Comprag DV Series User manual

OPERATING MANUAL
DV-Series
Screw air compressor
DV11–DV22
Version 1.3
EN
BEDIENUNGSANLEITUNG
Schraubenkompressoren
DV-Serie
Version 1.3
DE
Seite. 33

© 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 DV-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 Installation dimensions
3.4 Requirements on installation area
3.5 Connection to the compressed airline
3.6 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 Replacing oil and oil lter
5.4 Replacing air lter
5.5 Changing air-oil separator
5.6 Cleaning radiator
5.7 Checking suction valve
5.8 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 .3
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.
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!

5
COMPRAG Screw air compressor DV-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 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, ope-
ration 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 suspend-
ed. 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 notclutter
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!
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. 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 protec-
tion devices
is the responsibility of the user.

6Version 1 .3
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 ma-
chine may start operating without warning!’
12. Any tanks and vessels working under pressure must be tted with safety-relief valves! Unautho-
rised 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
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
during 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.

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COMPRAG Screw air compressor DV-Series
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, ope-
ration 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 man-
ufactures 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
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 equip-
ment. 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

8Version 1 .3
working pressure, temperature and other characteristics are correctly set. Ensure that all con-
trol 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 com-
ing 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).
2. Technical data and functional description
Entitlement to free handling of faults arising during the guarantee
period is forfeited when:
- No warranty service coupon for the compressor or it is lled out incorrectly
- 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
11300025 DV1108 11 81,5
3/380-
420/50
72
1/2" 8
11300026 DV1110 10 1,3
11300035 DV1508 15 82,3 72
11300036 DV1510 10 2,1
11300045 DV1808 18 82,9 72
3/4" 8
11300046 DV1810 10 2,6
11300055 DV2208 22 8 3,6 72
11300056 DV2210 10 3,2
* Measured according to ISO 1217; ** Measured according to ISO 3744
2.2 General description
The DV-Series oil-lled screw compressor series is designed for uninterrupted and ef-
cient compressed-air production. The DV-Series compressor is an electric motor-operated,
intake-regulated, direct-driven and air-cooled compressor, enclosed in a sound-insulated
canopy. An electronic controller v-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.

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COMPRAG Screw air compressor DV-Series
2.3 Function diagram and main components
Fig. 2.3 Function diagram DV11 – DV22
М
Р
Т
16
14
15
17
19
18
6
2
1
3
10 9
4
5
8
7
11
12
13
20
Air flow
Air/Oil mix flow
Oil flow
Т
Temperature sensor
Р
Pressure sensor
Pneumatic control line
Main components
1Electric motor 11 Min. Pressure valve
2 Flexible coupling 12 Non-return valve
3Air end 13 Heat-exchanger, Air section
4Air 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

10 Version 1.3
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-exchang-
er (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
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 thermostatic valve depends on the model. See table Technical Data.
Cooling system: The cooling system is a combined radiator consisting of a part for air (13) and a
part for oil (14). The ventilation takes place with a fan with separate electric motor.
2.5 Regulating system
The system is controlled by an electronic controller v-Log (2) which keeps the net pressure
within programmable pressure limits by automatically loading and unloading the compressor
in relation to air consumption.
Main operating mode: Upon start-up, the frequency inverter accelerates the compressor over
15 seconds to the maximum permitted frequency. Pressure builds up to the specied target val-
ue. When it is reached, the compressor maintains the set pressure by varying the current signal
coming from the frequency inverter. If the consumption of compressed air increases, the frequency
coming from the frequency inverter also increases and thus the rotation of the main motor shaft. If
the consumption of compressed air decreases, the frequency coming from the frequency inverter
also decreases. However, the compressed-air pressure remains constant. When the off button is
pressed, the frequency inverter lowers the frequency over 15 seconds to the minimum permitted
frequency and switches off the compressor.
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 (3) is de-energized. The damper (5) of the intake valve (1) closes
the air inlet opening by a spring force:
1. The control pressure present in the chambers of the intake valve (1) and the unloading
valve (7) is vented into the atmosphere via the solenoid valve (3).
2. The damper (5) of the intake valve (1) closes the air inlet opening.
3. The unloading valve (7) is opened by the air-oil separation tank pressure. The pressure
from the air-oil separation tank (4) 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.