KAESER KOMPRESSOREN i.Comp 3 User manual

Operator manual
Reciprocating compressor
i.Comp 3
No.: 901731 24E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
www.kaeser.com

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

1 Regarding this document
1.1 Using this document
This document, hereafter called the service manual, contains important information about all life
phases of the machine.
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents
Included with this operating manual are additional documents intended to assist in the safe opera‐
tion of the machine:
■ Declaration of Conformity in accordance with applicable directives.
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you give the data from the nameplate when ordering documents.
1.3 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
1.4 Symbols and labels
➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warnings indicate danger potentially resulting in personal injury, if the measures specified are not
taken.
Warnings indicate three levels of danger identified by the corresponding signal word:
Signal word 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 sit‐
uation
May result in moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
1 Regarding this document
1.1 Using this document
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 1

Some warning notes may precede a chapter. They apply to the entire chapter including all sub-sec‐
tions.
Example:
DANGER
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The word "DANGER" indicates that death or severe injury can very likely result from ignoring
the warning.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent step are integrated into the procedure
and numbered as a step.
Example:
1. WARNING!
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.
1.4.2 Potential damage warnings
Contrary to the warnings shown above, damage warnings do not indicate potential personal injury.
Damage warnings have only one danger level, identified by this signal word:
Signal word Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
The type and source of the imminent danger is shown here!
Potential effects when ignoring the warning are indicated here.
➤ 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.
1 Regarding this document
1.4 Symbols and labels
2
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E

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.
➤ 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 referring to potential problems is identified by a question mark.
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.
1 Regarding this document
1.4 Symbols and labels
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 3

2 Technical Specifications
2.1 Nameplate
The machine's nameplate contains the model type and important technical information.
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
Flow rate
Phase: 1
Frequency
Voltage
Full load current
Wiring diagram
Tab. 3 Reciprocating compressor nameplate
2.2 Weight
The values shown are maximum values. The actual weight of the machine is dependent on the
equipment fitted.
Compressor type Weight [kg]
i.Comp 3 25/291)
——
——
1) Machine mobile
Tab. 4 Weight
2 Technical Specifications
2.1 Nameplate
4
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E

2.3 Compressor block
Compressor block Flow rate [l/min] Number of cylinders
i.Comp 3 265 1
—— —
Flow rate as per ISO 1217: 2009, Annex E
Tab. 5 Compressor block
2.4 Flow rate
Figure shows the flow rate 1 control range in relation to the set required pressure 5.
Fig. 1 Flow rate and control range
1Q
Flow rate
2Qmax
maximum flow rate at required pressure rp
3Qmin
minimum flow rate at required pressure rp
4rpmin
minimum selectable required pres‐
sure 1 bar
5rp
set required pressure
6rpmax
maximum selectable required pres‐
sure 11 bar
7p
required pressure
8Qmin (rp)
minimum flow rate (dependent on rp)
9Qmax (rp)
maximum flow rate (dependent on rp)
2.4.1 Flow rate Q [l/min] at maximum required pressure of 11 bar:
Rated voltage 100 – 127V / 1 / 50/60Hz
rp [bar] i.Comp 3 — —
Qmin Qmax Qmin Qmax Qmin Qmax
rpmin ——————
6.0 — — — — —
Flow rate in accordance with ISO 1217:2009, Annex E
2 Technical Specifications
2.3 Compressor block
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 5

rp [bar] i.Comp 3 — —
Qmin Qmax Qmin Qmax Qmin Qmax
11.0 (rpmax) ——————
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 – 240V / 1 / 50/60Hz
pA [bar] i.Comp 3 — —
Qmin Qmax Qmin Qmax Qmin Qmax
pAmin 100 170 — — — —
6.0 85 160 — — — —
11.0 (pAmax) 65 117 — — — —
Flow rate in accordance with ISO 1217:2009, Annex E
Tab. 7 Flow rate 200 – 240V / 11,0 bar
2.5 Ambient conditions
Installation
Maximum eleva‐
tion AMSL 1) [m]
1000
Permissible ambient tem‐
perature [°C]
3–35
1) Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 8 Ambient conditions
2.6 Ventilation
The values given are minimum guide values that must be maintained.
Compressor model Inlet aperture (Z) [m2] Exhaust fan (A) 1) [m3/h]
i.Comp 3 0.4 720
—— —
1) Forced ventilation: required air volume for exhaust fan at static compression 1 mbar and max.
duty cycle (ΔT≙10 K)
Tab. 9 Ventilation
2 Technical Specifications
2.5 Ambient conditions
6
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E

