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Related Manuals for BERG KOMPBERG ZX75
Summary of Contents for BERG KOMPBERG ZX75
- Page 1 OPERATING AND MAINTENANCE MANUAL Oil‐free screw compressor KOMPBERG ZX75 ...
- Page 2 Ladies and Gentlemen, We heartily welcome you among our valued Customers and thank you for your trust to purchase the BERG compressor. We are sure you will be fully satisfied with both the choice you have made and the cooperation you started with us. Our compressors are machines of top quality, which is the guarantee for a long years and reliable performance. Our sales and service staff is available to answer all your queries regarding the installation ...
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Page 3: Table Of Contents
Table of contents 1. Information concerning the document ................ 4 1.1. Scope and intended use of the manual .................. 4 1.2. Intended use of the compressor and conditions of safe use ............ 4 1.3. Qualification requirements for operation of the compressor. ........... 5 1.4. Operation ............................. 5 1.5. Other remarks and instructions .................... 6 1.6. Warranty ............................ 6 2. Operating safety rules ...................... 6 2.1. Basic requirements for safe transport and positioning of the screw compressor ...... 7 2.2. Operating safety requirements .................... 8 2.3. Other hazards .......................... 8 2.4. Meaning of pictograms ........................ 9 3. Technical data .......................... 9 4. Setting .......................... 1 0 4.1. Room requirements ........................ 10 4.2. Requirements concerning electrical system ................ 11 ... -
Page 4: Information Concerning The Document
1. Information concerning the document This operating and maintenance manual is an integral part of the machine. It includes the information necessary to start, operate and maintain the compressor and requirements for its safe operation. Following the manual rules will help you: Avoid hazards, Reduce repair costs and downtime, Increase the machine reliability and life. Getting ... -
Page 5: Qualification Requirements For Operation Of The Compressor
1.4. Operation While operating the compressor: Observe the instructions provided in the Operating and Maintenance Manual and Warranty Book. Follow the periodic inspection schedule during both warranty period and after its completion. Regular performance of periodic inspections is necessary to ensure the required reliability and life of the BERG equipment. The inspections performed according the schedule reduce the number of repairs and their cost. The technical and operating inspections should be carried out in accordance with the schedule and conditions by the factory service or authorised service, using the manufacturer’s consumables and spare parts. ... -
Page 6: Other Remarks And Instructions
2. Operating safety rules The present rules are valid for BERG screw compressors. In addition to the general health and safety at work and the Office of Technical Inspection (UDT) regulations applicable to compressors, their assemblies and accessories, the safety instructions given below should be ... -
Page 7: Basic Requirements For Safe Transport And Positioning Of The Screw Compressor
The limit values may not be changed by the user. The manufacturer accepts no responsibility for any personal injuries, damage of equipment or the compressor itself, at present and in the future, resulting from user’s negligence and failure to observe the installation, operation and maintenance requirements contained herein. No responsibility is also taken for failure to observe valid safety standards relating to the equipment and qualified staff. 2.1. Basic requirements for safe transport and positioning of the screw compressor In addition to the general health and safety at work and the Office of Technical Inspection (UDT) regulations, the following rules must be observed: Use only the lifting equipment that is compliant with the H&S and UDT regulations to lift the compressor. Fix in place all rotating or loose parts of the machine before its lifting. It is strictly ... -
Page 8: Operating Safety Requirements
2.2. Operating safety requirements In addition to the requirements contained in the sections: Screw compressor operation description; Start up; Maintenance; the following rules should be observed. The compressor is only designed to compress air. All safety equipment must be in place while operating the machine. The factory‐mounted safety equipment must not be removed. Please, remember to remove any transport brackets (if applicable)before first start‐up of the compressor. The transport brackets are only used to protect the machine during transport. There are hot parts in the compressor e.g. conduits, air and oil coolers, screw block. They will scald when touched. No unauthorized modifications in the control system are allowed. After power failure, the compressor must be restarted when the power supply is recovered. ... -
Page 9: Meaning Of Pictograms
2.4. Meaning of pictograms Pictograms (safety symbols) located on and inside the compressor are described below. Explanation is provided below any of them. For technical reasons, it is not always possible to attach the pictograms in the very vicinity of the points of risk. AUTOMATIC MACHINERY RISK OF SCALDING RISK OF ELECTRIC SHOCK MAY START ... -
Page 10: Setting
It is necessary to consult our specialists when you want to install a duct supplying air from the outside or use air for heating the rooms. The compressor room should be well lighted to ensure trouble‐free and safe service of the equipment. To improve ventilation in the compressor room, the machine can be connected to the discharge air duct; in such case, please contact BERG. The suitable ventilation in a room will prevent the possibility of negative pressure generation or undesired temperature increase. ... -
Page 11: Requirements Concerning Electrical System
Recommended power cable cross sectional area and fuse sizes 4.3. Compressed air connection It is recommended to use galvanized steel or plastic tubes for the compressed air system. When the compressed air treatment equipment (filters, dryer) is installed, the existing compressed air piping should be replaced with a new one, unless air supplied previously wastreated by similar equipment. Each BERG compressor should be connected to the compressed air network by using a flexible conduit or flexible connector (axial expansion joint) and shut‐off valve. Elbow Pneumatic hose ... -
Page 12: Screw Compressor Operating Description
5. Screw compressor operating description 5.1. Screw compressor KOMPBERG ZX75 – operating description General view of an oil‐free screw compressor KOMPBERG ZX75... - Page 13 The compressor is equipped with two stage air end ("of dry‐type") without oil injection into the compression chamber with the bearings and gearing and the coat of the high pressure part are lubricated and cooled with oil. POWER AND CONTROL The compressor (screw air‐end) is driven by an electric motor through a flexible coupling . Control of the entire electrical system is placed in a electrical box. AIR CIRCULATION The air is sucked through the air filter (1) and the suction controller (2) to the first stage (3). The compressor suction regulator is equipped with a second stage discharge (4) terminated by a noise damper (5). After compression to the overpressure of 0,35 MPa the air is forced from the 1st stage to the intercooler (air‐water exchanger) (6). After cooling in the cooler, the air flows through the condensate separator (7) and is sucked to the second stage (8). I‐stage compression and internal system are protected against pressure rise above the permissible value by a safety valve ...
