BERG KOMPBERG ZX75 Operating instructions

OPERATINGANDMAINTENANCEMANUAL

Oil‐freescrewcompressor
KOMPBERGZX75

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.

Tableofcontents

1.Informationconcerningthedocument...............................................................................4
1.1.Scopeandintendeduseofthemanual.......................................................................................4
1.2.Intendeduseofthecompressorandconditionsofsafeuse......................................................4
1.3.Qualificationrequirementsforoperationofthecompressor....................................................5
1.4.Operation.....................................................................................................................................5
1.5.Otherremarksandinstructions..................................................................................................6
1.6.Warranty......................................................................................................................................6
2.Operatingsafetyrules.........................................................................................................6
2.1.Basicrequirementsforsafetransportandpositioningofthescrewcompressor......................7
2.2.Operatingsafetyrequirements...................................................................................................8
2.3.Otherhazards..............................................................................................................................8
2.4.Meaningofpictograms................................................................................................................9
3.Technicaldata.................................................................................................................................9
4.Setting................................................................................................................................10
4.1.Roomrequirements...................................................................................................................10
4.2.Requirementsconcerningelectricalsystem.............................................................................11
4.3.Compressedairconnection.......................................................................................................11
5.Screwcompressoroperatingdescription..........................................................................12
5.1.ScrewcompressorKOMPBERGZX75–operatingdescription..................................................12
Technologicaldiagram......................................................................................................................14
6.Start‐up..............................................................................................................................17
6.1.Start‐uppreparation..................................................................................................................17
6.2.Restart(afterlongerdowntime)...............................................................................................18
7.Maintenance......................................................................................................................19
7.1Generalrequirements................................................................................................................19
7.2.Maintenanceandchecks...........................................................................................................20
7.2.1Maintenanceatthebeginningofcompressoruse,afteroilanddrivebelts(ifpresent)
change..........................................................................................................................................20
7.2.2Dailymaintenance..............................................................................................................20
7.2.3Periodicmaintenance.........................................................................................................20
7.2.4Warrantyandpost‐warrantychecks..................................................................................20
7.3.Basiccomponentsrequiringmaintenance.Maintenanceoperations................................21
7.3.1.Airfiltercartridge..............................................................................................................21
7.3.2Cleaningorreplacingthefiltermats..................................................................................21
7.3.3.Oilfilter..............................................................................................................................22
7.3.4.Oillevel..............................................................................................................................22
7.3.5Changingoil........................................................................................................................23
7.3.6.Handlingwastesproducedwhileoperatingthecompressor............................................24
7.3.7Oilcooler(exchanger)/interstage/finalair.....................................................................24
7.3.8..Electricmotor...................................................................................................................25
7.3.9Safetyvalve.........................................................................................................................25
8.Troubleshooting.................................................................................................................26
9.Consumablesforoneyearguarantee...............................................................................30
10.Electricalscheme.............................................................................................................30

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.
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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.


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/UE.
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.

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.SpedditionStraße21,40221DüsseldorfGermany
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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.
-Thecompressormustbetransportedonlywithaforklift.
-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
rangeof+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.












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Transport of the machine with a forklift.


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.


Unit

ResidualriskActionPrecautions
watercooler,frameminorcutstouchingavoidtouching,wear
protectivegloves
screwassembly,end
cooler,pressure
conduits
dangerof
scaldstouchingavoidtouching,wear protectivegloves
metallicpartsand
electricwireelectricshock
damageofwire
insulationupstream
themotorbreaker,
livemetallicparts
adequateguardforthe
powersupplylead;check
thewireinsulationfor
damages
aroundthe
compressordangerofscalds
fireduetoshorting
oroverheatingofthe
powercordbefore
theelectricalbox
usethecrosssectionofthe
powercordandthe
protectioncorrespondingto
theapplicablestandards


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.

