VPK COMPRAG A3008 User manual

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Инструкция
по эксплуатации
Компрессор COMPRAG A3713
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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 4
1.1 Symbols used in the instructions 4
1.2 General safety guidelines 4
1.3 Safety precautions for start-up 5
1.4 Safety precautions during operation 6
1.5 Safety precautions for maintenance and repair 7
2. Technical data and functional description 8
2.1 Technical data 8
2.2 General description 9
2.3 Function diagram and main components 9
2.4 Functional description 10
2.5 Regulating system 10
2.6 Electrical diagram and main components 12
2.7Electrical connection values 12
3. Start up 13
3.1 Lifting and carrying 13
3.2 Dimensions 13
3.3 Requirements on installation area 14
3.4 Connection to the compressed airline 15
3.5 Connection to power supply 15
4. Operation 17
4.1 Controller and operating panel 17
4.2 Error indication 20
4.3 Starting the compressor 23
4.4 Switching off the compressor 23
5. Maintenance 24
5.1 Maintenance schedule 24
5.2 Checking oil level 24
5.3 Checking drive belt 25
5.4 Replacing oil and oil filter 26
5.5 Replacing air filter 27
5.6 Changing drive belt 27
5.7 Changing air-oil separator 28
5.8 Cleaning radiator 28
5.9 Checking suction valve 29
5.10Servicing bearings of electric motor 29
6. Fault handling 29
6.1 Faults and corrective actions 29
7. Storage and disposal 30
7.1Storage conditions 30
7.2 2 Disposal of oils and process condensate 30
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.
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
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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, 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 sus-
pended. 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:‘ATTENTION: 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 condi-
tions of the electrical motor installed in the equipment.
Equipment must be used with protection devices.
The protection devices must protect the electric motor from short circuits,
overloading (systematic and start-up) and open-phase conditions. Installa-
tion 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!
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.
In some types of equipment, open doors or removal of panels
during 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, 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
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.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 equip-
ment until the temperature falls to room temperature, in order to prevent burns or injury.
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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. 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 pe-
riod is forfeited when:
-No warranty service couponfor the compressor or it is filled 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 power,
compressor
(kW)
Max. operat-
ing pressure
(bar)
Output
(m3/min)
Rated
voltage,
compressor
(phase/V/Hz)
Noise
(dB)
Screw
connection
Oil
capacity,
liter
11100061 A3008
30
84,7
3/380/50
70
1-1/4 15
11100062 A3010 10 4,0
11100063 A3013 13 3,5
11100071 A3708
37
85,9
72
11100072 A3710 10 5,1
11100073 A3713 13 4,4
11100081 A4508
45
87,0
73
1-1/2
20
11100082 A4510 10 6,2
11100083 A4513 13 5,3
11100091 A5508
55
88,7
11100092 A5510 10 7,7
11100093 A5513 13 6,5
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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 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.
2.3 Function diagram and main components
Fig. 2.3 Function diagram A30-A55
Air ffow T Temperature sensor
P Pressure sensor
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Main components
1Electric motor 11 Min. Pressure valve
2Belt drive 12 Non-return valve
3Air end 13 Heat-exchanger, Air section
4Air filter 14 Heat-exchanger, Oil section
5Intake valve 15 Thermostatic valve
6Air-Oil separation tank 16 Oil filter
7Safety valve 17 Drain valve
8Air-Oil separator 18 Oil filling plug
9Throttle valve 19 Oil level sight glass
10 Non-return valve 20 Air outlet valve
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 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) 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
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.
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Fig. 2.5 Regulating system
Unloading:
If air consumption is less than the air delivered by the compressor, the net pressure increas-
es. 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.
