Comprag A-Series User manual

OPERATING MANUAL
Version 1.2
A-Series
Screw air compressor
A, AR, ARD 07–22
EN
BEDIENUNGSANLEITUNG
Seite. 36
Version 1.2
Schraubenkompressoren
A-Serie
DE
ИНСТРУКЦИЯ ПО ЭКСПЛУАТАЦИИ
стр. 70
Версия 1.2
Компрессор воздушный
винтовой A-серия
РУС

© 2015 Comprag ®. All rights reserved.
No part of the text and /or diagram may be reprinted or used without the prior written permission of Comprag.
The manufacturer reserves the right to make changes to a product design in order to enhance its technological and
operational parameters without notifying the user.
The product type may considerably differ to that displayed in documents.

3COMPRAG Screw air compressor A-Series
Table of contest
1 Safety guidelines 4
1.1 Symbols used in the instructions 4
1.2 General safety guidelines 4
1.3 Safety precautions for start-up 5
1.4 Safety precautions during operation 6
1.5 Safety precautions for maintenance and repair 7
2 Technical data and functional description 9
2.1 Technical data 10
2.2 General description 11
2.3 Function diagram and main components 11
2.4 Functional description 13
2.5 Regulating system 14
2.6 Electrical diagram and main components 15
2.7 Electrical connection values 16
3 Start up 17
3.1 Lifting and carrying 17
3.2 Dimensions 18
3.3 Requirements on installation area 20
3.4 Connection to the compressed airline 21
3.5 Connection to power supply 22
4 Operation 23
4.1 Controller and operating panel 23
4.2 Error indication 26
4.3 Starting the compressor 27
4.4 Switching off the compressor 28
5 Maintenance 28
5.1 Maintenance schedule 28
5.2 Checking oil level 29
5.3 Checking drive belt 30
5.4 Replacing oil and oil lter 31
5.5 Replacing air lter 32
5.6 Changing drive belt 32
5.7 Changing air-oil separator 33
5.8 Cleaning radiator 33
5.9 Checking suction valve 34
5.10 Servicing bearings of electric motor 34
6 Fault handling 34
6.1 Faults and corrective actions 34
7 Storage and disposal 35
7.1 Storage conditions 35
7.2 Disposal of oils and process condensate. 35
EN

4Version 1.2
1. Safety guidelines
1.1 Symbols used in the instructions.
Lethal hazard.
Warning.
Attention.
1.2 General safety guidelines.
Carefully familiarise yourself with the technical documentation,
operating instructions and safety guidelines. Most accidents as-
sociated with the use of compressor equipment occur as a result
of non-compliance with safety guidelines. Prevent hazards from
developing and adhere to the safety guidelines. The main rules
are given in the following section.
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1. The operator must stringently adhere to safety guidelines provided for by these instruc-
tions and local legislation!
2. When choosing between these safety guidelines and the regulations provided for by
local legislation, those rules which provide for more stringent requirements shall apply.
3. Only trained maintenance personnel with the relevant level of professional training are
permitted to operate, service and repair Comprag equipment.