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

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
3.Technicaldata

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




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*)‐Capacitymeasuredacc.toENISO1217:2006andENISO5167‐2.
**)‐Noiselevelacc.toENISO2151.
‐MomentaryvalueofacousticpressurecorrectedbyCcharacteristicdoesnotexceed130dB.
‐EquivalentacousticpressurelevelcorrectedbyAcharacteristicdoesnotexceed85db(A).
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AUTOMATICMACHINERY
MAYSTART RISKOFSCALDINGRISKOFELECTRICSHOCK
Type
KOMPBERGZX75

Overpressure* MPa 1,0
Maxcapacitym3/h 587
9,78
m3/min
Weightkg 3700kg
Dimensions(LxWxH)mm 2800/1600/2000
Compressedairconnection G2
Ambienttemperature0C+5÷+400C
Compressedairtemperature0C+10do150Caboveambient
temperature
NoiselevelL**DB(A) 85
Screwair‐endtypeCD8D
NominalmotorpowerkW 75
Supplyvoltage400V/50Hz/3ph
NominalfanmotorpowerkW4
Coolingairrequirementm3/h 16500
Powerleadcrosssectionalareamm23x70+PE
ProtectionA160


4.Setting
4.1.Roomrequirements

-Thecompressorrequiresnofoundations.Itmustbepositionedonahardandevensurface.Take
intoconsiderationthefloorloadcapacity,ifthemachineisinstalledinabuilding.
-Strictlyobservetheminimumdistancesfromwallsandothermachines.Whenseveral
compressorsareinstalled,payattentiontothedirectionofcoolingairflow;nocompressor
shouldsuckairwhichisheatedbyothermachine.Minimumdistancesfromtheroomwallsand
otherobjectsaregiveninthedrawingsbelow.
-Protecttheroominwhichthecompressorisinstalledfromnegativetemperatures.Theinletsand
outletstoandfromtheroomshouldbelocatedinsuchamannertoprotecttheinteriorfrom
weatherconditions.
-Heatgeneratedduringcompressionshouldbeextractedoutside(ortootherrooms),andfresh
airshouldbesuppliedfromtheoutside.
-Ifthegravityventilationisinsufficient(windows,openingsinawalletc.)inthecompressorroom,
airexchangeshouldbeprovidedbyfans.Toensurecorrectheatextraction,thefansshouldhave
totalcapacityabout15to20%higherthanthetotalcoolingairrequirementforallcompressors
installedintheroom.TherequiredcoolingairvolumeisspecifiedintheTechnicalDatasection.
-Ambienttemperatureintheroomshouldbefrom+5Cto+40C.
-Providesufficientroomformaintenanceoperations.
-Itisnecessarytoconsultourspecialistswhenyouwanttoinstallaductsupplyingairfrom
theoutsideoruseairforheatingtherooms.
-Thecompressorroomshouldbewelllightedtoensuretrouble‐freeandsafeserviceofthe
equipment.
-Toimproveventilationinthecompressorroom,themachinecanbeconnectedtothedischarge
airduct;insuchcase,pleasecontactBERG.

Thesuitableventilationinaroomwillpreventthepossibilityofnegativepressuregenerationor
undesiredtemperatureincrease.

Whenthereareanyproblemsinensuringthesuitableventilationinaroom,pleasecontactBERG.

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
4.2.Requirementsconcerningelectricalsystem

-Thecompressorsaredesignedtobesuppliedbyafour‐conductor400VAC,50Hzpowerline.
-ThecompressorsareequippedwithPEterminal.

No.


Compressortype



Powerleadcross
sectionalarea
mm2
Fusesize
NHgL/gG,500V,100kA
DgL/gG,500V,50kA
1KOMPBERGZX75
3x70mm2+PE160

-Thepowercablecrosssectionalareashouldbematchedtothecurrentdrawnbythe
compressor.
-Thecompressorscanonlybeoperatedonthree‐phaseearthedsystem(TN).
-Thecompressormustbesuppliedfromthedistributionboardequippedwithaslowblowfuse
andcircuit‐breakerthatenablesthecompressorpowersupplytobecompletelydisconnected.
-Electricalconnectionofthecompressorshouldbeperformedinaccordancewiththeattached
electricaldiagram.
-Onlyauthorisedpersonnelorqualifiedelectricianisallowedtoperformelectricalconnections.
-Usetherequiredsafetymeasuresinaccordancewiththesuitableregulations.
-Calculatethepowercablecrosssectionalareaandfusesizesaccordingtothelocalregulations
andoperatingconditions.
-Belowtherearepresentedtherecommendedpowercablecrosssectionalareasandfusesizes
forstandardcompressors.
-Ausertakesafullresponsibilityforselectionofanelectricalsystemandpowersupplyconnection
forthecompressor.

