Comprag A-Series User manual

OPERATING MANUAL
Version 1.2
A/F-Series
Screw air compressor
A/F, AR/FR, ARD/FRD 05–22
EN
BEDIENUNGSANLEITUNG
Seite. 42
Version 1.2
Schraubenkompressoren
A/F-Serie
DE

© 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/F-Series
Table of contest
1 Safety guidelines
1.1 Symbols used in the instructions
1.2 General safety guidelines
1.3 Safety precautions for start-up
1.4 Safety precautions during operation
1.5 Safety precautions for maintenance and repair
2 Technical data and functional description
2.1 Technical data
2.2 General description
2.3 Function diagram and main components
2.4 Functional description
2.5 Regulating system
2.6 Electrical diagram and main components
3 Start up
3.1 Lifting and carrying
3.2 Dimensions
3.3 Requirements on installation area
3.4 Connection to the compressed airline
3.5 Connection to power supply
4 Operation
4.1 Controller and operating panel
4.2 Error description
4.3 Staring the compressor
4.4 Switching off the compressor
5 Maintenance
5.1 Maintenance schedule
5.2 Checking oil level
5.3 Checking drive belt
5.4 
5.5 
5.6 Changing drive belt
5.7 Changing air-oil separator
 Cleaning radiator
5.9 Checking suction valve
5.10 Servicing bearings of electric motor
6 Fault handling
6.1 Faults and corrective actions
7 Storage and disposal
7.1 Storage conditions
7.2 Disposal of oils and process condensate.
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, operat-
ing instructions and safety guidelines. Most accidents associated 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.
 
-
able 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 un-
intended 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!

5COMPRAG Screw air compressor A/F-Series
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.

must not be released into the atmosphere.
6. Ensure unrestricted access to the compressed-air hose from the compressor. Do not clut-

7. Do not pinch or deform the compressed-air feed hoses.

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 warn-
ing!’ An operator who is remotely controlling equipment must ensure that no installation or
other work is being performed with the equipment at that moment. Once the equipment 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.

6Version 1.2
The user bears full responsibility for compliance with the operating
conditions of the electrical motor installed in the equipment. Equip-
ment must be used with protection devices. The protection devices
must protect the electric motor from short circuits, overloading (sys-
tematic and start-up) and open-phase conditions. Installation of
protection devices is the responsibility of the user.

an independent control system featuring an automatic restart function: ‘ATTENTION: This
machine may start operating without warning!’

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 fastened
hose may cause serious injury.

3. The operator remotely controlling equipment must ensure that no installation or other work

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 advisable
to wear hearing protection.
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.

7COMPRAG Screw air compressor A/F-Series
7. If the air used for cooling equipment is used while the facility is being heated, undertake


• 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.
-


the control panel to warn against unauthorised start-up. For example, “Do not turn on. Per-
sonnel operating!”
            
work is being performed with the equipment at that moment! An information plate must be

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.

Version 1.2
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 equip-
ment until the temperature falls to room temperature, in order to prevent burns or injury.

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.

where they are installed with a dry cloth.
-
ing 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/F-Series
2. Technical data and functional description
Entitlement to free handling of faults arising during the guarantee
period is forfeited when:

- 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 
7,5
1,1

420/50 65
- -
1/2” 5
11100012 A0710 10 0,9
11100013 A0713 13 0,6
11100015  1,1 270
-
  500
11100016 AR0710-270 10 0,9 270
11100019  500
11110011  1,1 270

11110013  500
11110012 ARD0710-270 10 0,9 270
11110014 ARD0710-500 500
11100021 
11
1,6

420/50 67
- -
1/2”
5
11100022 A1110 10 1,4
11100023 A1113 13 1,3
11100025  1,6 270
-
  500
11100026 AR1110-270 10 1,4 270
11100029  500
11110015  1,6 270
3/4”
11110017  500
11110016 ARD1110-270 10 1,4 270
 ARD1110-500 500

10 Version 1.2
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***
11100031 
15
2,3

420/50 69
- -
1/2”

11100032 A1510 10 1,9
11100033 A1513 13 1,5
11100035  2,3 270
-
  500
11100036 AR1510-270 10 1,9 270
11100039  500
11110019  2,3 270
3/4”
11110021  500
11110020 ARD1510-270 10 1,9 270
11110022 ARD1510-500 500
11100041 

3,1

420/50 70
- -
3/4”

11100042  10 2,5
11100043  13 2,2
11100045   3,1
500
-
11100046  10 2,5
11110023   3,1 1”
111100234  10 2,5
11100051 
22
3,6
- -
3/4”
11100052 A2210 10 3
11100053 A2213 13 2,6
11100055   3,6
500
-
11100056 AR2210-500 10 3
11110027   3,6 1”
 ARD2210-500 10 3
* Measured according to ISO 1217; ** Measured according to ISO 3744

11COMPRAG Screw air compressor A/F-Series
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***
11510101 
5,5
0,75

420/50 62
- -
1/2” 5
11510102 F0510 10 0,65
11510103 F0513 13 0,55
11510104  0,75 270
-
11510106  500
11510105 FR0510-270 10 0,65 270
11510107 FR0510-500 500
  0,75 270

11510110  500
11510109 FRD0510-270 10 0,65 270
11510111 FRD0510-500 500
11510201 
7,5
1,1

420/50 65
- -
1/2” 5
11510202 F0710 10 0,9
11510203 F0713 13 0,6
11510204  1,1 270
-
11510206  500
11510205 FR0710-270 10 0,9 270
11510207 FR0710-500 500
  1,1 270

11510210  500
11510209 FRD0710-270 10 0,9 270
11510211 FRD0710-500 500
11510301 
11
1,6

420/50 67
- -
1/2”

