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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  familiar  with  this  manual  in  detail,  using  the  machine  in  accordance  with  descriptions 
included in it and following all safety conditions  are  the  basis for correct and safe operation of 
the machine.  
 
In addition to the operating and maintenance manual and the regulations applied in the country 
of destination  and health and safety at work regulations applied locally  at the workstation, the 
generally recognised technical rules for safe and correct work are also valid. 

 

1.1. Scope and intended use of the manual 

 

The  operating  and  maintenance  manual  is  intended  for  qualified  /  suitably  trained  operating 
personnel  of  the  compressor.  The  personnel  assigned  to  operation  of  the  compressor  must, 
before starting work, get 

familiar with the manual contents, in particular the “

Health and safety 

at work regulations”

 section. 

 

The manual includes 

 

 

Description of daily service and maintenance of the compressor and control system, 

 

Technical documentation of the electrical part.  It includes the data necessary to perform correct 
connections and repairs of the electrical equipment, 

 

Technical documentation of the mechanical part. It includes the data necessary to perform repairs 
of the mechanical equipment, 

 

Technical documentation of the control system. It includes the data necessary to switch on and 
off, and set operating parameters of the compressor. 

 

The  qualified  personnel  is  understood  to  be  the  persons  who  because  of  received  training, 
experience  and  knowledge  of  important  standards,  documentation  and  regulations  concerning 
safety and operating conditions were authorised to carry out necessary operations and are able 
to recognise and avoid possible hazards. 

 

1.2. Intended use of the compressor and conditions of safe use 

 

The compressor is designed to produce only compressed air. It should be installed in accordance 
with  the  stipulations  concerning  the  compressor  installation  and  connection.  The  compressor 
must  not  be  used  for  any  other  purposes  that  are  non-compliant  with  its  intended  use.  The 
manufacturer shall not be liable for any damage resulting from that reason. In that case, the risk 
is born by the machine user only.

 

During  the  compres

sor  operation,  you  must  follow  the  procedures  given  in  the  “Maintenance” 

section as regards scope and frequency of maintenance work and materials to be used. 

 

 
 
 
 
 

Summary of Contents for KOMPBERG ZX90

Page 1: ...OPERATING AND MAINTENANCE MANUAL Oil free screw compressor KOMPBERG ZX90...

Page 2: ...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 sta...

Page 3: ...w compressor KOMPBERG ZX90 operating description 12 Technological diagram 14 6 Start up 17 6 1 Start up preparation 17 6 2 Restart after longer downtime 18 7 Maintenance 19 7 1 General requirements 19...

Page 4: ...e and maintenance of the compressor and control system Technical documentation of the electrical part It includes the data necessary to perform correct connections and repairs of the electrical equipm...

Page 5: ...gases it is required to obtain the manufacturer s consent The above consent must be in written form The compressor must not be used for any other purposes that are non compliant with its intended use...

Page 6: ...referred to as the Warrantor provides the warranty for the products sold ensures correct operation of the offered products provided that they are used in accordance with their intended use and operat...

Page 7: ...such a way that they do not place pressure on it If the transport harness is fastened and secured incorrectly the machine may get damaged The compressor must be transported only with a forklift Fasten...

Page 8: ...rohibited to service the safety valves or to change their settings Do not change settings of the pressure switches above the value given in the identification plate or in the Operating and Maintenance...

Page 9: ...eed 130dB Equivalent acoustic pressure level corrected by A characteristic does not exceed 85 db A AUTOMATIC MACHINERY MAY START RISK OF SCALDING RISK OF ELECTRIC SHOCK Type KOMPBERG ZX90 Overpressure...

Page 10: ...ntilation is insufficient windows openings in a wall etc in the compressor room air exchange should be provided by fans To ensure correct heat extraction the fans should have total capacity about 15 t...

Page 11: ...electrical connections Use the required safety measures in accordance with the suitable regulations Calculate the power cable cross sectional area and fuse sizes according to the local regulations an...

Page 12: ...5 Screw compressor operating description 5 1 Screw compressor KOMPBERG ZX90 operating description General view of an oil free screw compressor KOMPBERG ZX90...

Page 13: ...and then flows to the oil filter assembly 18 The oil filter set is fitted with a thermostat 17 which depending on the oil temperature directs the oil directly through the oil filter 18 to the manifol...

Page 14: ...25 Solenoid valve with time system 8 Venturi nozzle 26 Air filter pollution sensor 9 2nd stage cooler 27 Temperature sensor 10 Check valve 28 Safety valve 11 2nd stage unloading 29 Pressure sensor 12...

Page 15: ...correctness of the lubrication and sealing processes Therefore these spaces must be ventilated This is accomplished by means of a flexible hose and an air filter located at the tunnel of the fan In th...

Page 16: ...itched 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 wh...

Page 17: ...ons are in place do not connect the compressor to a power source of different voltage than that specified in the Operating and Maintenance Manual Connect the phase conductors so that the rotation dire...

Page 18: ...t switches to the stand by mode and starts again after its drop Incorrect rotation direction of the screw block rotors for more than 5 seconds will damage the screw compressor Proper direction of scre...

Page 19: ...e components Take appropriate safety measures against toxic vapours from cleaning agents Biodegradable detergents should be used The workplace must be kept absolutely clean when maintenance work is ca...

Page 20: ...he filter is recommended check the condition of the elastic coupling clean the air and oil cooler ribs if necessary 7 2 4 Warranty and post warranty checks every 2000 work hours or after 1 year change...

Page 21: ...ot apply force avoid damaging the cartridge Clean contact surfaces of gaskets Purging purge the external surface of the cartridge with dry compressed air at the pressure up to 0 5 MPa askew from the i...

Page 22: ...ner to replace the filter Caution hot oil Rub some oil onto the gasket of the new filter before screwing it in Fill the new filter held vertically with the same type of oil as that in the separator ta...

Page 23: ...lves in the radiator see the controller operating instructions Unscrew the compressor crankcase ventilation hose on the compressor stage body see Fig 11 Place a suitable container and carefully unscre...

Page 24: ...ridges should be disposed of according to the valid legislation on handling wastes waste code 16 01 07 7 3 7 Oil cooler exchanger interstage final air The safety of the screw compressor requires regul...

Page 25: ...restarted after removing the cause of any failures Periodic motor inspections The motor inspection should be performed at least once per 2 years The inspection should be performed by the in house pers...

Page 26: ...lves delivered require no special maintenance They should only be periodically every 1000 hours blown by pulling the handle of the push pin Special care must be taken while performing this operation K...

Page 27: ...e the set value adjust the pressure switch or enter correct settings in the controller oil level too low top oil up as required oil thermostat malfunction replace the entire thermostat or its cartridg...

Page 28: ...alve damaged replace with a new one with appropriate setting or call service wrong microprocessor controller setting adjust the correct settings in the controller damaged pressure transducer call the...

Page 29: ......

Page 30: ...er Quantity 1 Air filter BL 480146 BL 480169 1 2 Compressed air filter cartridge Element for F 24 GW 24 G 1 3 Oil filter B 480001 1 4 Coupling insert BS 480165 1 5 Oil l 480069 40 l 6 Thermostat cartr...

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