Comprag FV3013 User manual

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Инструкция
по эксплуатации
Компрессор COMPRAG FV3013
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©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.

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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 filter
5.5 Replacing air filter
5.6 Changing drive belt
5.7 Changing air-oil separator
5.8 Cleaning radiator
5.9 Checking suction valve
5.10Servicing bearings of electric motor
6. Fault handling
6.1Faults and corrective actions
7. Storage and disposal
7.1Storage conditions
7.2 2 Disposal of oils and process condensate
EN

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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 andsafety 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 flowing immediately from the compressor may contain oil and impurities
and is not suitable for breathing! Compressed air has to be purified to an air purity grade
suitable for breathing, in accordance with the standards prescribed by local legislation.

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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 fire-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 flammable 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!

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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 affixed 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 fitted with safety-relief valves! Unau-
thorised installation, disassembly or adjustmentof 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 flammable 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 affixed 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.

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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 filtered 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 flammable solvents or carbon tetrachloride for cleaning structural ele-
ments. When wiping, take precautions against the poisonous vapours of cleaning fluids.
7. Whencarryingoutinstallationand repairwork,an informationplateshouldbe affixedto thecontrol
panelto warnagainst unauthorisedstart-up.Forexample,“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 affixed 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.

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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 flames 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 filters, 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 filter, 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).

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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 filled 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 power,
compressor
(kW)
Max. operat-
ing pressure
(bar)
Output
(m3/min)
Rated
voltage,
compressor
(phase/V/Hz)
Noise
(dB)
Screw
connection
Oil
capacity,
liter
11410704
FV3008
30
5-8
5,10
3/380/50
72
1-1/4"
15
11410705
FV3010
5-10
4,60
11410714
FV3708
37
5-8
6,20
72
11410715
FV3710
5-10
5,50
11410804
FV4508
45
5-8
7,50
75
1-1/2"
20
11410805
FV4510
5-10
6,50
11410814
FV5508
55
5-8
9,00
11410815
FV5510
5-10
7,90
2.2 General description
The FV-Series oil-filled screw compressor series is designed for uninterrupted and efficient
compressed-air production.
The FV-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.

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2.3 Function diagram and main components
Fig. 2.3 Function diagram FV30-55
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
Air filter
14
Heat-exchanger, Oil section
5
Intake valve
15
Thermostatic valve
6
Air-Oil separation tank
16
Oil filter
7
Safety valve
17
Drain valve
8
Air-Oil separator
18
Oil filling plug
9
Throttle valve
19
Oil level sight glass
10
Non-return valve
20
Air outlet valve
Air ffow
T Temperature sensor
P
Pressure sensor

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2.4 Functional description (see Fig. 2.3)
Air flow:
Air drawn through Air filter (4) and open Intake valve (5) into compressor Air-end (3) is compressed.
Compressed air and oil flow 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 flow:
Air pressure forces oil from the air-oil separation tank (6) through the heat-exchanger(14) and the oil filter
(16) to thecompressorair-end(3) and thelubricationpoints.In theair-oilseparationtank(6), mostof theoil
is removedcentrifugally;therestis removedby theair-oilseparator(8). Theoilsystemis fittedwitha thermo-
staticvalve(15).Whentheoiltemperatureis belowtheset-pointof thethermostaticvalve,thethermostatic
valveshutsoff theoil supply from oilheat-exchanger (14). The thermostatic valvestartsopeningthe supply
fromheat- exchanger(14) when the oil temperature exceeds the valve’s setting. The setting of the thermo-
staticvalvedependsonthemodel.SeetableTechnicalData.
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

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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 intakevalve (1) closes the air inlet opening by a springforce:
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. Theloadingplunger(3) movesforwardsandcausestheintakevalve(1)to closetheair inletopening.
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. Thepressureisstabilizedatalowvalue,airoutputisstopped(0%) andthecompressorrunsunloaded.
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.