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Page 14: Technological Diagram
Technological diagram 1 Air filter 19 Oil filter 2 Suction valve 20 Overflaw valve 3 First stage 21 Oil distributor 4 Venturi nozzFirst stage coolerle 22 Vent filter 5 First satage cooler 23 Hydraulic cylinder 6 Cyclone separator 24 Solenoid valve 7 2nd stage 25 Solenoid valve with time system 8 Venturi nozzle ... - Page 15 MEASURING SENSORS The following temperature sensors and pressure transducer are installed in the compressor installation: (39) ‐ air filter pollution sensor, (33) ‐ temperature sensor ‐ realizes the measurement of the compressed air temperature after the I stage (3), (35) ‐ temperature sensor ‐ realizes the measurement of the compressed air temperature after cooling in the radiator (6), ...
- Page 16 After stopping the compressor with the EMERGENCY STOP (STOP AWARYJNY) button and after the supply voltage is switched off and on, the compressor can be started by unlatching the EMERGENCY STOP (STOP AWARYJNY) button and pressing the START button. The compressor is provided with an additional protective function which prevents machine start when any of parameters given in Tab.[Technical data] is exceeded. Screw air end CD8D ...
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Page 17: Start
Suction regulator Operating panel Controller instruction is an integral part of the OMM of compressor KOMPBERG ZX75 6. Start‐up 6.1. Start‐up preparation Each compressor unit is tested in the factory and carefully inspected to ensure proper machine performance and meeting the specifications declared. Strictly obey the following rules before starting the machine for the first time: Get thoroughly familiar with the compressor Operating and Maintenance Manual and the Warranty Book. Check the power cables for possible damage, short‐circuits and electrical breakdowns. Only authorised / qualified electrician can perform work on electrical equipment and components. ... -
Page 18: Restart (After Longer Downtime)
Check if all doors/covers are closed. Open the valve that shuts off the compressor from compressed air system. Check the “EMERGENCY STOP” button position. Switch on the compressor power supply. When the compressor and compressed air system condition is checked, you can proceed with starting the compressor. To start the compressor, press the "START" button on the control panel. The compressor motor starts working and depending on the overpressure in the compressed air system,the machine switches to the loaded operation mode or, if the overpressure in the compressed air systemis higher than the minimum start pressure, it switches to the stand‐by mode and starts again after ... -
Page 19: Maintenance
7. Maintenance 7.1 General requirements To ensure proper functioning, the compressor must undergo maintenance procedures. The following general requirements must be met while performing the maintenance: Place the warning sign as shown below in a visible location, while the maintenance work is in progress: WARNING MACHINE UNDER REPAIR ... -
Page 20: Maintenance And Checks
7.2. Maintenance and checks 7.2.1 Maintenance at the beginning of compressor use, after oil and drive belts (if present) change Maintenance interval Operation after 2 work hours check oil level in the receiver, top it up if necessary, after 2 work days check oil level in the receiver, top it up if necessary, after 1 week of work check oil level in the receiver, top it up if necessary, 7.2.2 Daily maintenance visually inspect the state of pneumatic and oil conduit connections, check the air overpressure gauge and temperature indicator for correct readings, check the compressor performance for unusual symptoms, such as excessive noise and vibration, check oil level, 7.2.3 Periodic maintenance Every 1000 work hours: check the air filter for contamination and replace if necessary (in case of higher air dustiness, more frequent cleaning and changing of the filter is recommended), ... -
Page 21: Basic Components Requiring Maintenance. Maintenance Operations
7.3. Basic components requiring maintenance. Maintenance operations. 7.3.1. Air filter cartridge The filter cartridge can't be soaked in oil or other liquids. Change the filter cartridge every 2000 work hours or once a year. In case of highly contaminated . ambient air, the cartridge must be cleaned or replaced more frequently Maintenance procedure: Stop the compressor and close the pressure conduit valve. Reduce the overpressure in the screw assembly body to reach the atmospheric pressure (see the microprocessor controller). Safeguard the compressor from restarting by an unauthorized person, e.g. by cutting power supply off. Open the filter cover and carefully remove the dust. Take the cartridge out, clean it or replace with a new one. Rinsing: do not apply force, avoid damaging the cartridge. Clean contact surfaces of gaskets. ... -
