KAESER KOMPRESSOREN i.Comp 3 User manual
Original instructions
/KKW/PWPC 2.04 en SBA-KOLBEN-ANLAGE M
20200310 081012
1 Regarding this document
1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alert notes and their symbols .................................................................... 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Weight .............................................................................................................................. 4
2.3 Compressor block ............................................................................................................ 5
2.4 Flow rate .......................................................................................................................... 5
2.4.1 Flow rate Q [l/min] at maximum required pressure of 11 bar: ............................. 5
2.4.2 Flow rate Q [l/min] at maximum required pressure of 11 bar: ............................. 6
2.5 Ambient conditions ........................................................................................................... 6
2.6 Ventilation ........................................................................................................................ 6
2.7 Pressure ........................................................................................................................... 7
2.8 Noise emission ................................................................................................................. 7
2.9 Motor power and speed ................................................................................................... 7
2.10 Electrical connection ........................................................................................................ 7
2.10.1 Electrical connection data ................................................................................... 8
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 10
3.2 Intended use .................................................................................................................... 10
3.3 Improper use .................................................................................................................... 10
3.4 User's responsibilities ....................................................................................................... 11
3.4.1 Observe statutory and universally accepted regulations .................................... 11
3.4.2 Determining personnel ........................................................................................ 11
3.4.3 Complying with inspection schedules and accident prevention regulations ....... 11
3.5 Dangers ............................................................................................................................ 11
3.5.1 Safely dealing with sources of danger ................................................................ 12
3.5.2 Safe machine operation ...................................................................................... 13
3.5.3 Organisational Measures .................................................................................... 15
3.6 Safety devices .................................................................................................................. 15
3.7 Safety signs ...................................................................................................................... 16
3.8 In emergency ................................................................................................................... 17
3.8.1 Correct fire fighting ............................................................................................. 17
3.9 Warranty ........................................................................................................................... 17
3.10 Environmental protection ................................................................................................. 18
4 Design and Function
4.1 Machine operation ............................................................................................................ 19
4.2 Safety devices .................................................................................................................. 20
4.3 Operating points and control mode .................................................................................. 20
4.3.1 Machine operating points .................................................................................... 20
4.3.2 Control mode ...................................................................................................... 20
4.4 i.Comp CONTROLLER .................................................................................................... 21
4.5 Control panel .................................................................................................................... 22
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 24
5.2 Installation conditions ....................................................................................................... 24
5.2.1 Risk of falling due to vibrations or negligence .................................................... 25
Contents
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 i
5.2.2 Ensuring ventilation ............................................................................................ 25
5.2.3 Operation in a compressed air network .............................................................. 25
6 Installation
6.1 Ensuring safety ................................................................................................................ 26
6.2 Reporting Transport Damage ........................................................................................... 27
6.3 Creating the air connection .............................................................................................. 27
6.4 Disconnect the compressed air connection ..................................................................... 27
6.5 Connecting the machine to the power supply network ..................................................... 28
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 29
7.2 Instructions to be observed before commissioning .......................................................... 30
7.3 Checking installation and operating conditions ................................................................ 30
7.4 Starting the machine for the first time .............................................................................. 30
7.5 Adjusting the required pressure ....................................................................................... 31
8 Operation
8.1 Switching the machine on and off .................................................................................... 32
8.1.1 Switching on ....................................................................................................... 32
8.1.2 Switching off ....................................................................................................... 32
8.1.3 Activating/deactivating the LOAD/PARTIAL LOAD control mode ...................... 33
8.2 Acknowledging messages ................................................................................................ 33
8.3 Service menu ................................................................................................................... 34
8.3.1 Activating the service menu ................................................................................ 34
8.3.2 Deactivating the service menu ............................................................................ 35
8.3.3 Service function 1: Condensate .......................................................................... 35
8.3.4 Service function 2: Leakage test ......................................................................... 35
8.3.5 Service function 3: Safety valve .......................................................................... 36
8.3.6 Service function 4: Maintenance number ........................................................... 37
8.3.7 Service function 5: Fault message number ........................................................ 37
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 38
9.2 Fault messages (machine shut down) ............................................................................. 38
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 40