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2.6 Electrical diagram and main components
Fig. 2.6 Electrical diagram FV30-55
Main components
К1---К4
Contactor
YA
Solenoid valve
М1, М2
Electric motor
QS
Automatic power switch
Т
Temperature sensor
CT2
Transformer
I/P
Pressure sensor
R,C
RC filter
SB
Emergency stop
Tr
Transformer
F1, F2
Fuses
v-LOG
Controller
FI
Frequency inverter
H
Indicator
2.7 General description
Voltage (V)
Frequency (Hz)
FV30..
FV37..
FV45..
FV55..
Мaterial - copper. Cable size (mm²)
380 / 400
50
16
25
35
50
Fuse value (A)
380 / 400
50
63
80
100
125

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3. Start up
3.1 Lifting and carrying
For transport with a forklift
truck, use the rigging holes
in the frame. The compressor
has slotted rigging holes with
width C –fig. 3.1. Move the
compressor carefully.
Fig. 3.1 Lifting and carrying
FV30-55.
Model
A,mm
B, mm
C, mm
D, mm
G, mm
FV30
332
775
185
292
1200
FV37
FV45
540
150
1300
FV55
3.2 Dimensions
Fig. 3.2 Dimension drawing FV30-55.
G
A
Model
Compressor dimensions
Length
L, mm
Width
D, mm
Height
H,mm
Weight,
kg
FV30
1400
1000
1500
725
FV37
765
FV45
1650
1250
1720
1015
FV55
1190
Packaging dimensions
FV30
1600
1100
1750
755
FV37
795
FV45
1850
1350
1950
1055
FV55
1240
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.

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3.3 Requirements on installation facility
Fig. 3.3 Installation facility proposal FV30-55.
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 thecompressoris not anchored to the baseon which it is installed,the tilt anglewith respect
tothehorizontalsurface mustnotexceed3°.
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
fitted with a combined extract-and-input ventilation system.
The facility where the compressor is installed should be provided
with air inflow equivalent to twice the compressor’s capacity.
1500
1500
1500
1500
1500

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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 flexible hose. All components of the compressed-air line must
havea working pressure no less than the compressor’snominal pressure. Use a pressure vesselwith a
capacity corresponding to the compressor’s performanceand 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 fire retardant compound. An isolating switch must be fitted 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 fluctuation and
phase failure.
The power cable has to be fed into the compressor.
Fig. 3.5.1 Power cable connection Fig. 3.5.2 Power cable terminal connection
Remove the left side panel, pass the cable under the compressor into the orifice (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.

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4.
Operation
Non-qualified personnel must not be allowed to operate the com-
pressor.
4.1 Control panel
The frequency-controlled compressors FV30 and FV90 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
statusesare also recorded.
4.1.1 v-Log control panel
Fig. 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 flashes 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 .

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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 Current motor frequency
compressor outlet
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
USAGE PARAM
FACTORY PARAM
Includes current values (available for viewing)
Includes operating settings of the main parameters (available for viewing,
changes password-protected)
Forservicingmode(viewwithpassword).Modificationonlypossiblebymanufacturer
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
Runparameters.Selecttherunparametersusingtheup anddown buttonsand enter .
FAN, VSD PARAM
FREQUENCY 50.0 Hz
VOLTAGE 400V
CURRENT:
POWER:
At the output of the frequency inverter.
FAN CURRENT (A)
Current consumption of all 3 phases of the fan.
А: 0.0
В: 0.0
С: 0.0

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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 filter change.
SEPARATOR: 0000H
Operating time since last separator change.
AIR FILTER: 0000H
Operating time since last air filter 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
MFD, SERIAL NO
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:
Thecontentsofthismenuitemcanbe displayed,butmodificationsarepassword-protected.Modifications
may only be carried out by trained andqualified personnel.
Errors history
The last 5 error messages.
Serial number:
Manufact. date:
Serial number and data of manufacture of the compressor.

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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.