BERG KOMPBERG BSDF Series Operating instructions

09.2019
OPERATING AND MAINTENANCE MANUAL
Screw compressors
KOMPBERG®BSDF
PART I

Operating and Maintenance Manual 09/2019 –part I
Screw compressors
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Ladies and Gentlemen,
We heartily welcome you among our valued Customers and thank you for your trust
to purchase the BERG compressor.
We are sure you will be fully satisfied with both the choice you have made and
the cooperation you started with us. Our compressors are machines of top quality,
which is the guarantee for a long years and reliable performance.
Our sales and service staff is available to answer all your queries regarding the
installation and operation of your compressor. You are also encouraged to use our
warranty and post-warranty technical service.

Operating and Maintenance Manual 09/2019 –part I
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1. Information concerning the document...................................................................5
1.1. Scope and intended use of the manual.......................................................................5
1.2. Intended use of the compressor and conditions of safe use........................................5
1.3. Qualification requirements for operation of the compressor........................................6
1.4. Operation....................................................................................................................6
1.5. Other remarks and instructions...................................................................................7
1.6. Warranty.....................................................................................................................7
2. Operating safety rules...........................................................................................7
2.1. Basic requirements for safe transport and positioning of the screw compressor .........8
2.2. Operating safety requirements....................................................................................9
2.3. Other hazards.............................................................................................................9
2.4. Meaning of pictograms..............................................................................................10
3. Identification plate...............................................................................................10
4. Setting ................................................................................................................11
4.1. Room requirements ..................................................................................................11
4.2. Requirements concerning electrical system..............................................................11
4.3. Compressed air connection ......................................................................................13
4.4. Compressed air treatment ........................................................................................13
5. Operation description of the screw compressor..................................................14
5.1. Operation description of the screw compressors with microprocessor controller.......14
5.2. Operation description of the screw compressors with inverter...................................15
5.3. ULTRA SPEED function –in screw compressors with motor power of 5.5 kW - 90 kW
and frequency converter..................................................................................................16
5.4 Description of the compressed air treatment system..................................................16
6. Start-up...............................................................................................................18
6.1. Start-up preparation..................................................................................................18
6.2. Restart (after longer downtime).................................................................................19
7. Procedure in case of compressor self-deactivation or shut down by using the
emergancy stop......................................................................................................19
8. Maintenance.......................................................................................................20
8.1 General requirements................................................................................................20
8.2. Maintenance and inspections....................................................................................21
8.2.1. Maintenance at the beginning of the compressor use and after oil and V-belts
(where applicable) change...........................................................................................21
8.2.2 Daily maintenance.............................................................................................21
8.2.3 Periodic maintenance........................................................................................21
8.2.4 Warranty and post-warranty inspections............................................................22
8.2.5 General remarks................................................................................................23
8.3 Basic components requiring maintenance and descriptions of maintenance
operations........................................................................................................................24
8.3.1. Air filter cartridge ...............................................................................................24
8.3.2. Filter mat ..........................................................................................................25
8.3.3. Oil filter..............................................................................................................26
8.3.4. Oil separator......................................................................................................26
8.3.5. Oil level..............................................................................................................28
8.3.6. Water condensate draining................................................................................29
8.3.7. Oil change and recommendations concerning oil...............................................29
8.3.8. Handling wastes produced while operating the compressors............................30
8.3.9 Pressure switch.................................................................................................30
8.3.10Oil temperature gauge(where applicable)..........................................................31

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8.3.11 Oil cooler / air cooler.........................................................................................31
8.3.12. Electric motor...................................................................................................31
8.3.13. Safety valve.....................................................................................................32
8.3.14 Radial / axial fan...............................................................................................34
9.Troubleshooting.....................................................................................................36
10. Appendices.......................................................................................................39
10.1. Compressor with the heating system–guidelines concerning operation ..................39
10.2. Compressor with additional water cooling...............................................................40
10.2.1. Water connection.............................................................................................40
10.2.2. Description of construction and operation of the screw compressors with
additional water cooling (complement to the description in section 5 ).........................40
11.Condensate drains ............................................................................................41
Condensate drains in the compressors on the air receiver models..................................41