5COMPRAG Screw air compressor A-Series
4. Compressed air owing immediately from the compressor may contain oil and impurities
and is not suitable for breathing! Compressed air has to be puried to an air purity grade
suitable for breathing, in accordance with the standards prescribed by local legislation.
5. Compressed air is an extremely hazardous energy source. Compressed air must not
be used for unintended purposes! Do not use it to clean clothing and footwear and never
point compressed air hoses at people and animals! When using air to clean equipment,
take extra caution and wear safety goggles!
6. All maintenance, repair, setup and installation work etc. must be performed while the
equipment is turned off, disconnected from the power source, with compressed-air hoses
disconnected from the equipment, and with the use of safety goggles! Ensure that equip-
ment is disconnected from the compressed air system and is not under pressure.
1.3 Safety precautions for start-up
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, operati-
on or servicing, as well as unauthorised use of equipment!
1. Equipment must only be unloaded/loaded using the appropriate handling devices or
hoisters. Equipment must not be manually lifted or moved. Do not leave equipment sus-
pended. Use a helmet during unloading operations.
2. Arrange the equipment in a dry and clean facility which provides shelter from precipi-
tation. The facility must be well ventilated, and forced ventilation should be provided if
necessary.
3. Worn, damaged or spoiled compressed-air hoses should not be used. Ensure that
hoses correspond to the equipment in terms of nominal diameter and working pressure.
4. When using several compressor stations in a system, each compressor must have a manu-
ally operated valve for cutting off any of the compressors in the case of emergency.
5. Explosive and re-hazardous admixtures such as solvent vapours and carbon dust etc.
must not be released into the atmosphere.
6. Ensure unrestricted access to the compressed-air hose from the compressor. Do not
clutter it and do not store ammable materials in its immediate vicinity.
7. Do not pinch or deform the compressed-air feed hoses.
8. Do not cover holes used to provide equipment with air for cooling. Ensure the facility is well
ventilated.
9. When using remote control, the equipment must give a legible and clear warning of this:
‘ATTENTION: this machine is being controlled remotely and may start operating without
warning!’ An operator who is remotely controlling equipment must ensure that no installa-

6Version 1.2
tion or other work is being performed with the equipment at that moment. Once the equip-
ment is turned off remotely, the operator must ensure that the equipment is actually turned off!
10. Equipment must be earthed. Provide short-circuit protection. The starting knife switch
must be in the immediate vicinity of the equipment and protect against unauthorised start-up.
The user bears full responsibility for compliance with the operating condi-
tions of the electrical motor installed in the equipment.
Equipment must be used with protection devices.
The protection devices must protect the electric motor from short circuits,
overloading (systematic and start-up) and open-phase conditions.
Installation of protection devices is the responsibility of the user.
11. There must be an information plate afxed next to the control panel on equipment with
an independent control system featuring an automatic restart function: ‘ATTENTION: This
machine may start operating without warning!’
12. Any tanks and vessels working under pressure must be tted with safety-relief valves!
Unauthorised installation, disassembly or adjustment of attached safety-relief valves is
not allowed.
1.4 Safety precautions during operation
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1. Ensure that hoses correspond to the equipment in terms of nominal diameter and working
pressure. Check the attachment of every hose coupling before start-up. An insecurely fas-
tened hose may cause serious injury.
2. Never turn on equipment if you suspect the presence of highly ammable impurities in the air!
3. The operator remotely controlling equipment must ensure that no installation or other work
is being performed with the equipment at that moment! An information plate must be afxed
to the equipment in relation to this: ‘ATTENTION: this machine is being controlled remotely
and may start operating without warning!’
4. An operator is not allowed to operate equipment if the operator is fatigued, in a state of
intoxication from alcohol, drugs or medicine that reduces the body’s reaction time.
5. The equipment must not be operated if parts of the casing have been removed. Doors or
panels may be opened for short durations for inspection and scheduled checks. It is advis-
able to wear hearing protection.

7COMPRAG Screw air compressor A-Series
In some types of equipment, open doors or removal of panels du-
ring operation may lead to overheating.
6. Personnel in conditions or a facility where the sound pressure level reaches or exceeds
90 dB (A), must wear ear protectors.
7. If the air used for cooling equipment is used while the facility is being heated, undertake
measures for it to be ltered so that it is suitable for breathing.
8. Regularly check that:
• safety devices and attachments are in place;
• all hoses and pipes are in good condition and sealed;
• there are no leaks;
• brackets and structural components are tightened;
• all electrical cables and contacts are in good condition and safe to use;
• safety devices are fully functional and there is no contamination etc;
• all structural components are in working order, with no signs of wear and tear.
1.5 Safety precautions for maintenance and repair
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, operati-
on or servicing, as well as unauthorised use of equipment!
1. Only original spare parts and ancillary items may be used. Using spare parts from other
manufactures may lead to unpredictable results and consequently accidents.
2. When performing installation and repair work, always wear goggles!
3. Before connecting or disconnecting equipment, disconnect it from the main pneumatic
system. Ensure that the hoses aren’t under pressure!
4. Before beginning installation or other work, ensure that equipment is not pressurised.
Installation work must not be carried out on equipment under pressure.
5. All maintenance work should be carried out only when the temperature of all structural
elements falls to room temperature.
6. Never use highly ammable solvents or carbon tetrachloride for cleaning structural ele-
ments. When wiping, take precautions against the poisonous vapours of cleaning uids.

