OPERATING AND MAINTENANCE MANUAL

Oil-free screw compressor

KOMPBERG ZX75
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
and operation of your compressor. You are also encouraged to use our warranty and post-
warranty technical service.
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 ................................................................................................................................ 10
4.1. Room requirements................................................................................................................... 10
4.2. Requirements concerning electrical system.............................................................................. 11
4.3. Compressed air connection ....................................................................................................... 11
5. Screw compressor operating description .......................................................................... 12
5.1. Screw compressor KOMPBERG ZX75 – 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
7.2. Maintenance and checks ........................................................................................................... 20
7.2.1 Maintenance at the beginning of compressor use, after oil and drive belts (if present)
change.......................................................................................................................................... 20
7.2.2 Daily maintenance .............................................................................................................. 20
7.2.3 Periodic maintenance ......................................................................................................... 20
7.2.4 Warranty and post-warranty checks .................................................................................. 20
7.3. Basic components requiring maintenance. Maintenance operations................................. 21
7.3.1. Air filter cartridge .............................................................................................................. 21
7.3.2 Cleaning or replacing the filter mats. ................................................................................. 21
7.3.3. Oil filter .............................................................................................................................. 22
7.3.4. Oil level .............................................................................................................................. 22
7.3.5 Changing oil ........................................................................................................................ 23
7.3.6. Handling wastes produced while operating the compressor ............................................ 24
7.3.7 Oil cooler (exchanger) / interstage / final air ..................................................................... 24
7.3.8. . Electric motor................................................................................................................... 25
7.3.9 Safety valve ......................................................................................................................... 25
8. Troubleshooting................................................................................................................. 26
9. Consumables for one year guarantee ............................................................................... 30
10. Electrical scheme ............................................................................................................. 30
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 compressor operation, you must follow the procedures given in the “Maintenance”
section as regards scope and frequency of maintenance work and materials to be used.
Warning bout forbidden use

▪ The compressor must not be used for any other purposes that are non-compliant with its
intended use.
▪ Under no circumstances must the limit operating parameters of the compressor be exceeded and
changed - refer to section 10 "Technical data".
▪ To use it for compression of other gases than air, it is required to obtain the manufacturer’s
consent. The above consent must be in written form.
▪ The compressor must not be used in potentially explosive atmospheres within the meaning of
Directive 2014/34/UE.
▪ The compressor must not suck any toxic, acid-containing, flammable or explosive gases and
vapours.
▪ Never direct a jet of compressed air at people or animals.

Safe use of the compressor

▪ The compressor must be operated in accordance with all guidelines included in this operating
and maintenance manual.
▪ The sucked air must be clean and must not contain any harmful substances.
▪ The heated cooling air may be used for heating purposes if only its harmfulness to people and
animals is excluded. Otherwise, it is necessary to provide the appropriate treatment of cooling
air.
▪ Compressed air may only be used for breathing after its appropriate treatment.
▪ Compressed air not subjected to the appropriate treatment must not be used in production
processes in which there is contact of air with food.

The compressor delivered is designed to compress only air.To use it for compression of other
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.

Fulfil the obligation to register the compressor air receiver in the Office of Technical Inspection
(UDT).The compressor documentation is accompanied by the set of the required documentation
of the air receiver (if applicable) and safety valve.

1.3. Qualification requirements for operation of the compressor.

The personnel who installs, operates and maintains the compressor should have the appropriate
education and qualifications enabling safe operation of electro technical and electrical
equipment.

Installation, operation and maintenance of the compressor may only be carried out by the
persons who are familiar with this operating and maintenance manual, follow instructions
included in it, know safety regulations and recognised technical rules.

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.
 - During the warranty period, use only the manufacturer’s consumables and spare parts.

The detailed list of maintenance operations can be found in the "Maintenance and inspections"
section.

1.5. Other remarks and instructions

- This Operating and Maintenance Manual provides all information on how to install, start and
operate the compressor. This manual should also be used when any maintenance work is carried
out,
- The Manual should be read and always available to the compressor operator,
- During the maintenance work and periodic inspections, the provisions of the Warranty Book
should be observed,
- The Maintenance section provides all measures and requirements necessary to keep the
compressor in a correct technical state,
- Record all operating data, maintenance operations performed etc. into the Warranty Book.
Observe all reference and local safety regulations relating to the compressor, including those
listed herein and in the following sections,
- Failure to follow the requirements included in this Operating and Maintenance Manual and
Warranty Book and/or unauthorised changes in the compressor or its integral units delivered by
us shall make the warranty null and void.
- During warranty period, any repairs must be performed by the manufacturer service or
authorised service centre listed in the Warranty Book.