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1. Information concerning the document
This operating and maintenance manual is an integral part of the machine. It includes the
information necessary to start, operate and maintain the compressor and requirements for
its safe operation.
Following the manual rules will help you:
Avoid hazards,
Reduce repair costs and downtime,
Increase the machine reliability and life.
Getting familiar with this manual in detail, using the machine in accordance with
descriptions included in it and following all safety conditions are the basis for correct and
safe operation of the machine.
In addition to the operating and maintenance manual and the regulations applied in the
country of destination and health and safety at work regulations applied locally at the
workstation, the generally recognised technical rules for safe and correct work are also
valid.
1.1. Scope and intended use of the manual
The operating and maintenance manual is intended for qualified / suitably trained operating
personnel of the compressor. The personnel assigned to operation of the compressor must,
before starting work, get familiar with the manual contents, in particular the “Health and
safety at work regulations” section.
The manual includes
Description of daily service and maintenance of the compressor and control system,
Technical documentation of the electrical part. It includes the data necessary to perform
correct connections and repairs of the electrical equipment,
Technical documentation of the mechanical part. It includes the data necessary to perform
repairs of the mechanical equipment,
Technical documentation of the control system. It includes the data necessary to switch on
and off, and set operating parameters of the compressor.
The qualified personnel is understood to be the persons who because of received training,
experience and knowledge of important standards, documentation and regulations
concerning safety and operating conditions were authorised to carry out necessary
operations and are able to recognise and avoid possible hazards.
1.2. Intended use of the compressor and conditions of safe use
The compressor is designed to produce only compressed air. It should be installed in
accordance with the stipulations concerning the compressor installation and connection.
The compressor must not be used for any other purposes that are non-compliant with its
intended use. The manufacturer shall not be liable for any damage resulting from that
reason. In that case, the risk is born by the machine user only.
During the compressor operation, you must follow the procedures given in the
“Maintenance” section as regards scope and frequency of maintenance work and materials
to be used.

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Warning bout forbidden use
The compressor must not be used for any other purposes that are non-compliant with its
intended use.
Under no circumstances must the limit operating parameters of the compressor be
exceeded and changed - refer to section 10 "Technical data".
To use it for compression of other gases than air, it is required to obtain the manufacturer’s
consent. The above consent must be in written form.
The compressor must not be used in potentially explosive atmospheres within the meaning
of Directive 2014/34/EU.
The compressor must not suck any toxic, acid-containing, flammable or explosive gases
and vapours.
Never direct a jet of compressed air at people or animals.
Safe use of the compressor
The compressor must be operated in accordance with all guidelines included in this
operating and maintenance manual.
The sucked air must be clean and must not contain any harmful substances.
The heated cooling air may be used for heating purposes if only its harmfulness to people
and animals is excluded. Otherwise, it is necessary to provide the appropriate treatment of
cooling air.
Compressed air may only be used for breathing after its appropriate treatment.
Compressed air not subjected to the appropriate treatment must not be used in production
processes in which there is contact of air with food.
The compressor delivered is designed to compress only air. To use it for
compression of other gases, it is required to obtain the manufacturer’s consent. The
above consent must be in written form. The compressor must not be used for any
other purposes that are non-compliant with its intended use.
Fulfil the obligation to register the compressor air receiver in the Office of Technical
Inspection (UDT).The compressor documentation is accompanied by the set of the
required documentation of the air receiver (if applicable) and safety valve.
1.3. Qualification requirements for operation of the compressor.
The personnel who installs, operates and maintains the compressor should have the
appropriate education and qualifications enabling safe operation of electro technical and
electrical equipment.
Installation, operation and maintenance of the compressor may only be carried out by the
persons who are familiar with this operating and maintenance manual, follow instructions
included in it, know safety regulations and recognised technical rules.
1.4. Operation
While operating the compressor:
-Observe the instructions provided in the Operating and Maintenance Manual and Warranty
Book.
-Follow the periodic inspection schedule during both warranty period and after its completion.
Regular performance of periodic inspections is necessary to ensure the required reliability
and life of the BERG equipment. The inspections performed according the schedule reduce
the number of repairs and their cost.
-The technical and operating inspections should be carried out in accordance with the
schedule and conditions by the factory service or authorised service, using the
manufacturer’s consumables and spare parts.
-During the warranty period, use only the manufacturer’s consumables and spare parts.