8Version 1.2
7. When carrying out installation and repair work, an information plate should be afxed
to the control panel to warn against unauthorised start-up. For example, “Do not turn on.
Personnel operating!”
8. The operator remotely controlling equipment must ensure that no installation or other
work is being performed with the equipment at that moment! An information plate must be
afxed to the equipment in relation to this: See 1.3.9.
9. Maintain cleanliness in the facility where the equipment is installed. Close open inlets
and outlets during installation with dry clothes or paper to prevent rubbish entering the
equipment.
10. Welding or other similar operations must not be carried out in the immediate vicinity of
the equipment and vessels under pressure.
11. If there is any suspicion of overheating, combustion or other emergency, turn off the
equipment. Immediately disconnect it from the power supply. Do not open the doors of
equipment until the temperature falls to room temperature, in order to prevent burns or injury.
12. Naked ames must not be used as a light source for inspecting and checking equipment.
13. Never use caustic solvents, which may damage materials of the pneumatic system
14. After performing installation or other work, ensure that no instruments, rags or spare
parts have been left inside the equipment.
15. Pay particular attention to the safety-relief valves. Thoroughly inspect them and remove
any dust and dirt. They must not be allowed to suffer any loss in function under any circum-
stances. Remember that your safety depends on their functionality!
16. Before beginning work in normal mode after maintenance or repair work, check that the
working pressure, temperature and other characteristics are correctly set. Ensure that all
control devices are installed and functioning properly.
17. When replacing lters, separators etc., wipe away dust, dirt and oil residue from the
area where they are installed with a dry cloth.
18. Protect the motor, air lter, electrical components and control components etc. from
coming into contact with condensate. For instance, blow down with dry air.
19. Safety precautions for operation with refrigerants:
• Never inhale refrigerant vapours. Ensure that the work zone is properly ventilated; use a
respirator if necessary;
• Always wear special-purpose gloves. If the refrigerant comes into contact with skin, rinse
the area of contact with plenty of water. If refrigerant comes into contact with skin through
clothing, do not try to remove clothing. Thoroughly rinse clothing with fresh water until the
refrigerant is washed off. Then seek medical assistance.
20. Use protective gloves during installation and repair work in order to avoid burns and
injury (for instance, during oil change).

9COMPRAG Screw air compressor A-Series
2. Technical data and functional description
Entitlement to free handling of faults arising during the guarantee pe-
riod is forfeited when:
- No warranty service coupon for the compressor or it is lled out incor-
rectly
- No records for the compressor’s scheduled maintenance are entered
in the compressor’s service book
- Unoriginal parts and lubricants are used
2.1 Technical data
Article
Model
Drive power,
compressor
(kW)
Max. operat-
ing pressure
(bar)
Output
(m3/min)
Rated
voltage,
compressor
(phase/V/Hz)
Noise
(dB)
Receivers
Volume
(liter)
Refrigerated
dryer,
RDX-Series*
Screw
connection
Oil capacity,
liter
11100011 A0708
7,5
81,1
3/380/50
65
- -
1/2”
5
11100012 A0710 10 0,8
11100013 A0713 13 0,6
11100015 AR0708 81,1
270
-
11100016 AR0710 10 0,8
11110011 ARD0708 81,1 Х
11110012 ARD0710 10 0,8
11100021 A1108
11
81,6
67
- -11100022 A1110 10 1,4
11100023 A1113 13 1,3
11100025 AR1108 81,6
270
-
11100026 AR1110 10 1,4
11110015 ARD1108 81,1 Х
11110016 ARD1110 10 0,8
11100031 A1508
15
8 2,3
69
- -
8
11100032 A1510 10 1,8
11100033 A1513 13 1,5
11100035 AR1508 8 2,3
270
-
11100036 AR1510 10 1,8
11110019 ARD1508 81,1 Х
11110020 ARD1510 10 0,8

