VPK COMPRAG A1108 User manual

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Инструкция
по эксплуатации
Компрессор COMPRAG A1108
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station/a-1108/
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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
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 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
5.10 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

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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,
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.

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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.
5. Compressed air is an extremely hazardous energy source. Compressed air must not
be used for unintended purposes! Do not use it to clean clothing and footwear and never
point compressed air hoses at people and animals! When using air to clean equipment,
take extra caution and wear safety goggles!
6. All maintenance, repair, setup and installation work etc. must be performed while the
equipment is turned off, disconnected from the power source, with compressed-air hoses
disconnected from the equipment, and with the use of safety goggles! Ensure that equip-
ment is disconnected from the compressed air system and is not under pressure.
1.3 Safety precautions for start-up
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, operati-
on or servicing, as well as unauthorised use of equipment!
1. Equipment must only be unloaded/loaded using the appropriate handling devices or
hoisters. Equipment must not be manually lifted or moved. Do not leave equipment sus-
pended. Use a helmet during unloading operations.
2. Arrange the equipment in a dry and clean facility which provides shelter from precipi-
tation. The facility must be well ventilated, and forced ventilation should be provided if
necessary.
3. Worn, damaged or spoiled compressed-air hoses should not be used. Ensure that
hoses correspond to the equipment in terms of nominal diameter and working pressure.
4. When using several compressor stations in a system, each compressor must have a manu-
ally operated valve for cutting off any of the compressors in the case of emergency.
5. Explosive and 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 not
clutter 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:
‘ATTENTION: this machine is being controlled remotely and may start operating without
warning!’ An operator who is remotely controlling equipment must ensure that no installa-

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tion or other work is being performed with the equipment at that moment. Once the equip-
ment is turned off remotely, the operator must ensure that the equipment is actually turned off!
10. Equipment must be earthed. Provide short-circuit protection. The starting knife switch
must be in the immediate vicinity of the equipment and protect against unauthorised start-up.
The user bears full responsibility for compliance with the operating condi-
tionsof theelectrical motorinstalledin theequipment.
Equipmentmustbe usedwithprotectiondevices.
The protection devices must protect theelectric motor from short circuits,
overloading(systematicand start-up)andopen-phaseconditions.
Installationof protectiondevicesis theresponsibilityof theuser.
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!
Unauthorised installation, disassembly or adjustment of attached safety-relief valves is
not allowed.
1.4 Safety precautions during operation
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1. Ensure that hoses correspond to the equipment in terms of nominal diameter and working
pressure. Check the attachment of every hose coupling before start-up. An insecurely fas-
tened hose may cause serious injury.
2. Never turn on equipment if you suspect the presence of highly 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
panels may be opened for short durations for inspection and scheduled checks. It is advis-
able to wear hearing protection.

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In some types of equipment, open doors or removal of panels du-
ring operation may lead to overheating.
6. Personnel in conditions or a facility where the sound pressure level reaches or exceeds
90 dB (A), must wear ear protectors.
7. If the air used for cooling equipment is used while the facility is being heated, undertake
measures for it to be 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.

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7. When carrying out installation and repair work, an information plate should be affixed
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
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 outlets during installation with dry clothes or paper to prevent rubbish entering the
equipment.
10. Welding or other similar operations must not be carried out in the immediate vicinity of
the equipment and vessels under pressure.
11. If there is any suspicion of overheating, combustion or other emergency, turn off the
equipment. Immediately disconnect it from the power supply. Do not open the doors of
equipment until the temperature falls to room temperature, in order to prevent burns or injury.
12. Naked 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 circum-
stances. Remember that your safety depends on their functionality!
16. Before beginning work in normal mode after maintenance or repair work, check that the
working pressure, temperature and other characteristics are correctly set. Ensure that all
control devices are installed and functioning properly.
17.When replacing 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. 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).