1.6. Warranty

BERG Kompressoren GmbH. Speddition Straße 21, 40221 Düsseldorf Germany

hereinafter 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 operating conditions specified in this documentation.

The Purchaser shall lose its warranty rights for the product when:
- The machine is used in a way non-compliant with its intended use,
- Unauthorised modifications are carried out on the product,
- Interventions are carried out by unauthorised persons,
- Any repair attempts are carried out by unauthorised persons,
- The obligation to carry out periodic inspections is not observed,
- Non-original consumables are used.

The manufacturer reserves the right to make modifications in the product, resulting
from continuous technical development, without prior notice.

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
followed in particular. The operators are supposed to observe safe work practices. It is the user’s
responsibility to continuously maintain the compressor fully operable. Components and
equipment considered to be no longer suitable for safe operation should be promptly replaced.
Adjustments, installation, operation, maintenance and servicing should be entrusted only
to properly trained, qualified and authorized staff.
The limit values (pressure, temperature, time settings etc.) are given in the Technical Data
section.
 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
forbidden to stay in the hazardous zone of the lifting equipment operation. The compressor
movement can be accelerated or slowed down only within the permissible limits.
- When the compressor is transported, the transport straps should be pulled under the machine
and secured above the housing in 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 the compressor frame with cargo straps to appropriate holders on the vehicle platform to
prevent it from sliding or overturning.
- All screw and pipe connections should be of appropriate size and designed for a given operating
pressure.
- The compressor is not designed to operate outdoors; it cannot be exposed to weather
conditions.
- The compressor should be positioned in a closed room, where ambient air is cool and clean.
Never block air flow to and from the room. Ensure sufficient inflow of cooling air and discharge of
hot air outside the room. Temperature in a room with the compressor should be within the
rangeof + 5C to + 40C.
- The air sucked in should contain no vapours or flammable gases, e.g. paint thinners, that might
cause internal fire.
- There can be no objects close to the air inlet that could be sucked in with a jet of air.
- The pressure conduit connecting the compressor with the compressed air line should allow free
expansion due to generated heat. It must not touch hot objects or flammable materials.

The detailed requirements concerning the machine positioning in the compressor room are
described in section 4.1.

Transport of the machine with a forklift.

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.
- It is prohibited to remove the green and yellow protective conductors that prevent electric shock.
- No additional equipment can be mounted on the air receiver(except for the equipment allowed
for use by the manufacturer).
- No welding operations or any other repairs can be performed on the air receiver.
- The plugs and other air receiver accessories can only be removed after the air receiver
depressurisation to the ambient pressure.
- General safety rules should be observed while depressurising the air receiver. Air must be vented
slowly. Keep the air stream away from people.
- Do not allow oil spill around the compressor.
- It is strictly prohibited 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 Manual.
- Fulfil the obligation to register the compressor air receiver in the Office of Technical Inspection
(UDT). Two sets of the required documents of the air tank (if provided) and safety valve are
included with the compressor documentation. The compressor documentation is accompanied
by the set of the required documentation of the air receiver (if applicable) and safety valve.
- Do not remove the temperature sensor (transmitter) or pressure transmitter.

2.3. Other hazards

The compressor installation, switching on/off and maintenance must be carried out by the
qualified personnel who strictly follows the data included in the product technical documentation
and safety rules to avoid any hazards. The risks that could not have been eliminated during the
design stage are described in the table below.

Unit Residual risk Action Precautions

avoid touching, wear

water cooler, frame minor cuts touching
protective gloves
screw assembly, end
danger of avoid touching, wear
cooler, pressure touching
scalds protective gloves
conduits
damage of wire adequate guard for the
metallic parts and insulation upstream power supply lead; check
electric shock
electric wire the motor breaker, the wire insulation for
live metallic parts damages
fire due to shorting use the cross section of the
around the or overheating of the power cord and the
danger of scalds
compressor power cord before protection corresponding to
the electrical box the applicable standards
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

3. Technical data
KOMPBERG ZX75
Type
Overpressure* MPa 1,0
m3/h 587
Max capacity
m3/min 9,78
Weight kg 3700 kg
Dimensions (LxWxH) mm 2800/1600/2000
Compressed air connection G2
0
Ambient temperature C +5 ÷ +40 0C
0 +10 do 15 0C above ambient
Compressed air temperature C
temperature
Noiselevel L** DB(A) 85
Screw air-end type CD8D
Nominal motor power kW 75
Supply voltage 400V/50Hz/3ph
Nominal fan motor power kW 4
Cooling air requirement m3/h 16500
Power lead cross sectional area mm2 3x70+PE
Protection A 160

*) - Capacity measured acc. to EN ISO 1217: 2006 and EN ISO 5167-2.

