumable parts ........................Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 10 List of Tables Operator manual Reciprocating compressor viii i.Comp 3 No.: 901731 24E...
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Page 11: Regarding This Document Using This Document
WARNING Warns of potentially imminent danger May result in death or severe injury CAUTION Warns of a potentially dangerous sit‐ May result in moderate physical injury uation Tab. 1 Danger levels and their definition (personal injury) Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 12: Potential Damage Warnings
➤ The protective measures against the damages are shown here. ➤ Carefully read and fully comply with warnings against damages. 1.4.3 Other alert notes and their symbols This symbol indicates particular important information. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... - Page 13 The cause is specified in the help text ... ➤ ... as is a solution. This symbol refers to important information or measures concerning environmental protec‐ tion. Further information Further subjects are introduced here. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
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Page 14: Technical Specifications Nameplate
The nameplate is located on the outside of the machine: ■ below the compressed air outlet. ➤ Enter the data from the nameplate here as a reference: Feature Value Reciprocating compressor i.Comp 3 Material No. Serial no. Ambient temperature Rated power Max. gauge working pressure PS Rated motor speed... -
Page 15: Compressor Block
Technical Specifications Compressor block Compressor block Compressor block Flow rate [l/min] Number of cylinders i.Comp 3 — — — Flow rate as per ISO 1217: 2009, Annex E Tab. 5 Compressor block Flow rate Figure shows the flow rate control range in relation to the set required pressure Fig. -
Page 16: Flow Rate Q [L/Min] At Maximum Required Pressure Of 11 Bar
Technical Specifications Ambient conditions rp [bar] i.Comp 3 — — 11.0 (rp — — — — — — Flow rate in accordance with ISO 1217:2009, Annex E Tab. 6 Flow rate 100 – 127V / 11,0 bar 2.4.2 Flow rate Q [l/min] at maximum required pressure of 11 bar: Rated voltage 200 –... -
Page 17: Pressure
6.2.3d at distance d = 1 m, Q2 = Logarithmic surface ratio: dB. ■ EC type approval certificate no. OR/000225/066 Compressor type Sound power level [dB(A)] Emission sound Logarithmic sur‐ pressure level face ratio [dB] Measured Guaranteed [dB(A)] i.Comp 3 79.5 13.5 — — — — — — — — —... -
Page 18: Electrical Connection Data
Further information The circuit diagram in chapter 13.3 contains further details of the electrical connection data. 2.10.1.1 Mains frequency 50/60Hz Rated voltage: 100 – 127V / 1 / 50/60Hz i.Comp 3 — Current consumption [A] — — —... -
Page 19: Tab. 14 Rated Voltage 200 - 240V / 1 / 50/60Hz
Technical Specifications 2.10 Electrical connection Rated voltage: 200 – 240V / 1 / 50/60Hz i.Comp 3 — Current consumption [A] 9.5 – 7.6 — — Max. backup fuse [A] — Max. circuit breaker [A] Short-circuit cur‐ — rent (Icc) [kA] 3x1.5... -
Page 20: Safety And Responsibility Basic Instructions
➤ Do not operate the machine in areas in which specific requirements with regard to explosion protection are in force. ➤ Do not transport the compressor by crane or other hoists. ➤ Do not misuse handle or other components. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 21: User's Responsibilities
The user must ensure that from a rated motor power greater than 0.5 kW the machine's safety devices are checked for function at least once annually. Dangers Basic instructions The following describes the various forms of danger that can occur during machine operation. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 22: Safely Dealing With Sources Of Danger
Touching the fan while the machine is switched on can result in serious injury. ➤ Do not open the housing while the machine is switched on. ➤ Switch off and lock out the power supply isolating device and check that no voltage is present. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 23: Safe Machine Operation
Install safety valves with higher blow-off capacity. 3.5.2 Safe machine operation The following information will provide you with the necessary code of conduct to ensure safe han‐ dling of the machine during individual product life phases. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... - Page 24 ➤ Do not position the machine in the warm exhaust air flow from other machines. ➤ Keep suitable fire-extinguishing media ready for use Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
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Page 25: Organisational Measures
➤ 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 4.2. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 26: Safety Signs
5 minutes. Hot surface! Risk of burns caused by contact with hot components. ➤ Do not touch the surface. ➤ Wear long-sleeved garments (no synthetics such as polyester) and protec‐ tive gloves. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 27: In Emergency
Due to the multitude of applications for which the machine is suitable, the user is obliged to deter‐ mine its suitability for his specific application. Furthermore, we do not assume any warranty obligation for damages caused by: ■ use of unsuitable parts, ■ arbitary modifications, Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 28: Environmental Protection
The operation of this machine may cause dangers for the environment. ➤ Store and dispose of replaced parts (electrical parts, electronic parts, PTFE pistons) in accord‐ ance with local environment protection regulations. ➤ Observe relevant national regulations. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 29: Design And Function