Recommendedpowercablecrosssectionalareaandfusesizes
4.3.Compressedairconnection
Itisrecommendedtousegalvanizedsteelorplastictubesforthecompressedair
system.
Whenthecompressedairtreatmentequipment(filters,dryer)isinstalled,theexisting
compressedairpipingshouldbereplacedwithanewone,unlessairsupplied
previouslywastreatedbysimilarequipment.
EachBERGcompressorshouldbeconnectedtothecompressedairnetworkbyusinga
flexibleconduitorflexibleconnector(axialexpansionjoint)andshut‐offvalve.




Compressed air
outlet
Pneumatic
hose
Elbow

5.Screwcompressoroperatingdescription
5.1.ScrewcompressorKOMPBERGZX75–operatingdescription

Generalviewofanoil‐freescrewcompressorKOMPBERGZX75


Thecompressorisequippedwithtwostageairend("ofdry‐type")withoutoilinjectionintothe
compressionchamberwiththebearingsandgearingandthecoatofthehighpressurepartare
lubricatedandcooledwithoil.


POWERANDCONTROL
Thecompressor(screwair‐end)isdrivenbyanelectricmotorthroughaflexiblecoupling.Control
oftheentireelectricalsystemisplacedinaelectricalbox.

AIRCIRCULATION
Theairissuckedthroughtheairfilter(1)andthesuctioncontroller(2)tothefirststage(3).The
compressorsuctionregulatorisequippedwithasecondstagedischarge(4)terminatedbyanoise
damper(5).Aftercompressiontotheoverpressureof0,35MPatheairisforcedfromthe1st
stagetotheintercooler(air‐waterexchanger)(6).Aftercoolinginthecooler,theairflowsthrough
thecondensateseparator(7)andissuckedtothesecondstage(8).I‐stagecompressionand
internalsystemareprotectedagainstpressureriseabovethepermissiblevaluebyasafetyvalve
(9).Aftercompression,itreachesanoverpressureofupto1,0MPaandisforcedintotheend
cooler(air‐waterexchanger)(10),andthenthroughthecheckvalve(11)tothecompressoroutlet.

OILCIRCUM
Theoilissuckedbythepump(13)fromthecompressorreservoir(13)andisforcedtothe
overflowvalve(16)inwhichtheoiloverpressureislimitedto0.25‐0.30MPaandthenflowsto
theoilfilterassembly(18).Theoilfiltersetisfittedwithathermostat(17)which,dependingon
theoiltemperature,directstheoildirectlythroughtheoilfilter(18)tothemanifold(19)orat
temperatureexceeding55°Ctotheoilcooler(20)andthenthroughoilfilter(18)tothe
manifold(19).Thepressureinthemanifoldislimitedto0.14‐0.16MPawithanoverflowvalve
(15).Theoutletsfromtheoilfilterassemblytotheoilcoolerandinletfromtheradiatortothe
unitareequippedwithelectromagneticshutoffvalves(21)and(30)whichareclosed(normally
closedNZ)wheninthede‐energizedcondition.Thesevalvesaredesignedtopreventtheflowof
oilfromtheradiatortotheinstallationandfurthertotheoiltank,whichavoidstheneedto
alwaysfilltheradiatorwithoilafterthecompressor'sstandstill.Inaddition,theoilleveldisplayin
thesightglass(22)isalwaysreliable(withoutshutoffvalvesthesightglasswouldbecompletely
filledwithoil).


Fromthemanifoldtheoilisdistributedtobothcompressionstagesiebearings,sealsandcoatsof
I‐stageandII‐stage.Afterpassingthroughthecompressor,theoilflowstoitsreservoir(14).
Afterthefilter,theoilisalsofedtothethree‐wayvalve(23)and,dependingonthecompressor
load,flowstothehydrauliccylinder(24)controllingtheshutter(25)inthesuctioncontroller(3).
Inthesecondposition,theoilfromthevalve(23)flowstothecompressorreservoir(14).Alsothe
oilfromthehydrauliccylinderisdirectedtothecompressortank.