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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 incor-
rectly
-No records for the compressor’s scheduled maintenance are entered
in the compressor’s service book
-Unoriginal parts and lubricants are used
2.1 Technical data
Article
Model
Drive power,
compressor
(kW)
Max. operat- ing pressure
(bar)
Output
(m3/min)
Rated
voltage,
compressor
(phase/V/Hz)
Noise
(dB)
Receivers
Volume
(liter)
Refrigerated
dryer,
RDX-Series*
Screw
connection
Oil capacity,
liter
11100011
A0708
7,5
8
1,1
3/380/50
65
-
-
1/2”
5
11100012
A0710
10
0,9
11100013
A0713
13
0,6
11100015
AR0708-270
8
1,1
270
-
11100018
АR0708-500
500
11100016
AR0710-270
10
0,9
270
11100019
АR0710-500
500
11110011
ARD0708-270
8
1,1
270
Х
11110013
ARD0708-500
500
11110012
ARD0710-270
10
0,9
270
11110014
ARD0710-500
500
11100021
A1108
11
8
1,6
3/380/50
67
-
-
1/2”
5
11100022
A1110
10
1,4
11100023
A1113
13
1,3
11100025
AR1108-270
8
1,6
270
-
11100028
АR1108-500
500
11100026
AR1110-270
10
1,4
270
11100029
АR1110-500
500
11110015
ARD1108-270
8
1,6
270
Х
3/4”
11110017
ARD1108-500
500
11110016
ARD1110-270
10
1,4
270
11110018
ARD1110-500
500

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Article
Model
Drive power,
compressor
(kW)
Max. operating
pressure
(bar)
Output
(m3/min)
Rated
voltage,
compressor
(phase/V/Hz)
Noise
(dB)
Receivers
Volume
(liter)
Refrigerated
dryer,
RDX-Series*
Screw
connection
Oil capacity,
liter
11100031
A1508
15
8
2,3
3/380/50
69
-
-
1/2”
8
11100032
A1510
10
1,9
11100033
A1513
13
1,5
11100035
AR1508-270
8
2,3
270
-
11100038
АR1508-500
500
11100036
AR1510-270
10
1,9
270
11100039
АR1510-500
500
11110019
ARD1508-270
8
2,3
270
Х
3/4”
11110021
ARD1508-500
500
11110020
ARD1510-270
10
1,9
270
11110022
ARD1510-500
500
11100041
A1808
18,5
8
3,1
3/380/50
70
-
-
3/4”
8
11100042
A1810
10
2,5
11100043
A1813
13
2,2
11100045
AR1808-500
8
3,1
500
-
11100046
AR1810-500
10
2,5
11110023
ARD1808-500
8
3,1
Х
1”
111100234
ARD1810-500
10
2,5
11100051
A2208
22
8
3,6
-
-
3/4”
11100052
A2210
10
3
11100053
A2213
13
2,6
11100055
AR2208-500
8
3,6
500
-
11100056
AR2210-500
10
3
11110027
ARD2208-500
8
3,6
Х
1”
11110028
ARD2210-500
10
3
2.2 General description
The A-Series oil-filled screw compressor series is designed for uninterrupted and efficient
compressed-air production.
The A-Series compressor is an electric motor-operated, intake-regulated, belt-driven and air-
cooled compressor, enclosed in a sound-insulated canopy. An electronic controller e-Log with
an LCD indicator panel is provided, including start and stop buttons and an emergency stop
button. Pressure and temperature relays are used for system control and protection.

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2.3 Function diagram and main components
Fig. 2.3.1 Function diagram A07..-A22..
Air flow
T
Temperature sensor
Oil flow
P
Pressure sensor
Air/Oil mix flow
Pneumatic control line
Main components
1
Electric motor
11
Min. Pressure valve
2
Belt drive
12
Non-return valve
3
Air end
13
Heat-exchanger, Air section
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

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Fig. 2.3.2 Function diagram AR07..-AR22.., ARD07..-ARD22..
Air flow
T
Temperature sensor
Oil flow
P
Pressure sensor
Air/Oil mix flow
Pneumatic control line
Main components
1
Electric motor
12
Non-return valve
2
Belt drive
13
Heat-exchanger, Air section
3
Air end
14
Heat-exchanger, Oil section
4
Air filter
15
Thermostatic valve
5
Intake valve
16
Oil filter
6
Air-Oil separation tank
17
Drain valve
7
Safety valve
18
Oil filling plug
8
Air-Oil separator
19
Oil level sight glass
9
Throttle valve
20
Air outlet valve
10
Non-return valve
21
Refrigerated dryer (ARD only)
11
Min. Pressure valve
22
Pressure vessel
Р
13
12
22
21
11
20
10
17
3 7
18
16
19
15
14
17

