Comprag AV30 User manual

OPERATING MANUAL
AV-Series
Screw air compressor
AV30–AV55
Version 1.5
EN
BEDIENUNGSANLEITUNG
Schraubenkompressoren
AV-Serie
Version 1.5
DE
Seite. 32
ИнструкцИя по эксплуатацИИ
Версия 1.5
стр.64
AV-Серия
Компрессор воздушный винтовой
RU

© 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.

3
COMPRAG Screw air compressor AV-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
2.7Electrical connection values
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 indication
4.3 Starting 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 Replacing oil and oil lter
5.5 Replacing air lter
5.6 Changing drive belt
5.7 Changing air-oil separator
5.8 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 1.5
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 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.
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
COMPRAG Screw air compressor AV-Series
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 hos-
es disconnected from the equipment, and with the use of safety goggles! Ensure that
equipment 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
suspended. Use a helmet during unloading operations.
2. Arrange the equipment in a dry and clean facility which provides shelter from precipitation.
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 notclut-
ter 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:‘AT-
TENTION: this machine is being controlled remotely and may start operating without warning!’
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 equip- ment is turned
off remotely, the operator must ensure that the equipment is actually turned off!

6Version 1.5
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 con-
di-
tions of the electrical motor installed in the equipment. Equipment
must be used with protection
devices. The protection devices must pro-
tect
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! Unau-
thorised 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.
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 pan-
els 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.

7
COMPRAG Screw air compressor AV-Series
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.
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 out-
lets during installation with dry clothes or paper to prevent rubbish entering the equipment.

8Version 1.5
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 equip-
ment. 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.
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 cir-
cum- 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. Use protective gloves during installation and repair work in order to avoid burns and
injury (for instance, during oil change).

9
COMPRAG Screw air compressor AV-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 in-
correctly
- 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 po w er ,
compressor
(kW)
Max. operat-
ing pressure
(bar)
Output*
(m3/min)
Rated
v oltage ,
compressor
(phase/V/Hz)
Noise**
(dB)
Screw
connection
Oil
capac-
ity***,
liter
11100064 AV3008 30 5-8 4,70
3/380/50
72
1-1/4" 15
11100065 AV3010 5-10 4,00
11100074 AV3708 37 5-8 5,90 72
11100075 AV3710 5-10 5,10
11100084 AV4508 45 5-8 7,00
75 1-1/2" 20
11100085 AV 4510 5-10 6,20
11100094 AV5508 55 5-8 8,70
11100095 AV 5510 5-10 7,70
* Measured according to ISO 1217; ** Measured according to ISO 3744
2.2 General description
The AV-Series oil-lled screw compressor series is designed for uninterrupted and efcient
compressed-air production.
The AV-Series compressor is an electric motor-operated, intake-regulated, belt-driven and air-
cooled compressor, enclosed in a
sound-insulated canopy. An electronic controller pro-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.

10 Version 1.5
2.3 Function diagram and main components
М
Air flow
Air/Oil mix flow
Oil flow
Т
Temperature sensor
Р
Pressure sensor
Pneumatic control line
Р
Т
16
14
15
17
19
18
6
2
1
3
10 9
4
5
8
7
11
12
13
20
Fig. 2.3 Function diagram AV30-55
Main components
1Electric motor 11 Min. Pressure valve
2Belt drive 12 Non-return valve
3Air end 13 Heat-exchanger, Air section
4 Air lter 14 Heat-exchanger, Oil section
5Intake valve 15 Thermostatic valve
6Air-Oil separation tank 16 Oil lter
7Safety valve 17 Drain valve
8Air-Oil separator 18 Oil lling plug
9Throttle valve 19 Oil level sight glass
10 Non-return valve 20 Air outlet valve

11
COMPRAG Screw air compressor AV-Series
2.4 Functional description (see Fig. 2.3)
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 filter
(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 fitted with a thermo-
static valve (15). When the oil temperature is below the set-point of the thermostatic valve, the thermostatic
valve shuts off the oil
su pply 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 thermo-
static 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
Fig. 2.5 Regulating system
1
6
5
2
7
34

12 Version 1.5
The system is controlled by an electronic controller pro-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 unload-
ing 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.