Technologicaldiagram

1Airfilter19Oilfilter
2Suctionvalve20Overflawvalve
3Firststage21Oildistributor
4VenturinozzFirststagecoolerle 22Ventfilter
5Firstsatagecooler23Hydrauliccylinder
6Cycloneseparator24Solenoidvalve
72ndstage25Solenoidvalvewithtimesystem
8Venturinozzle26Airfilterpollutionsensor
92ndstagecooler27Temperaturesensor
10Checkvalve28Safetyvalve
112ndstageunloading29Pressuresensor
12Silencer30Temperaturesensor
13Oilsightglass31 Temperaturesensor
14Oiltank32 Temperaturesensor
15 Oilpomp33Safetyvalve
16 Thermostaticvalve34Pressuresensor
17Solenoidvalve35Temperaturesensor
18Oilcooler36Pressuresensor
  37Manometer






MEASURINGSENSORS
Thefollowingtemperaturesensorsandpressuretransducerareinstalledinthecompressor
installation:
(39)‐airfilterpollutionsensor,
(33)‐temperaturesensor‐realizesthemeasurementofthecompressedairtemperatureafter
theIstage(3),
(35)‐temperaturesensor‐realizesthemeasurementofthecompressedairtemperatureafter
coolingintheradiator(6),
(34)‐pressuretransducer‐performsmeasurementofairpressureaftertheradiator(6),
(38)‐temperaturesensor‐realizesairtemperaturemeasurementaftertheIIstage(8),
(37)‐temperaturesensor‐realizesairtemperaturemeasurementaftertheradiator(10),
(36)‐pressuretransducer‐performsthemeasurementofcompressedairpressureafterthe
cooler,behindthecheckvalve,
(31)‐temperaturesensor‐performsmeasurementofoiltemperature,
(32)‐pressuretransducer‐performsoilpressuremeasurement.

ThesesensorsandtransducersworkwiththePLC.

WATERCONDENSATEDRAIN
Waterinthecompressorairsystemmeansaveryhighriskoffailure,includingthescrewairend
failure.Thisiswhythewatercondensatefromtheairiscarefullydrainedinthecompressor.The
condensatefromtheseparator(7)aftertheintercooler(6)isdrainedoutofthecompressorby
floatoperatedmechanicalcondensatedrain(25).

VENTILATIONOFTHESCREWAIR‐ENDINSIDE
Duringoperationofthecompressorinthespacesintheinteriorofitsbodies,bearinghousings
andsealsasmalloverpressureisproduced.Thisisdetrimentaltothecorrectnessofthe
lubricationandsealingprocesses.Therefore,thesespacesmustbeventilated.Thisis
accomplishedbymeansofaflexiblehoseandanairfilterlocatedatthetunnelofthefan;Inthe
figureitismarkedwithasymbol(40).

COMPRESSORCOOLING
Thecompressoriscooledinaforcedmannerbymeansofafanwithitsownelectricdrive.Theair
issuckedinthroughtheinletsonthefrontandrearwallofthehousingandpushedthroughaset
ofradiatorsplacedontopofthecompressorandthrownoutsidethecompressor.

OPERATIONOFTHEOILFREECOMPRESSOR
ThecompressorisstartedbypressingtheSTARTbuttononthecontrolpanel.Afterthebuttonis
pressed,thecompressordriveisactivated.Thecompressorisdesignedforintermittentrun.The
intermittentoperationinvolvesairpressurisationuntilthemaximumoverpressuresetonthe
pressureswitchisreached.

Whenthispressureisreached,thecompressorswitchestoidlerunning(thehydraulicactuator
closestheairsupplyonthecompressorsuctionside)andthenthereisacountdownofthetimeto
stop.Ifduringthistimetheairpressuredecreases,thecompressorwillstartagain,andifnot,it
willshutdownafterthecountdown.Thecompressorisrestartedwhentheoverpressureinthe
pipingdropstotheminimumvaluesetinthecontroller.

ThecompressorcanbestoppedatanytimebypressingtheSTOPbuttononthecontrollerpanel.
TheoperationisresumedbypressingtheSTARTbutton.
Whentheoverpressureinthepipingonthecompressorstartexceedsthevaluesetin
thepressureswitch,thecompressorwillstartonlyaftertheoverpressuredropstotheminimum
value.