Walking on, standing on or sitting on ■ Loads of any kind should not be placed or stored on the machine Safe and reliable operation is only assured with the housing closed. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 30: Safety Devices
4.3.2 Control mode You can activate or deactivate the LOAD/PARTIAL LOAD control mode when the machine is running or ready. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 31: I.comp Controller
Controller switching points Fig. 4 Controller switching points Network pressure Set required pressure Time Pressure differential (0.2 bar) cannot be Cut-out pressure Cut-in pressure Switching differential (0.8 bar) cannot be Pressure trend Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 32: Control Panel
«OFF / Acknowledge» Switch off the machine / Acknowledge (confirm alarms and warning messages) «DOWN» Reduce the required pressure. «UP» Increase the required pressure. «FUNCTION» Activating/deactivating LOAD/PARTIAL LOAD. See chapter 8 for further key functions Tab. 16 Keys Displays Fig. 6 Displays overview Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 33: Tab. 17 Displays
Continuous red light indicates a fault of the machine. Is off again after acknowledgement. Function Illuminates white in LOAD/PARTIAL LOAD operation. Maintenance Illuminates yellow for: ■ required maintenance work Tab. 17 Displays Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 34: Installation And Operating Conditions
Installation conditions Securely fasten the machine in areas with risk of falling (e.g. scaffolding, banisters or open storey ceilings). Precondition The floor must be firm and capable of bearing the weight. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 35: Risk Of Falling Due To Vibrations Or Negligence
When the machine is connected to a compressed air network, the network working pressure may not exceed the maximum working pressure of the machine. ➤ Consult KAESER for advice on this subject. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 36: Installation
Touching voltage carrying components can result in electric shocks, burns or death. ➤ Switch off and lock out the power supply isolating device (disconnect the plug/plug connection) and verify that no voltage is present. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 37: Reporting Transport Damage
Disconnect the compressed air connection Precondition The machine is connected to the compressed air consumer. Fig. 9 Disconnect the compressed air connection 1. Press the hose coupling in the direction of the compressor. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 38: Connecting The Machine To The Power Supply Network
If the LED “ON” flashes in green after this test, the macchine starts automatically when pres‐ sure is required. You can switch off the machine during the flashing sequence by pressing the «OFF» key. The network pressure is displayed. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 39: Initial Start-Up Ensuring Safety
Touching voltage carrying components can result in electric shocks, burns or death. ➤ Switch off and lock out the power supply isolating device (disconnect the plug/plug connection) and verify that no voltage is present. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 40: Instructions To Be Observed Before Commissioning
Starting the machine for the first time The machine may only be switched on by using the «ON» key. Precondition No personnel are working on the machine. All removable parts are screwed down. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 41: Adjusting The Required Pressure
3. The new required pressure value is flashing on the display. If one of the keys isno longer pressed, the new required pressure is applied after a short time and the network pressure is shown again. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 42: Operation
2. Switch off the power supply isolating device (disconnect the plug/plug connection) (all poles) and secure against unintentional reactivation. The machine is fully unloaded and disconnected from the power supply. Controller displays ex‐ tinguish. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 43: Activating/Deactivating The Load/Partial Load Control Mode
At the same time, the fault symbol and message number is constantly displayed. Acknowledging is only possible if the following prerequisites have been met: ■ voltage applied, ■ machine is switched off and ■ the «OFF» key has been pressed for 2 seconds. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 44: Service Menu
➤ Press the «FUNCTION» and «UP» key simultaneously. Result The service menu is activated. The selected service function and the maintenance symbol are dis‐ played. Press «UP» or «DOWN» to open a different service function. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 45: Deactivating The Service Menu
Service function 2: Leakage test Precondition Use the «OFF» key to switch off the machine. Machine is isolated from any compressed air consumers. Vent the crankcase, see chapter 10.6. Service function 2 has been selected. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 46: Service Function 3: Safety Valve
➤ Press the «OFF» key again. Exit the service menu. Only reconnect compressed air consumers to the machine once the machine's air main pres‐ sure drops below the consumer's working pressure. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 47: Service Function 4: Maintenance Number
The maintenance symbol and number of the last acknowledged fault is displayed for 5 sec‐ onds, see chapter 10.2.2. ➤ Press the «OFF» key. Exit the service menu. ➤ Press the «ON» key to switch the machine back on. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 48: Fault Recognition And Rectification