**) - Noise level acc. to EN ISO 2151.
- Momentary value of acoustic pressure corrected by C characteristic does not exceed 130dB.
- Equivalent acoustic pressure level corrected by A characteristic does not exceed 85 db(A).
4. Setting
4.1. Room requirements

- The compressor requires no foundations. It must be positioned on a hard and even surface. Take
into consideration the floor load capacity, if the machine is installed in a building.
- Strictly observe the minimum distances from walls and other machines. When several
compressors are installed, pay attention to the direction of cooling air flow; no compressor
should suck air which is heated by other machine. Minimum distances from the room walls and
other objects are given in the drawings below.
- Protect the room in which the compressor is installed from negative temperatures. The inlets and
outlets to and from the room should be located in such a manner to protect the interior from
weather conditions.
- Heat generated during compression should be extracted outside (or to other rooms), and fresh
air should be supplied from the outside.
- If the gravity ventilation 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 to 20% higher than the total cooling air requirement for all compressors
installed in the room. The required cooling air volume is specified in the Technical Data section.
- Ambient temperature in the room should be from + 5C to +40C.
- Provide sufficient room for maintenance operations.
- 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.

When there are any problems in ensuring the suitable ventilation in a room, please contact BERG.
4.2. Requirements concerning electrical system

- The compressors are designed to be supplied by a four-conductor 400 V AC, 50 Hz power line.
- The compressors are equipped with PE terminal.

Fuse size
Power lead cross
No. Compressor type NH gL/gG, 500V, 100kA
sectional area
D gL/gG, 500V, 50kA
mm2
KOMPBERG ZX75
1 3x70mm2+PE 160

- The power cable cross sectional area should be matched to the current drawn by the
compressor.
- The compressors can only be operated on three-phase earthed system (TN).
- The compressor must be supplied from the distribution board equipped with a slow blow fuse
and circuit-breaker that enables the compressor power supply to be completely disconnected.
- Electrical connection of the compressor should be performed in accordance with the attached
electrical diagram.
- Only authorised personnel or qualified electrician is allowed to perform 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
and operating conditions.
- Below there are presented the recommended power cable cross sectional areas and fuse sizes
for standard compressors.
- A user takes a full responsibility for selection of an electrical system and power supply connection
for the compressor.

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

Compressed air
outlet
5. Screw compressor operating description
5.1. Screw compressor KOMPBERG ZX75 – operating description

General view of an oil-free screw compressor KOMPBERG ZX75

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
(9). After compression, it reaches an overpressure of up to 1,0 MPa and is forced into the end
cooler (air-water exchanger) (10), and then through the check valve (11) to the compressor outlet.

OIL CIRCUM
The oil is sucked by the pump (13) from the compressor reservoir (13) and is forced to the
overflow valve (16) in which the oil overpressure is limited to 0.25-0.30 MPa 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 manifold (19) or at
temperature exceeding 55 ° C to the oil cooler (20) and then through oil filter (18) to the
manifold (19). The pressure in the manifold is limited to 0.14-0.16 MPa with an overflow valve
(15). The outlets from the oil filter assembly to the oil cooler and inlet from the radiator to the
unit are equipped with electromagnetic shut off valves (21) and (30) which are closed (normally
closed NZ) when in the de-energized condition. These valves are designed to prevent the flow of
oil from the radiator to the installation and further to the oil tank, which avoids the need to
always fill the radiator with oil after the compressor's standstill. In addition, the oil level display in
the sight glass (22) is always reliable (without shut off valves the sight glass would be completely
filled with oil).

From the manifold the oil is distributed to both compression stages ie bearings, seals and coats of
I-stage and II- stage. After passing through the compressor, the oil flows to its reservoir (14).
After the filter, the oil is also fed to the three-way valve (23) and, depending on the compressor
load, flows to the hydraulic cylinder (24) controlling the shutter (25) in the suction controller (3).
In the second position, the oil from the valve (23) flows to the compressor reservoir (14). Also the
oil from the hydraulic cylinder is directed to the compressor tank.
 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 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 Silencer 30 Temperature sensor
13 Oil sight glass 31 Temperature sensor
14 Oil tank 32 Temperature sensor
15 Oil pomp 33 Safety valve
16 Thermostatic valve 34 Pressure sensor
17 Solenoid valve 35 Temperature sensor
18 Oil cooler 36 Pressure sensor
37 Manometer
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),
(34) - pressure transducer - performs measurement of air pressure after the radiator (6),
(38) - temperature sensor - realizes air temperature measurement after the II stage (8),
(37) - temperature sensor - realizes air temperature measurement after the radiator (10),
(36) - pressure transducer - performs the measurement of compressed air pressure after the
cooler, behind the check valve,
(31) - temperature sensor - performs measurement of oil temperature,
(32) - pressure transducer - performs oil pressure measurement.