AfterstoppingthecompressorwiththeEMERGENCYSTOP(STOPAWARYJNY)buttonandafter
thesupplyvoltageisswitchedoffandon,thecompressorcanbestartedbyunlatchingthe
EMERGENCYSTOP(STOPAWARYJNY)buttonandpressingtheSTARTbutton.
Thecompressorisprovidedwithanadditionalprotectivefunctionwhichpreventsmachinestart
whenanyofparametersgiveninTab.[Technicaldata]isexceeded.



ScrewairendCD8D











Suctionregulator




Operatingpanel

ControllerinstructionisanintegralpartoftheOMMofcompressorKOMPBERG
ZX75


6.Start‐up
6.1.Start‐uppreparation

Eachcompressorunitistestedinthefactoryandcarefullyinspectedtoensurepropermachine
performanceandmeetingthespecificationsdeclared.
Strictlyobeythefollowingrulesbeforestartingthemachineforthefirsttime:
-GetthoroughlyfamiliarwiththecompressorOperatingandMaintenanceManualandthe
WarrantyBook.
-Checkthepowercablesforpossibledamage,short‐circuitsandelectricalbreakdowns.Only
authorised/qualifiedelectriciancanperformworkonelectricalequipmentandcomponents.
-Makesurethepowersupplyvoltageiscorrectandtherequiredprotectionsareinplace;donot
connectthecompressortoapowersourceofdifferentvoltagethanthatspecifiedinthe
OperatingandMaintenanceManual.
-Connectthephaseconductorssothattherotationdirectionisasindicatedonthescrew
assemble.
-Checktheoillevelinthescrewblock,topitup,ifnecessary.
-Connectthecompressortothecompressedairsystemwithaflexibleconduit.
-Acompressedairreceivertankisnecessaryforpropercompressoroperation(min.2500l).
-Whenthecompressedairreceivertankislocatedoutsidethecompressorroom,installthe
pressuregauge,connectedtothetankorpressureconduitsupplyingthetank,inavisible
location.
-Donotoperatethecompressorabovethemaximumoperatingpressurethatisgivenonthe
identificationplate.Itisnotrecommendedtooperatethecompressoratthedeliverypressure
below0.5MPa.Pleasecontactourtechnicianswhenitisnecessarytosetthatoverpressure.

-Checkifalldoors/coversareclosed.
-Openthevalvethatshutsoffthecompressorfromcompressedairsystem.
-Checkthe“EMERGENCYSTOP”buttonposition.
-Switchonthecompressorpowersupply.

Whenthecompressorandcompressedairsystemconditionischecked,youcanproceedwith
startingthecompressor.
Tostartthecompressor,pressthe"START"buttononthecontrolpanel.Thecompressormotor
startsworkinganddependingontheoverpressureinthecompressedairsystem,themachine
switchestotheloadedoperationmodeor,iftheoverpressureinthecompressedairsystemis
higherthantheminimumstartpressure,itswitchestothestand‐bymodeandstartsagainafter
itsdrop.

Incorrectrotationdirectionofthescrewblockrotorsformorethan5secondswilldamage
thescrewcompressor.






Properdirectionofscrewairendrotation


6.2.Restart(afterlongerdowntime)
Followtheproceduredescribedbelowtostartthecompressorwhichhasbeenoutofuseor
storedforover3months:
Checkifthereisnowaterinthescrewassemble.
Turnthecompressorshaftseveraltimesbyhandintherotatingdirection.
checkoillevelinthescrewassemblybody,topitupifnecessary,

Performthetrialrunofthecompressorscrewblocklastingforatleast15minutes.

Duringthetrialrun,checkthemachineforcorrectoperation,noise,vibration,oilleaksand
tightnessofconnectionsinthecompressedairsystem.