Call KAESER SERVICE. Shutdown because motor does not turn despite the command ON and the setpoint >0 rpm. Temperature fault, thermal overload. Reduce the ambient temperature. Check cooling air supply. Shut down consumer. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 49: Tab. 20 Fault Messages
Power demand too high. Call KAESER SERVICE. Temperature in the motor drive too high. Reduce the ambient temperature. Check cooling air supply. Speed target/actual deviation. Call KAESER SERVICE. Tab. 21 Warning display Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 50: 10 Maintenance
Touching voltage carrying components can result in electric shocks, burns or death. ➤ Switch off and lock out the power supply isolating device (disconnect the plug/plug connection) and verify that no voltage is present. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 51: Following The Maintenance Plan
General machine overhaul. — KAESER SERVICE i.Comp CONTROL Weekly Activate service function "Condensate". 8.3.3 Operator Annually Inspect safety valve. 10.4 Activate service function "Safety valve". 8.3.5 Activate service function "Leakage test". 8.3.4 Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 52: Replacing The Air Filter
The relevant safety valve opens to protect the machine if the permissible maximum gauge working pressure is exceeded. ➤ Never operate the machine without a correctly functioning safety valve. ➤ Do not adjust the safety valve. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 53: Venting The Machine (De-Pressurising)
Precondition The power supply isolating device (plug/plug connection) is switched off (all poles), the device is locked off, the absence of voltage has been verified. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 54: Venting The Crankcase (De-Pressurising)
The crankcase is de-pressurised by means of the safety valve. Precondition The machine has cooled down. DANGER Compressed air! ➤ Compressed air and pressurised components can injure or cause death if the contained energy is released suddenly. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 55: Fig. 15 Venting The Crankcase
➤ Disconnect machine from air consumer or have an authorized KAESER SERVICE tech‐ nician check the safety valve. ➤ If manual venting does not attain de-pressurisation in the crankcase: contact the author‐ ised KAESER SERVICE. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 56: Documenting Maintenance And Service Work
Documenting maintenance and service work Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 23 Logged maintenance tasks Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 57: 11 Spares, Operating Materials, Service
11.4 Replacement parts for service and repair Use these parts lists to plan your material requirement according to operating conditions and to or‐ der the required spare parts. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... - Page 58 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair ➤ Make sure that any service or repair tasks not described in this manual are carried out by an authorized KAESER SERVICE technician. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 59 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 60 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 61 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 62 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 63 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 64 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 65 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 66 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 67 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 68 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
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Page 69: 12.1 Decommissioning, Storage And Transport
1. Wrap the machine fully in plastic sheeting. 2. Place a sufficient quantity of desiccant (e.g. silica gel) inside the plastic sheeting. 3. Protect the machine in suitable transport packaging (carton with styrofoam insert) against me‐ chanical damages. Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... -
Page 70: Storage
➤ Maintain a storage temperature of >0 °C. 2. Transport the machine with transport packaging only 12.5 Disposal Precondition The machine is decommissioned. 1. Remove old filters. 2. Hand the machine over to an authorized disposal expert. Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... -
Page 71: 13 Annex
Annex 13.1 Dimensional Drawing 13 Annex 13.1 Dimensional Drawing Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... - Page 72 Annex 13.1 Dimensional Drawing Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 73 Annex 13.1 Dimensional Drawing Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
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Page 74: Pipeline And Instrument Flow Diagram (P&I Diagram)
Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) 13.2 Pipeline and instrument flow diagram (P&I diagram) Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E... - Page 75 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 76 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
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Page 77: Electrical Diagram
Annex 13.3 Electrical Diagram 13.3 Electrical Diagram Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3... - Page 78 Annex 13.3 Electrical Diagram Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
- Page 79 Annex 13.3 Electrical Diagram Operator manual Reciprocating compressor No.: 901731 24E i.Comp 3...
- Page 80 Annex 13.3 Electrical Diagram Operator manual Reciprocating compressor i.Comp 3 No.: 901731 24E...
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