10 Version 1.2
Article
Model
Drive power,
compressor
(kW)
Max. operating
pressure
(bar)
Output
(m3/min)
Rated
voltage,
compressor
(phase/V/Hz)
Noise
(dB)
Receivers
Volume
(liter)
Refrigerated
dryer,
RDX-Series*
Screw
connection
Oil capacity,
liter
11100041 A1808
18,5
83,1
3/380/50 70
- -
3/4” 8
11100042 A1810 10 2,5
11100043 A1813 13 2,2
11100045 AR1808 83,1
500
-
11100046 AR1810 10 2,5
11110023 ARD1808 83,1 Х
111100234 ARD1810 10 2,5
11100051 A2208
22
8 3,6
- -11100052 A2210 10 3
11100053 A2213 13 2,6
11100055 AR2208 8 3,6
500
-
11100056 AR2210 10 3
11110027 ARD2208 8 3,6 Х
11110028 ARD2210 10 3
2.2 General description
The A-Series oil-lled screw compressor series is designed for uninterrupted and efcient
compressed-air production.
The A-Series compressor is an electric motor-operated, intake-regulated, belt-driven and air-
cooled compressor, enclosed in a sound-insulated canopy. An electronic controller e-Log with
an LCD indicator panel is provided, including start and stop buttons and an emergency stop
button. Pressure and temperature relays are used for system control and protection.

11COMPRAG Screw air compressor A-Series
2.3 Function diagram and main components
Т
Р
Air ow
Т
Р
Temperature sensor
Т
Р
Oil ow
Т
Р
Pressure sensor
Т
Р
Air/Oil mix ow
Т
Р
Pneumatic control line
Main components
1 Electric motor 11 Min. Pressure valve
2 Belt drive 12 Non-return valve
3 Air end 13 Heat-exchanger, Air section
4Air lter 14 Heat-exchanger, Oil section
5 Intake valve 15 Thermostatic valve
6 Air-Oil separation tank 16 Oil lter
7Safety valve 17 Drain valve
8 Air-Oil separator 18 Oil lling plug
9 Throttle valve 19 Oil level sight glass
10 Non-return valve 20 Air outlet valve
М
Р
Т
16
14
15
17
19
18
6
2
1
3
10 9
4
5
8
7
11
12
13
20
Fig. 2.1 Function diagram A07..-A22..

12 Version 1.2
М
18
7
7
8
17
20
21
19
17
15
14
16
1
2
3
5
4
9
10
11
12
13
Р
т
22
6
Fig. 2.2 Function diagram AR07..-AR22.., ARD07..-ARD22..
Т
Р
Air ow
Т
Р
Temperature sensor
Т
Р
Oil ow
Т
Р
Pressure sensor
Т
Р
Air/Oil mix ow
Т
Р
Pneumatic control line
Main components
1 Electric motor 12 Non-return valve
2 Belt drive 13 Heat-exchanger, Air section
3 Air end 14 Heat-exchanger, Oil section
4Air lter 15 Thermostatic valve
5 Intake valve 16 Oil lter
6 Air-Oil separation tank 17 Drain valve
7Safety valve 18 Oil lling plug
8 Air-Oil separator 19 Oil level sight glass
9 Throttle valve 20 Air outlet valve
10 Non-return valve 21 Refrigerated dryer (ARD only)
11 Min. Pressure valve 22 Pressure vessel