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The detailed list of maintenance operations can be found in the "Maintenance
and inspections" section.
1.5. Other remarks and instructions
-This Operating and Maintenance Manual provides all information on how to install, start and
operate the compressor. This manual should also be used when any maintenance work is
carried out,
-The Manual should be read and always available to the compressor operator,
-During the maintenance work and periodic inspections, the provisions of the Warranty Book
should be observed,
-The Maintenance section provides all measures and requirements necessary to keep the
compressor in a correct technical state,
-Record all operating data, maintenance operations performed etc. into the Warranty Book.
Observe all reference and local safety regulations relating to the compressor, including
those listed herein and in the following sections,
-Failure to follow the requirements included in this Operating and Maintenance Manual and
Warranty Book and/or unauthorised changes in the compressor or its integral units
delivered by us shall make the warranty null and void.
-During warranty period, any repairs must be performed by the manufacturer service or
authorised service centre listed in the Warranty Book.
1.6. Warranty
BERG KOMPRESSOREN GmbH hereinafter referred to as the Warrantor provides the
warranty for the products sold, ensures correct operation of the offered products provided
that they are used in accordance with their intended use and operating conditions specified
in this documentation.
The Purchaser shall lose its warranty rights for the product when:
-The machine is used in a way non-compliant with its intended use,
-Unauthorised modifications are carried out on the product,
-Interventions are carried out by unauthorised persons,
-Any repair attempts are carried out by unauthorised persons,
-The obligation to carry out periodic inspections is not observed,
-Non-original consumables are used.
The manufacturer reserves the right to make modifications in the product,
resulting from continuous technical development, without prior notice.
2. Operating safety rules
The present rules are valid for BERG screw compressors. In addition to the general health
and safety at work and the Office of Technical Inspection (UDT) regulations applicable to
compressors, their assemblies and accessories, the safety instructions given below should
be followed in particular. The operators are supposed to observe safe work practices. It is
the user’s responsibility to continuously maintain the compressor fully operable.
Components and equipment considered to be no longer suitable for safe operation should
be promptly replaced. Adjustments, installation, operation, maintenance and servicing
should be entrusted only to properly trained, qualified and authorized staff.
The limit values (pressure, temperature, time settings etc.) are given in the Technical Data
section.
The limit values may not be changed by the user.
The manufacturer accepts no responsibility for any personal injuries, damage of equipment
or the compressor itself, at present and in the future, resulting from user’s negligence and
failure to observe the installation, operation and maintenance requirements contained

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herein. No responsibility is also taken for failure to observe valid safety standards relating
to the equipment and qualified staff.
2.1. Basic requirements for safe transport and positioning of the screw
compressor
In addition to the general health and safety at work and the Office of Technical Inspection
(UDT) regulations, the following rules must be observed:
-Use only the lifting equipment that is compliant with the H&S and UDT regulations to lift the
compressor. Fix in place all rotating or loose parts of the machine before its lifting. It is
strictly forbidden to stay in the hazardous zone of the lifting equipment operation. The
compressor movement can be accelerated or slowed down only within the permissible
limits.
-When the compressor is transported, the transport straps should be pulled under the
machine and secured above the housing in such a way that they do not place pressure on
it. If the transport harness is fastened and secured incorrectly, the machine may get
damaged.
-If the compressor is transported on wooden pallets, it should be secured against movement
during transport. Fasten the compressor frame with cargo straps to appropriate holders on
the vehicle platform to prevent it from sliding or overturning.
-All screw and pipe connections should be of appropriate size and designed for a given
operating pressure.
-The compressor is not designed to operate outdoors; it cannot be exposed to weather
conditions.
-The compressor should be positioned in a closed room, where ambient air is cool and
clean. Never block air flow to and from the room. Ensure sufficient inflow of cooling air and
discharge of hot air outside the room. Temperature in a room with the compressor should
be within the range of + 5C to + 40C.
-The air sucked in should contain no vapours or flammable gases, e.g. paint thinners, that
might cause internal fire.
-There can be no objects close to the air inlet that could be sucked in with a jet of air.
-The pressure conduit connecting the compressor with the compressed air line should allow
free expansion due to generated heat. It must not touch hot objects or flammable materials.
The detailed requirements concerning the machine positioning in the compressor room are
described in section 4.1.
Fig. 1 Transport of the machine with a
forklift.