3 4
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2.6 Electrical diagram and main components
Fig. 2.6 Electrical diagram A30-55
Main components
К1, K2, К3, К4 Contactor YA Solenoid valve
М1, М2 Electric motor RElectronic controller
ТTemperature sensor I/P Pressure sensor
SB Emergency stop TN1, TN2 Overload relay
F1, F2 Fuses TR Transformer
PK1.1 Phase sequence relay QS Automatic power switch
2.7 General description
Voltage (V) Frequency (Hz) A30.. A37.. A45.. A55..
Мaterial - copper. Cable size (mm²)
380 / 400 50 16 25 35 50
Fuse value (A)
380 / 400 50 63 80 100 125
Motor overload relay (A)
380 / 400 50 31,8 38,1 46,2 56
TN1 K4.1
PK1
3
11 22 33
TN2
K1.1 K2.1 K3.1 Tr1 380VAC
SB1.1
Re1 Re2 Re3 Re4
202 F2 201
K1.2
1 2 1
K1.2
300
302
2
3
2
SB1.2 301 PK1.1
208
K2
4
6
4
5
6
206
K3
1
TN1.1 TN2.1
7
8
9
2
I
P
K1 K4
4
5
6
3 X 380VAC
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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
A30-55.
Model A,mm B, mm C, mm D, mm G, mm
A30 332
775 185
292 1200
A37
A45 540 150 1300
A55
3.2 Dimensions
Fig. 3.2 Dimension drawing
A30 –A55.
All lifting should be carried out using a forklift truck with a carrying ca-
pacity 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.
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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
А30
1400 1000 1500 705 1600 1100 1750 777
А37 745 830
А45
1650 1100 1730 950 1850 1200 1860 1165
А55 1150 1194
3.3 Requirements on installation facility
Fig. 3.3 Installation facility proposal A30 –A55.
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 precipitation cannot reach.
1500 1500
1500
1500 1500
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Choose a facility for installing the compressor with a minimum level of dust. Install the com-
pressor 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 equipment connected
to the compressor.
The facility in which the compressor is installed must be fitted with a combined extract-and-in-
put ventilation system.
The facility where the compressor is installed should be provided
with air inflow equivalent to twice the compressor’s capacity.
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 com-
pressor should be connected via a flexible 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 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.
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Fig. 3.5.1 Power cable connection
Remove the left side panel, pass the cable under the compressor into the orifice (1) and
cable gland (2).
Fig. 3.5.2 Power cable terminal connection
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.
1 2
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4.
Operation
Non-qualified personnel must not be allowed to operate the com-
pressor.
4.1 Controller and operating panel
The compressors A30 to A55 are equipped with a pro-Log electronic controller.The pro-Log
electronic controller maintains the net pressure between programmable limits by automat-
ically loading and unloading the compressor. A number of programmable settings, e.g. the
unloading and loading pressures, the minimum stop time and the maximum number of
motor starts are taken into account.
The pro-Log electronic controller stops the compressor whenever possible to reduce the
power consumption and restarts it automatically when the net pressure decreases. In case
the expected unloading period is too short, the compressor is kept running to prevent too
short standstill periods.
Operating panel
In order to control the compressor and to read and modify programmable parame-
ters the controller has a control panel provided with:
-LEDs indicating the status of the compressor;
-a display indicating the operating conditions, a service need or a fault;
-buttons to control the compressor and access data collected by the controller;
-buttons to manually start and stop the compressor;
-an emergency stop button (separate installed)
Control panel buttons
Fig. 4.1 Controller panel
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Start Escape
Stop Up or Increment Value
Reset Down or Decrement Value
Enter
Information displayed on the LCD display.
Fig. 4.2 LCD display
The display is divided in to 4 areas.
Top, Left: Display Field: 4 character numeric display, with unit symbols,
used to continuously show delivery pressure in
normal operating mode or menu page number in
menu mode
Top, Right: Fault Symbol Field: Symbolic displays used to indicate common
general fault conditions
Middle: Symbolic displays used to reinforce meaning of
selected item, fault condition.