13COMPRAG Screw air compressor A-Series
2.4 Functional description (see Fig. 2.1 and Fig. 2.2)
Air ow:
Air drawn through Air lter (4) and open Intake valve (5) into compressor Air-end (3) is compressed.
Compressed air and oil ow into Air-Oil separation tank (6). The air is discharged via Min.
Pressure valve (11) through Heat-exchanger (13) towards the Air Outlet Valve (20).
Oil ow:
Air pressure forces oil from the air-oil separation tank (6) through the heat-exchanger (14)
and the oil lter (16) to the compressor air-end (3) and the lubrication points. In the air-oil
separation tank (6), most of the oil is removed centrifugally; the rest is removed by the
air-oil separator (8).
The oil system is tted with a thermostatic valve (15). When the oil temperature is below
the set-point of the thermostatic valve, the thermostatic valve shuts off the oil supply
from oil heat-exchanger (14). The thermostatic valve starts opening the supply from heat-
exchanger (14) when the oil temperature exceeds the valve’s setting. The setting of the
thermostatic valve depends on the model. See table Technical Data.
Cooling system:
The cooling system comprises a combined air section (13) and an oil section (14) heat-
exchanger. A cooling fan, mounted directly on the motor shaft, generates the cooling air in
order to cool the heat-exchanger.
2.5 Regulating system
5
4
3
1
2
6
7
Fig. 2.3 Regulating system

14 Version 1.2
The system is controlled by an electronic controller e-Log (4) which keeps the net pressure
within programmable pressure limits by automatically loading and unloading the compressor
in relation to air consumption.
Unloading:
If air consumption is less than the air delivered by the compressor, the net pressure
increases. When the net pressure reaches the upper limit of working pressure (unloading
pressure), the solenoid valve (6) is de-energized. The damper (2) of the intake valve (1)
closes the air inlet opening by a spring force:
1. The control pressure present in the chambers of the loading plunger (3) and the
unloading valve (5) is vented into the atmosphere via the solenoid valve (6).
2. The loading plunger (3) moves forwards and causes the intake valve (1) to close the air
inlet opening.
3. The unloading valve (5) is opened by the air-oil separation tank pressure. The pressure
from the air-oil separation tank (7) is released towards the air inlet.
4. The pressure is stabilized at a low value, air output is stopped (0 %) and the compressor
runs unloaded.
Loading:
When the net pressure decreases to the loading pressure, the solenoid valve (6) is energized:
1. The control pressure is fed from the air-oil separation tank (7) via the solenoid valve (6)
to the loading plunger (3) and the unloading valve (5).
2. The unloading valve (5) closes the air blow-off opening. The loading plunger (3) moves
backwards and causes the intake valve (1) to open fully.
Air output is resumed (100 %), and the compressor runs loaded.

15COMPRAG Screw air compressor A-Series
2.6 Electrical diagram and main components
3~~380
1
2
3
4
5
6
1
2
3
4
12
1
2
3
4
5
Х01
Х02
Х03
204
203
205
207
1
2
3
123
QS
102
302 11
22
33
MKC1
11 22 33
SB1.1
301
380v
24v
F1
200
220v
202
101
102
P
I
T
MKC1.1
TN1.1
Х04
302
401
K 5
103 102
SB1.2
R
TR
К1.1
1
203
204 209
200
102
203 202 2A
201
200
YA
Re1
K1
K 5.1
1
2
2
3
3
TN1
М1
Fig. 2.4 Electrical diagram A07.., AR07.., ARD07..*
*For RDX Electrical diagram refer to the relevant documentation.
М1
3~380
6
5
4
3
2
1
2
1
1
2
3
4
5
Х01 Х04
NO (R4)/Delta
203
401
103
К1 К2 К3
К3
1
2
3
1
2
3
12 3 1 2 3
TN1
К1 К2
Rе2 Rе4 Rе3 K5.1
YA
1
2
3
12 3
QS
33
22
11
MKC-08
11
22 33
301
380v 33
22
1
2
3
4
S01
S02
S03
S04
204 206 208
205 207
203
202
209
200
SB1.1
K3.1 K2.1
201
101
F1 F2
202
102
200
103
301
301
Х03
102
NO (R3)/Star
NO (R2)/Main
K5
Х02
TN1.1
MKC-08
P
t°
SB1.2
R
TR
Fig. 2.5 Electrical diagram A11.. – A22.., AR11.. – AR22.., ARD11.. – ARD22..*,
*For RDX Electrical diagram refer to the relevant documentation.