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2.2. Operating safety requirements
In addition to the requirements contained in the sections: Screw compressor operation
description; Start up; Maintenance; the following rules should be observed.
-The compressor is only designed to compress air.
-All safety equipment must be in place while operating the machine.
-The factory-mounted safety equipment must not be removed. Please, remember to remove
any transport brackets (if applicable)before first start-up of the compressor. The transport
brackets are only used to protect the machine during transport.
-There are hot parts in the compressor e.g. conduits, air and oil coolers, screw block. They
will scald when touched.
-No unauthorized modifications in the control system are allowed. After power failure,
the compressor must be restarted when the power supply is recovered.
-It is prohibited to remove the green and yellow protective conductors that prevent electric
shock.
-No additional equipment can be mounted on the air receiver(except for the equipment
allowed for use by the manufacturer).
-No welding operations or any other repairs can be performed on the air receiver.
-The plugs and other air receiver accessories can only be removed after the air receiver
depressurisation to the ambient pressure.
-General safety rules should be observed while depressurising the air receiver. Air must be
vented slowly. Keep the air stream away from people.
-Do not allow oil spill around the compressor.
-It is strictly prohibited to service the safety valves or to change their settings.
-Do not change settings of the pressure switches above the value given in the identification
plate or in the Operating and Maintenance Manual.
-Fulfil the obligation to register the compressor air receiver in the Office of Technical
Inspection (UDT). Two sets of the required documents of the air tank (if provided) and
safety valve are included with the compressor documentation. The compressor
documentation is accompanied by the set of the required documentation of the air receiver
(if applicable) and safety valve.
-Do not remove the temperature sensor (transmitter) or pressure transmitter.
2.3. Other hazards
The compressor installation, switching on/off and maintenance must be carried out by the
qualified personnel who strictly follows the data included in the product technical
documentation and safety rules to avoid any hazards. The risks that could not have been
eliminated during the design stage are described in the table below.
Fig. 2 Transport of the machine with a
crane.

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Unit
Residual risk
Action
Precautions
Air cooler, guard,
frame
Minor cuts
Touching
Avoid touching, wear
protective gloves.
Fan guard and fan
Injuries
Inserting sharp
objects through the
protection mesh
when the fan is
running.
Do not insert any objects
through the protection
mesh and do not put any
objects on it.
Screw block, oil tank,
end cooler, pressure
conduits
Danger of scalds
Touching
Avoid touching, wear
protective gloves.
Metal parts and
electric cables
Electric shock
Damage of electric
cable insulation
upstream the motor
breaker, live metal
parts
Suitable guard for the
power supply cable;
check the cable insulation
for damage.
2.4. Meaning of pictograms
Pictograms (safety symbols) located on and inside the compressor are described below.
Explanation is provided below any of them.
For technical reasons, it is not always possible to attach the pictograms in the very vicinity
of the points of risk.
3. Identification plate
The identification plate as shown below is attached to the compressor housing or frame.
When contacting us regarding your compressor, please provide the data given on the
identification plate: compressor type, year of manufacture and factory number.
AUTOMATIC MACHINERY
MAY START
RISK OF SCALDING
RISK OF ELECTRIC
SHOCK