Symbolic status information in normal
operational mode ‘Information Screen’ item
Bottom: Item and Value Field: Item identification: 2 character alphanumeric, 14
segment
Item Value: 4 character numeric, 7 segment
Item Unit: 3 character alphanumeric, 14
segment
Operational Display Symbols:
Unloading Loading Timer Pressure indicator Locked
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Fault Display Symbols:
General fault Emergency stop Excess pressure
Power failure Above set temperature limit Service due, maintenance
Indicator States:
ON: Illuminated continuously
FF: Fast Flash: on/off four times per second
SF: Slow Flash: on/off once per second
IF: Intermittent Flash: on/off every four seconds
OFF: Extinguished continuously
State Number State description Status Fault
1Shutdown Error OFF FF
2Startup Init OFF OFF **
3Start Inhibit Check
Start inhibit condition
OFF OFF **
4Ready to Start OFF OFF **
5Blowdown if (load_request) FF else IF OFF **
6Standby IF OFF **
7Start Motor in Star/
Delta
if (load_request) FF else IF OFF **
8Load Delay if (load_request) FF else IF OFF **
9Load ON OFF **
10 Reload Delay if (load_request) FF else IF OFF **
11 Standby Run on Time IF OFF **
12 Stop Run on Time SF OFF **
** SF for Alarm condition
User menu:
Pos. Code Description Range Default
1P00:C> Information screen Number of compressor
switched on during
last one hour
0
2P00:Td Delivery air temperature -10 °C +132 °C
3P00:Pd Delivery air pressure 0-16 bar
4P00:H1 Running hours (electric motor on) 0-99999 h
5P00:H2 Loaded hours 0-99999 h
6P00:H3 ervice hours (countdown timer) 0-99999 h 50
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4.2 Fault Messages
Faults are abnormal operating condition states. Alarms are fault states that indicate nor- mal
operating conditions have been exceeded but do not present an immediate hazard or
potentially damaging condition. Alarms are intended as a warning only and will not stop the
compressor or prevent the compressor from being started and run.
Start inhibits are fault states that prevent the compressor from initially being starting. Start
inhibit faults are conditions that may present a hazard or damaging situation if the compres-
sor was to be started. A start inhibit will self reset when the condition being monitored returns
to normal operational levels. Start inhibit conditions are only checked during the initial start
procedure and will not stop the compressor once started and in the ‘started’ state. Start in-
hibit conditions are not chec\ked during an automated motor start from Standby.
Run inhibits are fault states that prevent the compressor from starting and running the main
motor. Run inhibit faults are conditions that may present a hazard or damaging situation if
the main motor is run. A run inhibit will self reset when the condition being monitored returns
to normal operational levels and the compressor will then be allowed to exit the standby con-
dition and run without further manual intervention. Run inhibit conditions are checked prior
to a main motor start sequence and will not stop the compressor motor once started. Run
inhibit conditions do not prevent the compressor from entering the ‘started’ state condition.
Shutdown trip errors are fault states that present a hazardous or damaging condition, the
compressor is stopped immediately. The Shutdown trip error condition must be resolved, and
the fault reset, before the compressor can be re-started.
The different fault state conditions are indicated on the screen with specific codes; the last
character indicating the fault type: E = Shutdown Trip Error, A= Alarm, S = Start Inhibit, R =
Run Inhibit. Shutdown trip errors are divided into two different categories: immediate shut-
down errors and controlled stop errors. Immediate sh\utdown errors stop the compressor
instantly (Emergency Stop button activated for example). Controlled stop errors stop the com-
pressor in a controlled way using a normal Stop command; the motor will continue to run
for the set stop run-on-time. Immediate shutdown errors have an error code where the first
character is 0 (zero). Controlled stop faults have a “1” as the first character. Alarm faults are
also divided into two different categories: alarms and service alarm messages. Alarms start
with a “2”, service alarm messages with a “4”. Start Inhibit fault codes start with a “3”.
fault type
fault description number
input number
input location number
fault type
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