13
COMPRAG Screw air compressor AV-Series
Main components
К1---К4 Contactor YA Solenoid valve
М1, М2 Electric motor QS Automatic power switch
ТTemperature sensor CT2 Transformer
I/P Pressure sensor R,C RC lter
SB Emergency stop Tr Transformer
F1, F2 Fuses v-LOG Controller
FI Frequency inverter HIndicator
2.7 General description
Voltage (V) Frequency (Hz) AV30.. AV37.. AV45.. AV55..
Мaterial - copper. Cable size (mm²)
380 / 400 50 16 25 35 50
Fuse value (A)
380 / 400 50 63 80 100 125
Fig. 2.6 Electrical diagram AV30-55
2.6 Electrical diagram and main components

14 Version 1.5
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. Lo-
cal safety guidelines for lifting have to be observed.
B
C
A
G
D
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.
Model A,mm B, mm C, mm D, mm G, mm
AV30 332
775 185
292 1200
AV37
AV45 540 150 1300
AV55
3.2 Dimensions
Fig. 3.1 Lifting and carrying
AV30-55.
L
D
H
Fig. 3.2 Dimension drawing AV30-55.
Model
Compressor dimensions
Length
L, mm
Width
D, mm
Height
H,mm
Weight,
kg
АV30 1400 1000 1500 725
АV37 765
АV45 1650 1250 1720 1015
АV55 1190
Packaging dimensions
АV30 1600 1100 1750 755
АV37 795
АV45 1850 1350 1950 1055
АV55 1240

15
COMPRAG Screw air compressor AV-Series
3.3 Requirements on installation facility
1500 1500
1500
1500
1500
2
1
Fig. 3.3 Installation facility proposal AV30-55.
1. Air inflow
2. Air outflow
Ensure that the floor of the facility can withstand the weight of the compressor. Install the compressor on
a level surface that is able to bear its weight. Adjust the horizontal axis of the compressor using a levelling
instrument. If the compressor is not anchored to the base on which it is installed, the tilt angle with respect
to the horizontal surface must not exceed 3°.
If the compressor is anchored to the base on which it is installed, the tilt angle with respect to
the horizontal surface must not exceed 7°. Install the compressor in a facility where precip-
itation cannot reach. Choose a facility for installing the compressor with a minimum level of
dust. Install the compressor at least 1,5 m from walls.
If multiple compressors are installed, there should be a 1,5 m minimum distance between
each compressor. There should be a 4 m safety distance from the area of the operated equip-
ment connected to the compressor.
The facility in which the compressor is installed must be
tted with a combined extract-and-input ventilation system.
The facility where the compressor is installed should be provided
with air inow equivalent to twice the compressor’s capacity.

16 Version 1.5
3.4 Connection to the compressed airline
Provide the throughput capacity of the compressed-air line in accordance with the perfor- mance of
the compressor. In order to avoid damage associated with seal failure of the compressed-air line, the
compressor should be connected via a exible hose. All components of the compressed-air line must
have a working pressure no less than the compressor’s nominal pressure. Use a pressure vessel with
a capacity corresponding to the compressor’s performance and the compressed air consumer.
3.5 Connecting to power supply
The compressor is not supplied with a power cable. The cable size must be chosen to ensure
that the maximum voltage drop not exceed 5 % of the nominal voltage value. Cable length
must not exceed 25 m. Ambient temperature in the facility must not exceed 40°C. The cable
must be sheathed with a re retardant compound. An isolating switch must be tted within
reach of the compressor to facilitate connection and maintenance.
The compressor must be earthed and protected against short
cir- cuits in each phase, impermissible voltage uctuation and
phase failure.
The power cable has to be fed into the compressor.
1 2
3 4
Fig. 3.5.1 Power cable connection
Remove the left side panel, pass the cable under the compressor into the orice (1) and ca-
ble gland (2). Connect the power supply cables to the terminal 4. The earth wire of the power
cable must be connected to the corresponding earthing bolt 3.
Fig. 3.5.2 Power cable terminal
connection

17
COMPRAG Screw air compressor AV-Series
4. Operation
Non-qualied personnel must not be allowed to operate the com-
pressor.
4.1 Control panel
The frequency-controlled compressors AV30 and AV90 are equipped with an electronic v-Log control.
The electronic v-Log control maintains the network pressure between the programmable limit values by
automatically adjusting the compressor speed. Operating data such as operating times and system
statuses are also recorded.
4.1.1 v-Log control panel
Start compressor Up or increase value
Stop compressor Down or reduce value
Back to the main menu Save setting
Accept value / manually switch between loaded and idle running
4.1.2 LCD indicator
Power indicator (red): The indicator lights up when the control is switched on and
the power supply is connected.
Power indicator (green): The indicator lights up when the motor is running.
Alarm/error indicator (red). Alarm (warning): The indicator ashes and the ma-
chine continues to run. Error: The indicator is permanently lit, there is an accom-
panying acoustic signal and the machine switches off. The error message can be
acknowledged after the cause of the error has been resolved. In order to acknowl-
edge the error message, press and hold the ‘back to main menu’ button .
Fig. 4.1.1 v-Log control
panel