Page 22: Oil Filter
7.3.3. Oil filter Change the oil filter every 8000 hours or once a year. screwing out screwing in Oil filter ‐ maintenance Maintenance procedure: Stop the compressor and close the pressure conduit valve. Reduce the overpressure in the screw assembly body and oil system to reach the atmospheric pressure (see the oil pressure manometer / microprocessor controller). Safeguard the compressor from restarting by an unauthorized person, e.g. by cutting power supply off. It is advised to use a special spanner to replace the filter. Caution – hot oil! ... -
Page 23: Changing Oil
Oil level indicator 7.3.5 Changing oil The oil can be changed only when the compressor is stopped and completely depressurised. The machine should be heated up to the operating temperature (oil temperature between 50 and 60°C). Maintenance procedure: Stop the compressor and wait until the overpressure in the screw assembly body and oil system reaches the atmospheric pressure (look at the microprocessor controller). Safeguard the compressor from restarting by an unauthorized person, e.g. by cutting power supply off. Start the options for manually opening of the oil control solenoid valves in the radiator (see the controller operating instructions). ... -
Page 24: Handling Wastes Produced While Operating The Compressor
For compressor lubrication is suitable hydraulic oil HLP according to DIN 51515 or turbine lubricant according to DIN 51524 Part 2. The oil should have the following parameters: Kinematic viscosityacc. ISO VG 46 41,4‐50,6 Kinematic viscosity at 40C Oil of the specified parameters is the only acceptable oil for use in BERG oil‐free screw compressors (oil ‐ part No. COL0069 ). ie.package of 10 L produced 7.3.6. Handling wastes while operating the compressor The condensate (condensed water from the compressor, tank or compressed air purification ... -
Page 25: Electric Motor
Maintenance procedure: Stop the compressor, close the pressure conduit valve. Lower the overpressure in the screw assembly body till reaches the atmospheric pressure (to lower the overpressure inside the screw assembly body wait about 5 minutes after switching off the compressor, Safeguard the compressor from restarting by an unauthorized person, e.g. by cutting power supply off. Dismantle the radiator. Clean and remove impurities. Reassemble all disassembled components. Fill (top up) the compressor with oil. Carry out a operating test for approx. 3 to 5 minutes. Stop the compressor, check the oil level and top up if necessary. . Electric motor 7.3.8. ... -
Page 26: Troubleshooting
valve mechanism, and consequently damage the entire pressure unit. Therefore, during the equipment operation particular attention should be paid to the following: Correct setting of the safety valve, appropriate to the operating parameters of the equipment being protected, Appropriate protection of the valve mechanism against unauthorized adjustment and a risk of damage. The valve seal must be intact, ... - Page 27 activation of main protection check the protection, replace or switch on activation of motor protection temperature indicator or check, replace if damaged temperature transducerfault temperature indicator check: (microprocessor controller) oil level and top it up if necessary, activated because the cooling: remove causes of insufficient temperature was too high cooling, thermostat: if faulty, replace the entire thermostat or its cartridge. ambient temperature too heat the room up to reach at least +5°C low difficult supply voltage too low check supply voltage, bring it to correct value compressor start ambient temperature too heat the room up to reach at least +5°C low non return valve fault call the service wrong rotation wrong phase sequence swap two phase leads in the compressor direction terminal block or in the electric cabinet oil temperature ambient temperature ensure adequate ventilation in the room. too high, the ...
- Page 28 screw seizure call service activation of safety valve damaged replace with a new one (with appropriate safety valve setting) or call service wrong microprocessor adjust the correct settings in the controller controller setting damaged pressure call the service staff transducer damaged suction regulator call the service staff ...
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Page 30: Consumables For One Year Guarantee
9. Consumables for one year guarantee No. Name Part number Quantity 1. Air filter cartridge MFS0201 1 Compressed air filter cartridge 2. UFW0100 1 FP 510S 3. Oil filter MFS0001 1 4. Coupling insert MCM0165 1 5. Oil COL0069* 50 l 6. Thermostat cartridge MCM3231 1 * package of 10 L 10. Electrical scheme ...
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