16 Version 1.2
Main components
К1, K2, К3, К4 Contactor YA Solenoid valve
М1 Electric motor R Electronic controller
Т Temperature sensor I/P Pressure sensor
SB Emergency stop TN1, TN2 Overload relay
F1, F2 Fuses TR Transformer
МКС Phase sequence relay QS Automatic power switch
2.7 Electrical connection values
Voltage (V) Frequency (Hz) A07.. A11.. A15.. A18.. A22..
Cable size (mm²)
400 50 2,5/4 4/6 6/10 10/16 10/16
380 50 2,5/4 4/6 10/10 10/16 16/16
Fuse value (A)
380-400 50 35 35 50 63 63
Motor overload relay (A)
380-400 50 15,5 12,7 16,7 20,2 23,7
3. Start up
3.1 Lifting and carrying
All lifting should be carried out using a forklift truck with a carrying
capacity suited to the compressor.
Lifting may be carried out with loading cranes, winches and other
machinery, using a crossbeam with the right length.
Local safety guidelines for lifting have to be observed.
For transport with a forklift truck, use the rigging holes in the frame.
The compressor has slotted rigging holes with width C – g. 3.1.
Move the compressor carefully.

17COMPRAG Screw air compressor A-Series
G
AC
B
D
Fig. 3.1 Lifting and carrying A07.. – A22..
Model A, mm B, mm C, mm D, mm G, mm
А07..
130
383 175
700 900
А11..
А15..
А18..
135 800 1000
А22..
Model A, mm B, mm C, mm D, mm G, mm
AR07.. / ARD07..
130
383 175
700 900
AR11../ ARD11..
AR15../ ARD15..
AR18../ ARD18..
135 800 1000
AR22../ ARD22..

18 Version 1.2
С
G
A
Fig. 3.2 Lifting and carrying AR07..-AR22, ARD07..-ARD22
Model Compressor dimensions Packaging dimensions
Length
L, mm
Width D,
mm
Height H,
mm
Weight ,
kg
Length
L, mm
Width D,
mm
Height H,
mm
Weight ,
kg
А07 750
700
985 260 850 800 1195 270
А11 900 1170 293 1100 800 1330 365
А15 315 383
А18 1000 800 1270 415 1200 900 1500 457
А22 435 486
L
D
H
Fig. 3.3 Dimension drawing A07.. – A22..
3.2 Dimensions

19COMPRAG Screw air compressor A-Series
Model
Compressor dimensions Packaging dimensions
Length
L, mm
Width D,
mm
Height H,
mm
Weight ,
kg
Length
L, mm
Width D,
mm
Height H,
mm
Weight,
kg
AR07.. / ARD07..
1510 700
1490 447 1610 800 1660 1540
AR11../ ARD11..
1653
457
1600 800 1830 1705
AR15../ ARD15.. 464
AR18../ ARD18..
1850 800 1870
631
2010 900 2070 1940
AR22../ ARD22.. 651
H
L
D
Fig. 3.4 Dimension drawing AR07..-AR22, ARD07..-ARD22

20 Version 1.2
3.3 Requirements on installation facility
1500 1500
1500
1500
1500
2
1
Fig. 3.5 Installation facility proposal A07.. – A22..
1500 1500
2500
1500
2500
2
1
Fig. 3.6 Installation facility proposal AR07..-AR22, ARD07..-ARD22
1. Air inow
2. Air outow
1. Air inow
2. Air outow