10.2 Following the maintenance plan ....................................................................................... 41
10.2.1 Document maintenance work ............................................................................. 41
10.2.2 Regular maintenance and service work .............................................................. 41
10.3 Replacing the air filter ...................................................................................................... 42
10.4 Checking the safety valve ................................................................................................ 42
10.5 Venting the machine (de-pressurising) ............................................................................ 43
10.6 Venting the crankcase (de-pressurising) .......................................................................... 44
10.7 Documenting maintenance and service work .................................................................. 46
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 47
11.2 Ordering consumable parts .............................................................................................. 47
11.3 KAESER AIR SERVICE ................................................................................................... 47
11.4 Replacement parts for service and repair ........................................................................ 47
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 59
12.2 Packing ............................................................................................................................ 59
12.3 Storage ............................................................................................................................. 60
12.4 Transport .......................................................................................................................... 60
Contents
ii
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E
12.4.1 Safety .................................................................................................................. 60
12.5 Disposal ........................................................................................................................... 60
13 Annex
13.1 Dimensional Drawing ....................................................................................................... 61
13.2 Pipeline and instrument flow diagram (P&I diagram) ....................................................... 64
13.3 Electrical Diagram ............................................................................................................ 67
Contents
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 iii
Contents
iv
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E
Fig. 1 Flow rate and control range ........................................................................................................ 5
Fig. 2 Location of safety signs .............................................................................................................. 16
Fig. 3 Machine operation ...................................................................................................................... 19
Fig. 4 Controller switching points ......................................................................................................... 21
Fig. 5 Keys – overview ......................................................................................................................... 22
Fig. 6 Displays overview ....................................................................................................................... 22
Fig. 7 Cooling air .................................................................................................................................. 25
Fig. 8 Creating the air connection ........................................................................................................ 27
Fig. 9 Disconnect the compressed air connection ................................................................................ 27
Fig. 10 Switching the machine on and off .............................................................................................. 32
Fig. 11 Acknowledging messages .......................................................................................................... 33
Fig. 12 Replace the air filter ................................................................................................................... 42
Fig. 13 Check the safety valve ............................................................................................................... 43
Fig. 14 Venting the machine ................................................................................................................... 44
Fig. 15 Venting the crankcase ................................................................................................................ 45
List of Illustrations
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 v
List of Illustrations
vi
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Reciprocating compressor nameplate ........................................................................................ 4
Tab. 4 Weight ........................................................................................................................................ 4
Tab. 5 Compressor block ...................................................................................................................... 5
Tab. 6 Flow rate 100 – 127V / 11,0 bar ................................................................................................. 5
Tab. 7 Flow rate 200 – 240V / 11,0 bar ................................................................................................. 6
Tab. 8 Ambient conditions ..................................................................................................................... 6
Tab. 9 Ventilation ................................................................................................................................... 6
Tab. 10 Safety valve actuating pressure ................................................................................................. 7
Tab. 11 Sound emission .......................................................................................................................... 7
Tab. 12 Motor power and speed .............................................................................................................. 7
Tab. 13 Rated voltage 100 – 127V / 1 / 50/60Hz ..................................................................................... 8
Tab. 14 Rated voltage 200 – 240V / 1 / 50/60Hz ..................................................................................... 9
Tab. 15 Safety signs ................................................................................................................................ 16
Tab. 16 Keys ........................................................................................................................................... 22
Tab. 17 Displays ...................................................................................................................................... 23
Tab. 18 Re-commissioning after storage/standstill of machine ............................................................... 30
Tab. 19 Check list of installation conditions ............................................................................................. 30
Tab. 20 Fault messages .......................................................................................................................... 38
Tab. 21 Warning display .......................................................................................................................... 39
Tab. 22 Maintenance and service work ................................................................................................... 41
Tab. 23 Logged maintenance tasks ........................................................................................................ 46
Tab. 24 Consumable parts ...................................................................................................................... 47
List of Tables
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 vii
List of Tables
viii
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E
Table of contents
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