Rotating
direction of
CD8D





7.Maintenance
7.1Generalrequirements

Toensureproperfunctioning,thecompressormustundergomaintenanceprocedures.The
followinggeneralrequirementsmustbemetwhileperformingthemaintenance:
-Placethewarningsignasshownbelowinavisiblelocation,whilethemaintenanceworkisin
progress:

WARNING
MACHINEUNDERREPAIR


-Allmaintenanceworkshouldbeperformedbyauthorisedandtrainedpersonnel.Contact
thefactoryserviceincaseoftechnicalproblems.
-Beforeanymaintenanceworkisstartedonthecompressor,disconnectitfrompowersupplyand
protectfromunauthorizedandaccidentalstarting.
-Checkifthesupplyvoltageislacking.
-Anymaintenanceandrepairworkcanonlybecarriedoutwhenthecompressedairsystemis
completelyunloadedi.e.airpressureinthesystemisreducedtoambientpressure.
-Beforerestartingthemachine,makesurethatthereisnobodyworkingonthecompressorand
therearenopeopleinthevicinity.
-Useappropriatetoolsformaintenanceandrepairwork.
-Useonlyoriginalspareparts.
-Forcleaningpurposesneveruseflammableorcorrosivesolventsthatcoulddamagethemachine
components.Takeappropriatesafetymeasuresagainsttoxicvapoursfromcleaningagents.
Biodegradabledetergentsshouldbeused.
-Theworkplacemustbekeptabsolutelycleanwhenmaintenanceworkiscarriedout.Donot
allowanypartstogetcontaminated.Partsandexposedholesshouldbecoveredwithaclean
cloth,paperoradhesivetape.
-Uponfinishingthemaintenancework,makesurenotoolsorotherobjectsareleftonorinside
thecompressor.
-Beforerestartingthemachineaftermaintenance,checkoperatingpressures,temperatures,time
settings,andtesttheswitchingandcontrolequipmentforproperfunctioning.
-Protectthemotor,airfilters,electriccomponents,controlequipmentetc.frompenetrationof
moisture.
-Donotperformanyweldingoranyotherworksgeneratingheatclosetotheoilsystem.
-Undernocircumstancesshouldthenoiseabsorbingmaterialberemovedorrelocated.


Themanufactureracceptsnoresponsibilityforanydamageandpersonalinjuriesresultingfrom
failuretoobservethepresentsafetyrulesorfromcarelessnessduringoperation,workand
maintenance,evenincircumstancesnotexpresslymentionedinthisOperatingandMaintenance
Manual.
Inordertoensurefault‐freeoperationofthecompressor,observethefollowinginstructions
relatingtoperiodicinspectionsandmaintenanceoperations.








7.2.Maintenanceandchecks

7.2.1Maintenanceatthebeginningofcompressoruse,afteroilanddrivebelts(ifpresent)
change

Maintenanceinterval Operation
after2workhours-checkoillevelinthereceiver,topitupifnecessary,
after2workdays-checkoillevelinthereceiver,topitupifnecessary,
after1weekofwork-checkoillevelinthereceiver,topitupifnecessary,

7.2.2Dailymaintenance
-visuallyinspectthestateofpneumaticandoilconduitconnections,
-checktheairoverpressuregaugeandtemperatureindicatorforcorrectreadings,
-checkthecompressorperformanceforunusualsymptoms,suchasexcessivenoise
andvibration,
-checkoillevel,

7.2.3Periodicmaintenance

Every1000workhours:
-checktheairfilterforcontaminationandreplaceifnecessary(incaseofhigherairdustiness,
morefrequentcleaningandchangingofthefilterisrecommended),
-checktheconditionoftheelasticcoupling,
-cleantheairandoilcoolerribsifnecessary.



7.2.4Warrantyandpost‐warrantychecks

every2000work
hours
orafter1year
-changethefiltermatatthecoolingairinlet,
-changetheairfiltercartridge,
-checkelectricclampterminals,fastenifnecessary,
-cleantheairandoilcoolerribs,
-testthenon‐returnvalveforproperfunctioning,
‐checktheconditionofelasticcoupling,
-checkthetubingforleaks,mendifany,
-testthepressureswitchforproperfunctioning,
-checktheoiltemperatureindicator,
-checktheconditionofsafetyvalve,
-checkthemotorthermalprotectionsetting.
every8000work
hours
orafter1year
Inadditiontotheactivitiesrequiredafter2000workhours:
-changethefiltermatatthecoolingairinlet,
-changetheairfiltercartridge,
-changeoilfilter,
-changeoil,
-inspecttheelectricsystemandcheckitforproperfunctioning.



Duringthewarrantyperiod,thechecksmustbeperformedonlybyoneoftheservicing
companieslistedintheWarrantyBook



