KAESER KOMPRESSOREN i.Comp 3, Operator'S Manual

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...

Page 3: ...ser 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 1...

Page 4: ...tion 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...

Page 5: ...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 compress...

Page 6: ...Contents iv Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 7: ...oling 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 f...

Page 8: ...List of Illustrations vi Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 9: ...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 Displ...

Page 10: ...List of Tables viii Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 11: ...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...

Page 12: ...res 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 n...

Page 13: ...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 mar...

Page 14: ...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 compre...

Page 15: ...quired pressure rp 4 rpmin minimum selectable required pres sure 1 bar 5 rp set required pressure 6 rpmax maximum selectable required pres sure 11 bar 7 p required pressure 8 Qmin rp minimum flow rate...

Page 16: ...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...

Page 17: ...sion 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 k...

Page 18: ...ee 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 b...

Page 19: ...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...

Page 20: ...ly 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 applic...

Page 21: ...to the safety instructions and sections of the operating manual applicable to installation and maintenance are fully conversant with the safety concepts and regulations of electrical and compressed ai...

Page 22: ...ed 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 fr...

Page 23: ...in this machine Use only original KAESER spare parts on pressure bearing parts Conversion or modification of the machine Modifications additions or conversions to or of the machine can result in unpr...

Page 24: ...hat work can be 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 protec...

Page 25: ...monitoring Do not pour oil into the crankcase The machine is oil free Pay particular attention to cleanliness during all maintenance and repair work Cover compo nents and exposed openings with clean...

Page 26: ...pment Switch off and lock out the power supply isolating device and verify the ab sence of any voltage Before starting work on the frequency converter or intermediate circuit ca pacitors wait at least...

Page 27: ...ated persons Close the doors When trained accordingly Attempt to extinguish the fire Extinguishing substances Suitable extinguishing media Foam Carbon dioxide Sand or soil Unsuitable extinguishing med...

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 loca...

Page 29: ...lve 12 Venting and condensate valve 13 Fan wheel 14 Air pipe When closed the housing serves various functions Sound insulation Protection against contact with components Cooling air flow The housing i...

Page 30: ...lectrical connections Protect against unintentional contact 4 3 Operating points and control mode 4 3 1 Machine operating points STOP The machine is connected to the power supply The machine is switch...

Page 31: ...chine generates compressed air Depending on the compressed air consumption the motor speed is adjusted within the permissi ble speed limits so that the network pressure corresponds with the set requir...

Page 32: ...irm alarms and warning messages 3 DOWN Reduce the required pressure 1 4 UP Increase the required pressure 1 5 FUNCTION Activating deactivating LOAD PARTIAL LOAD 1 1 See chapter 8 for further key funct...

Page 33: ...he machine is run outside of permissible operating limits Warning 8 Fault Continuous red light indicates a fault of the machine Is off again after acknowledgement 9 Function Illuminates white in LOAD...

Page 34: ...14 34 EC Equipment and Protective Sys tems intended for use in Potentially Explosive Atmospheres Ensure sufficient and suitable lighting such that the display can be read and work carried out comforta...

Page 35: ...lation evacuates the exhaust heat of the machine and thus ensures the required oper ating conditions Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely t...

Page 36: ...ay only be carried out by authorised electricians Switch off and lock out the power supply isolating device disconnect the plug plug connection and verify that no voltage is present Before starting wo...

Page 37: ...rm the carrier and the manufacturer in writing of any damage without delay 6 3 Creating the air connection Precondition The machine is isolated from the connected compressed air consumers Fig 8 Creati...

Page 38: ...Select fuse ratings in accordance with local regulations 4 The tolerance limits of the mains voltage power supply network are within the permissible tol erance limits of the rated voltage machine 5 DA...

Page 39: ...t may only be carried out by authorised electricians Switch off and lock out the power supply isolating device disconnect the plug plug connection and verify that no voltage is present Before starting...

Page 40: ...storage standstill of machine 7 3 Checking installation and operating conditions Check and confirm all the items of the checklist before commissioning the machine To be checked See chapter Confirmed...

Page 41: ...ns By pressing the UP or DOWN key for longer the required pressure can be adjusted in larger steps Do not set the machine s required pressure higher than the maximum gauge working pres sure of the con...

Page 42: ...ure occurs the compressor motor is not prevented from re starting automatical ly when power is resumed It can re start automatically as soon as power is restored Result The compressor motor starts as...

Page 43: ...e 8 2 Acknowledging messages Fig 11 Acknowledging messages 1 Maintenance symbol yellow 2 Fault symbol red 3 OFF Acknowledge key Fault message Messages are displayed based on the most recent principle...

Page 44: ...acknowledge the message with the Acknowledgement key The Maintenance indication extinguishes as soon as the warning message has been acknowl edged by means of the Acknowledgement key Warning Rectify f...

Page 45: ...unctioning correctly if the indicated air main pressure does not exceed 6 bar during the discharge phase After the testing procedure has completed the machine automatically switches off If the indicat...

Page 46: ...hine is isolated from any compressed air consumers Service function 3 has been selected 1 WARNING Safety valve blows off Loud noise when the safety valve blows off Risk of injury from bursting compone...

Page 47: ...e service menu Press the ON key to switch the machine back on 8 3 7 Service function 5 Fault message number Precondition Use the OFF key to switch off the machine Machine is isolated from any compress...