11510302 F1110 10 1,4
11510303 F1113 13 1,3
11510304  1,6 270
-
11510306  500
11510305 FR1110-270 10 1,4 270
11510307 FR1110-500 500
  1,6 270
3/4”
11510310  500
11510309 FRD1110-270 10 1,4 270
11510311 FRD1110-500 500

12 Version 1.2
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***
11510401 
15
2,3

420/50 69
- -
1/2”

11510402 F1510 10 1,9
11510403 F1513 13 1,5
11510404  2,3 270
-
11510406  500
11510405 FR1510-270 10 1,9 270
11510407 FR1510-500 500
  2,3 270
3/4”
11510410  500
11510409 FRD1510-270 10 1,9 270
11510411 FRD1510-500 500
11510501 

3,1

420/50 70
- -
3/4”

11510502  10 2,5
11510503  13 2,2
11510504   3,1
500
-
11510505  10 2,5
11510506   3,1 1”
11510507  10 2,5
11510601 
22
3,6
- -
3/4”
11510602 F2210 10 3
11510603 F2213 13 2,6
11510604   3,6
500
-
11510605 FR2210-500 10 3
11510606   3,6 1”
11510607 FRD2210-500 10 3
* Measured according to ISO 1217; ** Measured according to ISO 3744

13COMPRAG Screw air compressor A/F-Series
2.2 General description
The A/F
compressed-air production.
The A/F-Series compressor is an electric motor-operated, intake-regulated, belt-driven and
air-cooled compressor, enclosed in a sound-insulated canopy. An electronic controller t-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.
2.3 Function diagram and main components

&
Temperature sensor

$
Pressure sensor
 Pneumatic control line

$
&
16
14
15
17
19
18
6
2
1
3
10 9
4
5
8
7
11
12
13
20
Fig. 2.3.1 Function diagram A/F..

14 Version 1.2

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. 2.3.2 Function diagram AR/FR.. ,ARD/FRD..
Main components
1 Electric motor 11 Min. Pressure valve
2 Belt drive 12 Non-return valve
3 Air end 13 Heat-exchanger, Air section
4 14 Heat-exchanger, Oil section
5 Intake valve 15 Thermostatic valve
6 Air-Oil separation tank 16 
7 Safety valve 17 Drain valve
Air-Oil separator  
9 Throttle valve 19 Oil level sight glass
10 Non-return valve 20 Air outlet valve

&
Temperature sensor

$
Pressure sensor
 Pneumatic control line

15COMPRAG Screw air compressor A/F-Series
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
4 15 Thermostatic valve
5 Intake valve 16 
6 Air-Oil separation tank 17 Drain valve
7 Safety valve  
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
2.4 Functional description (see Fig. 2.3.1 and Fig. 2.3.2)


Pressure valve (11) through Heat-exchanger (13) towards the Air Outlet Valve (20).
Air pressure forces oil from the air-oil separation tank (6) through the heat-ex-

In the air-oil separation tank (6), most of the oil is removed centrifugally; the rest is re-

       -
low 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.
The cooling system comprises a combined air section (13) and an oil sec-
tion (14) heatexchanger. A cooling fan, mounted in the fresh air intake section, generates
the cooling air in order to cool the heat-exchanger.

16 Version 1.2
2.5 Regulating system
Fig. 2.5 Regulating system
1
2
3
4
5
The system is controlled by an electronic controller t-Log (2) which keeps the net pressure
within programmable pressure limits by automatically loading and unloading the compressor
in relation to air consumption.
 If air consumption is less than the air delivered by the compressor, the net
pressure Increases and reaches the upper limit of working pressure (unloading pressure).
The controller (2) stops energize the solenoid valve (3), the valve opens, the air pressure from
the separator tank (4) closes the damper (5) of the suction valve (1), and the compressor’s
pneumatic system is unloaded through the throttle.
When the net pressure decreases to the loading pressure, the controller (2) energizes
the solenoid valve (3). Air pressure from the separator tank (4) is interrupted and the damper
(5) opens. Air suction resumes and the compressor runs loaded.

17COMPRAG Screw air compressor A/F-Series
2.6 Electrical diagram and main components
Fig. 2.6 Electrical diagram A/F.., AR/FR.. ,ARD/FRD..*,
*For RDX Electrical diagram refer to the relevant documentation.
Main components
 Contactor YA Solenoid valve
 Electric motor R Electronic controller
 Temperature sensor I/P Pressure sensor
SB Emergency stop CT1 Transformer
F1, F2 Fuses TR Transformer
QS Automatic power switch

 Version 1.2
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

G
AC
B
D
Fig. 3.1.1 Lifting and carrying A/F..
Model A, mm B, mm C, mm D, mm G, mm
F05.. 100
 
92
900
A07../F07..
A11../F11.. 130 202
A15../F15..
 135 302 1000
A22../F22..

19COMPRAG Screw air compressor A/F-Series
С
G
A
Fig. 3,1.2 Lifting and carrying AR/FR.. ,ARD/FRD..
Model A, mm B, mm C, mm D, mm G, mm
FR05.. - FRD05.. 100
 
92
900
AR/FR07.. - ARD/FRD07..
AR/FR11..- ARD/FRD11.. 130 202
AR/FR15..- ARD/FRD15..
 135 302 1000
AR/FR22..- ARD/FRD22..

20 Version 1.2
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
F05 750
700
  

1115 310
A07../F07..  315
A11../F11.. 900 1170 293 1000 1320 325
A15../F15.. 315 350
 1000  1270 415 1100 900 1450 460
A22../F22.. 435 
L
D
H
Fig. 3.2.1 Dimension drawing A/F..
3.2 Dimensions