18 Version 1.5
LED indicators.
When switched on, the LCD display shows the following:
COMPRAG SCREW
AIR COMPRESSOR
The main parameters of the compressor are displayed after 5 seconds:
21°C 0.00HZ Oil/air mixture temperature at the
compressor outlet Current motor frequency
0.0BAR 0RPM Pressure at the compressor outlet Current motor speed
STOP Operating status of the compressor
0.00V O.0kW Current mains voltage Current power consumption of the
compressor
Main menu: Click in order to bring up the options menu:
RUN PARAMETERS Includes current values (available for viewing)
USAGE PARAM Includes operating settings of the main parameters (available for viewing,
changes password-protected)
FACTORY PARAM For servicing mode (view with password). Modication only possible by manufacturer
Description of the parameters. Run parameters:
Select the run parameters using the up and down buttons and enter . Current values
are displayed.
FAN, VSD PARAM
TOTAL RUN TIME
THIS RUN TIME
MAINTEN. PARAM
ERRORS HISTORY
MFD, SERIAL NO
THIS ERROR
DESCRIPTION
Run parameters. Select the run parameters using the up and down buttons and enter .
FAN, VSD PARAM
FREQUENCY 50.0 Hz
VOLTAGE 400V
CURRENT:
POWER:
At the output of the frequency inverter.
FAN CURRENT (A)
А: 0.0
В: 0.0
С : 0.0
Current consumption of all 3 phases of the fan.

19
COMPRAG Screw air compressor AV-Series
TOTAL RUN TIME
TOTAL RUN TIME: Total operating hours (loaded and idle run time).
TOTAL LOAD TIME: Total load hours.
THIS RUN TIM
THIS RUN TIME: Operating hours since last switched on (loaded and idle run time).
THIS LOAD TIME: Load hours since last switched on.
MAINTEN. PARAM — maintenance hours counter
TIME IN USAGE, h
OIL FILTER: 0000H Operating time since last oil lter change.
SEPARATOR: 0000H Operating time since last separator change.
AIR FILTER: 0000H Operating time since last air lter change.
OIL: 0000H Operating time since last oil change.
GREASE M1: 0000H Operating time since last lubrication of the motor.
BELTS: 0000H Operating time since last belt change.
ERRORS HISTORY
Errors history The last 5 error messages.
MFD, SERIAL NO
Serial number:
Manufact. date:
Serial number and data of manufacture of the compressor.
THIS ERROR — current error message
This error message No errors.
DESCRIPTION — software version, internal information
VER: Version
PASS: internal information
Software code
If there is no activity for 60 seconds in the current menu, the control will automatically
return to the main menu.
Description of the parameters. Usage parameters:
The contents of this menu item can be displayed, but modications are password-protected. Modications
may only be carried out by trained and qualied personnel.

20 Version 1.5
Select the usage parameters using the up and down buttons and enter .
SET P, T, FREQ
SET TIME
OPERATION MODE
SEQ PARAM SET
RST MAINT TIME
MAX RUN TIME
USER PASS:
LANG.
SET P, T, FREQ — set pressure and temperature
(Below are the example set values for the compressor with the max. 8-bar operating pressure).
P LOAD 05.2 BAR If the compressor is ready, it switches at this pressure to loaded running.
P ULD 08.00 BAR At this pressure the compressor switches to idle running.
FREQ P 007.0 BAR Set pressure of the frequency inverter.
T FAN 0095°C Switch-on temperature of the fan.
T FAN STOP 0060°C Switch-off temperature of the fan.
RAT. POWER 75.0kW Rated power of the electric motor.
RATED SPEED 2940RPM Rated speed of the electric motor.
SET TIME
FAN DELAY: 0002S Delay in overloading fan.
LOAD DELAY: 0002S Delay in load run (suction valve open).
IDLE DELAY: 0300S Idle run time. Suction valve closed, and main motor running.
STOP DELAY: 0005S Switch-off delay with off button. Suction valve closed, and main motor running.
START DELAY: 0040S Delay in restart. Drop in system pressure.
SPEED INCR: 0625 PID setting for the maximum speed increase.
SPEED DECR: 0625 PID setting for maximum speed reduction.
Operational mode
RUN REMOTE/LOCAL Switch on by remote control or locally via the control.
LOAD AUTO/MANUAL Loaded running/idle running automatically or manually.
COM: PC/BAN/GRP Communication mode: PC / MODBUS / group.
COM ADDRESS: 001 Communication port, network address.