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2.4 Functional description (see Fig. 2.3.1 and Fig. 2.3.2)
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 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 thermostatic valve (15). When the oil temperature is below
the set-point of the thermostatic valve, the thermostatic valve shuts off the oil supply
from oil heat-exchanger (14). The thermostatic valve starts opening the supply from heat-
exchanger (14) when the oil temperature exceeds the valve’s setting. The setting of the
thermostatic valve depends on the model. See table Technical Data.
Cooling system:
The cooling system comprises a combined air section (13) and an oil section (14) heatex-
changer. A cooling fan, mounted in the fresh air intake section, 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 t-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 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.
Loading:
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.

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2.6 Electrical diagram and main components
Fig. 2.6 Electrical diagram A07.. –A22.., AR07.. –AR22.., ARD07.. –ARD22..*,
*For RDX Electrical diagram refer to the relevant documentation.
Main components
К1, K2, К3
Contactor
YA
Solenoid valve
М1
Electric motor
R
Electronic controller
Т
Temperature sensor
I/P
Pressure sensor
SB
Emergency stop
CT1
Transformer
F1, F2
Fuses
TR
Transformer
QS
Automatic power switch

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3. Start up
3.1 Lifting and carrying
All lifting should be carried out using a forklift truck with a carrying
capacity suited to the compressor. Lifting may be carried out with
loading cranes, winches and other machinery, using a crossbeam
with the right length. Local safety guidelines for lifting have to be
observed.
For transport with a forklift truck, use the rigging holes in the frame. The compressor has
slotted rigging holes with width C –fig. 3.1. Move the compressor carefully.
Fig. 3.1.1 Lifting and carrying A07.. –A22..
Model
A, mm
B, mm
C, mm
D, mm
G, mm
А07..
100
383
185
92
900
А11..
130
202
А15..
А18..
135
302
1000
А22..
A

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Fig. 3,1.2 Lifting and carrying AR07..-AR22, ARD07..-ARD22
Model
A, mm
B, mm
C, mm
D, mm
G, mm
AR07.. / ARD07..
100
383
185
92
900
AR11../ ARD11..
130
202
AR15../ ARD15..
AR18../ ARD18..
135
302
1000
AR22../ ARD22..

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3.2 Dimensions
Fig. 3.2.1 Dimension drawing A07.. –A22..
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
A07
750
700
985
285
850
800
1115
315
A11
900
1170
293
1000
1320
325
A15
315
350
A18
1000
800
1270
415
1100
900
1450
460
A22
435
480
H

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Fig. 3.2.2 Dimension drawing AR07..-AR22, ARD07..-ARD22
Model
Compressor dimensions
Packaging dimensions
Length
L, mm
Width
D, mm
Height
H, mm
Weight ,
kg
Length
L, mm
Width
D, mm
Height
H, mm
Weight ,
kg
AR07-270
1370
700
1500
405
1700
780
1630
450
ARD07-270
440
485
AR07-500
1900
800
1650
447
2050
880
1780
500
ARD07-500
482
540
AR11-270
1470
700
413
1700
780
1800
460
ARD11-270
450
500
AR11-500
1900
800
455
2050
880
1780
510
ARD11-500
492
460
AR15-270
1470
700
420
1700
780
1800
470
ARD15-270
460
510
AR15-500
1900
800
462
2050
880
1780
515
ARD15-500
502
550
AR18-500
1900
860
1860
570
2050
960
2050
620
ARD18-500
635
685
AR22-500
590
640
ARD22-500
655
705
H

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3.3 Requirements on installation facility
Fig. 3.3.1 Installation facility proposal A07.. –A22..
1. Air inflow
2. Air outflow
Fig. 3.3.2 Installation facility proposal AR07..-AR22, ARD07..-ARD22
1. Air inflow
2. Air outflow
1500
1500
1500
1500
1500
1500
2500
1500
1500
2500