2.7 Pressure
Machine safety valve
Characteristic Value
Maximum gauge working
pressure [bar]
11
Safety valve actuating
pressure [bar]
12
Tab. 10 Safety valve actuating pressure
2.8 Noise emission
■ Sound power level in accordance with 2000/14/EC and ISO 3744
■ Emission sound pressure calculated from the measured average sound power level (Direc‐
tive 2000/14/EC, Sound Measuring Standard ISO 3744) according to EN ISO 11203:1995
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
pressure level
[dB(A)]
Logarithmic sur‐
face ratio [dB]
Measured Guaranteed
i.Comp 3 93 97 79.5 13.5
—— — — —
—— — — —
Tab. 11 Sound emission
2.9 Motor power and speed
Compressor type Compressor block Rated power [kW] Speed range [rpm]
i.Comp 3 i.Comp 3 1.5 1500 – 3200
—— — —
—— — —
Tab. 12 Motor power and speed
2.10 Electrical connection
The machine is designed in accordance with the conditions for electrical power supply specified in
EN 60204-1 (IEC 60204-1) section 4.3.
If no other conditions are specified by the operator, the thresholds described in this standard must
be adhered to.
It is recommended that the user and the supplier reach an agreement on the basis of EN 60204-1,
Annex B.
2 Technical Specifications
2.7 Pressure
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 7

The machine requires an alternating current power supply.
The machine may only be operated from an earthed alternating current supply network.
Compare information about the rated voltage on the nameplate to the rated voltage of the
power supply network.
NOTICE
Rated voltage!
Incorrect rated voltage can lead to irreparable damage to the electrical components.
➤ Connect rated voltage in accordance with the nameplate.
Check and adjust for other deployment conditions before commissioning.
2.10.1 Electrical connection data
The supply cable cross sections, fusing and circuit breaker are as per DIN VDE 0100 Part 430
(IEC 60364-4-43) and DIN VDE 0298-4:2013-06 for the following conditions:
■ Multicore copper conductors with an operating temperature up to 70 °C
■ Cable length ≤30 m (fusing - consumer)
■ For ambient temperature of 30 °C
In order to guarantee safety of personnel, cable lengths of over 30 m (up to a maximum of 150 m)
may only be used in the event that the machine is also equipped with a 30 mA
RESIDUAL CURRENT DEVICE (e.g. type A).
Fusing must be suitable for the current carrying capacity of the power cables provided (plug
and cable) and must not exceed the values for the backup fuse and circuit breaker supplied
in the table.
In the case of machines equipped with integrated fusing in the connector cable (e.g. inside
the plug), the integrated fusing serves as the backup fuse.
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] — —
Backup fuse, max. [A] 1) — —
Circuit break‐
er, max. [A] 2)
— —
Short-circuit cur‐
rent (Icc) [kA]
— —
Supply cable [mm2]— —
1) Operating class gG
2) Characteristic C
Tab. 13 Rated voltage 100 – 127V / 1 / 50/60Hz
2 Technical Specifications
2.10 Electrical connection
8
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E

Rated voltage: 200 – 240V / 1 / 50/60Hz
i.Comp 3 —
Current consumption [A] 9.5 – 7.6 —
Max. backup fuse [A] 1) 16 —
Max. circuit breaker [A] 2) 16 —
Short-circuit cur‐
rent (Icc) [kA]
50 —
Supply line [mm2]3x1.5 —
1) Operating class gG
2) Characteristic C
Tab. 14 Rated voltage 200 – 240V / 1 / 50/60Hz
2 Technical Specifications
2.10 Electrical connection
No.: 901731 24E
Operator manual Reciprocating compressor
i.Comp 3 9

3 Safety and Responsibility
3.1 Basic instructions
The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ impairments to the machine and other material assets.
Disregard of warning or safety instructions can cause serious injuries!
➤ 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.
3.2 Intended use
The machine is intended solely for generating compressed air for industrial use. Any other use is
considered improper. The manufacturer is not liable for any damages that may result from improp‐
er use. The user alone is liable for any risks incurred.
➤ Comply with the instructions in this operating manual.
➤ Ensure that installation conditions are being kept to.
➤ 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.
➤ Do not use compressed air for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated.
3.3 Improper use
➤ Never direct compressed air at persons or animals.
➤ Do not touch hot components during operation or after shutdown. Wait until they have cooled
before touching!
These components include, for example, cylinder heads, compressed air lines, coolers and
motors.
➤ Always switch off the compressor and disconnect it from the mains power supply when not in
use.
➤ In order to prevent injury, keep children away from the compressor work area and its associ‐
ated compressed air equipment.
➤ Children are not allowed to operate the compressor.
➤ Do not allow the machine to take in toxic, acidic, flammable or explosive gases or vapours.
➤ 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.
3 Safety and Responsibility
3.1 Basic instructions
10
Operator manual Reciprocating compressor
i.Comp 3 No.: 901731 24E