Page 48: ...ning Action 1 Pressure transducer open circuit Call KAESER SERVICE 2 Fault in communication with compressor motor Call KAESER SERVICE 3 Compressor motor blocked Call KAESER SERVICE 4 Fault in the powe...

Page 49: ...for 5 seconds by simultaneously pressing the UP and DOWN keys The warning code of the currently applicable or the last warning since the mains voltage has last been applied is displayed in the warnin...

Page 50: ...ipment may only be carried out by authorised electricians Switch off and lock out the power supply isolating device disconnect the plug plug connection and verify that no voltage is present Before sta...

Page 51: ...ation A prepared list is available in chapter 10 7 10 2 2 Regular maintenance and service work Carry out maintenance work when the corresponding maintenance message is indicated on the controller disp...

Page 52: ...key Changing the air filter 1 Unscrew and remove the cover 2 Remove the air filter and dispose of according to environmental protection regulations 3 Clean the air filter housing and sealing faces 4 I...

Page 53: ...ty valve replaced by KAESER SERVICE 10 5 Venting the machine de pressurising After being switched off by using the OFF key the machine is still under pressure from the air consumer up to the check val...

Page 54: ...alve venting and condensate valve 4 Check for zero pressure 10 6 Venting the crankcase de pressurising After being switched off the machine is still under pressure from the air consumer up to the non...

Page 55: ...rew back to its original position 4 Check for zero pressure The crankcase is not de pressurised after having been vented Air consumer is still connected to the machine or the safety valve is defective...

Page 56: ...ntenance and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 23 Logged maintenance tasks 10 Maintenance 10 7 Documenting maintenance and service wo...

Page 57: ...d KAESER SERVICE technician carry out regular maintenance Machine Name Number quantity Number Air filter 1 1250 Tab 24 Consumable parts 11 3 KAESER AIR SERVICE KAESER AIR SERVICE offers Authorised ser...

Page 58: ...ks not described in this manual are carried out by an authorized KAESER SERVICE technician 11 Spares Operating Materials Service 11 4 Replacement parts for service and repair 48 Operator manual Recipr...

Page 59: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair No 901731 24E Operator manual Reciprocating compressor i Comp 3 49...

Page 60: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair 50 Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 61: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair No 901731 24E Operator manual Reciprocating compressor i Comp 3 51...

Page 62: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair 52 Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 63: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair No 901731 24E Operator manual Reciprocating compressor i Comp 3 53...

Page 64: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair 54 Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 65: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair No 901731 24E Operator manual Reciprocating compressor i Comp 3 55...

Page 66: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair 56 Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 67: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair No 901731 24E Operator manual Reciprocating compressor i Comp 3 57...

Page 68: ...11 Spares Operating Materials Service 11 4 Replacement parts for service and repair 58 Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 69: ...as been isolated from the air consumer 1 Allow the machine to completely cool down 2 Disconnect all connecting lines plug plug connection from the power supply 12 2 Packing Suitable transport packagin...

Page 70: ...2 Store the machine in a dry frost proof room 12 4 Transport 12 4 1 Safety Avoid damaging the machine Transport the machine in its normal vertical position 1 NOTICE Moisture and frost can damage the m...

Page 71: ...13 Annex 13 1 Dimensional Drawing 13 Annex 13 1 Dimensional Drawing No 901731 24E Operator manual Reciprocating compressor i Comp 3 61...

Page 72: ...y other reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be give...

Page 73: ...other reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given...

Page 74: ...13 2 Pipeline and instrument flow diagram P I diagram 13 Annex 13 2 Pipeline and instrument flow diagram P I diagram 64 Operator manual Reciprocating compressor i Comp 3 No 901731 24E...

Page 75: ...M Ersatz f r Ersatz durch a b c nderung Datum Datum Bearb Gepr Norm Name Ursprung 1 E 08 03 2019 Nr 46206 FKKi COMP 00204 01 Plau Martin 3 1 2 1 19 6 8 8 1 7 48 6 9 1 9 4 9 4 23 13 Annex 13 2 Pipelin...

Page 76: ...e Hose coupling Compressed air outlet Venting and condensate valve open when de energised Pressure transducer Network pressure 1 2 3 4 5 6 7 8 Blatt P I diagram legend Ersatz f r Ersatz durch a b c nd...

Page 77: ...13 3 Electrical Diagram 13 Annex 13 3 Electrical Diagram No 901731 24E Operator manual Reciprocating compressor i Comp 3 67...

Page 78: ...third parties ATTENTION The document gives collective information on power supply voltages and frequencies for all machines The voltage and frequency and local conditions under which any particular m...

Page 79: ...ltage 24 V 24 V Motor M1 M1 1 5 kW Frequency converter T1 T1 7 8234 2 7 8234 3 Ziehl Abegg Ziehl Abegg 703229 Compressor control K20 K20 7 8482 1 7 8482 0 BOPLA BOPLA i Comp CONTROL Ferrit bead R2 R2...

Page 80: ...3G1 5mm W1 6x0 34mm 1 1 2 Control valve 1 Relief and load valve 2 2 Air main pressure W2 0 5mm 1 W3 0 75mm Control unit Control 1 1 2 Control valve 2 Venting and condensate valve 2 W4 0 5mm M 1 Sht a...