These sensors and transducers work with the PLC.

WATER CONDENSATE DRAIN

Water in the compressor air system means a very high risk of failure, including the screw air end
failure. This is why the water condensate from the air is carefully drained in the compressor. The
condensate from the separator (7) after the intercooler (6) is drained out of the compressor by
float operated mechanical condensate drain (25).

VENTILATION OF THE SCREW AIR-END INSIDE

During operation of the compressor in the spaces in the interior of its bodies, bearing housings
and seals a small overpressure is produced. This is detrimental to the 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 the
figure it is marked with a symbol (40).

COMPRESSOR COOLING
The compressor is cooled in a forced manner by means of a fan with its own electric drive. The air
is sucked in through the inlets on the front and rear wall of the housing and pushed through a set
of radiators placed on top of the compressor and thrown outside the compressor.

OPERATION OF THE OIL FREE COMPRESSOR

The compressor is started by pressing the START button on the control panel. After the button is
pressed, the compressor drive is activated. The compressor is designed for intermittent run. The
intermittent operation involves air pressurisation until the maximum overpressure set on the
pressure switch is reached.

When this pressure is reached, the compressor switches to idle running (the hydraulic actuator
closes the air supply on the compressor suction side) and then there is a countdown of the time to
stop. If during this time the air pressure decreases, the compressor will start again, and if not, it
will shut down after the countdown. The compressor is restarted when the overpressure in the
piping drops to the minimum value set in the controller.

The compressor can be stopped at any time by pressing the STOP button on the controller panel.
The operation is resumed by pressing the START button.
When the overpressure in the piping on the compressor start exceeds the value set in
the pressure switch, the compressor will start only after the overpressure drops to the minimum
value.
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

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.
- Make sure the power supply voltage is correct and the required protections 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 direction is as indicated on the screw
assemble.
- Check the oil level in the screw block, top it up, if necessary.
- Connect the compressor to the compressed air system with a flexible conduit.
- A compressed air receiver tank is necessary for proper compressor operation (min. 2500l).
- When the compressed air receiver tank is located outside the compressor room, install the
pressure gauge, connected to the tank or pressure conduit supplying the tank, in a visible
location.
- Do not operate the compressor above the maximum operating pressure that is given on the
identification plate. It is not recommended to operate the compressor at the delivery pressure
below 0.5 MPa. Please contact our technicians when it is necessary to set that overpressure.
 - 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
its drop.

Incorrect rotation direction of the screw block rotors for more than 5 seconds will damage
the screw compressor.

Rotating
direction of
CD8D

Proper direction of screw air end rotation

6.2. Restart (after longer downtime)

Follow the procedure described below to start the compressor which has been out of use or
stored for over 3 months:
Check if there is no water in the screw assemble.
Turn the compressor shaft several times by hand in the rotating direction.
check oil level in the screw assembly body, top it up if necessary,

Perform the trial run of the compressor screw block lasting for at least 15 minutes.

During the trial run, check the machine for correct operation, noise, vibration, oil leaks and
tightness of connections in the compressed air system.
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

- All maintenance work should be performed by authorised and trained personnel. Contact
the factory service in case of technical problems.
- Before any maintenance work is started on the compressor, disconnect it from power supply and
protect from unauthorized and accidental starting.
- Check if the supply voltage is lacking.
- Any maintenance and repair work can only be carried out when the compressed air system is
completely unloaded i.e. air pressure in the system is reduced to ambient pressure.
- Before restarting the machine, make sure that there is nobody working on the compressor and
there are no people in the vicinity.
- Use appropriate tools for maintenance and repair work.
- Use only original spare parts.
- For cleaning purposes never use flammable or corrosive solvents that could damage the machine
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 carried out. Do not
allow any parts to get contaminated. Parts and exposed holes should be covered with a clean
cloth, paper or adhesive tape.
- Upon finishing the maintenance work, make sure no tools or other objects are left on or inside
the compressor.
- Before restarting the machine after maintenance, check operating pressures, temperatures, time
settings, and test the switching and control equipment for proper functioning.
- Protect the motor, air filters, electric components, control equipment etc. from penetration of
moisture.
- Do not perform any welding or any other works generating heat close to the oil system.
- Under no circumstances should the noise absorbing material be removed or relocated.

The manufacturer accepts no responsibility for any damage and personal injuries resulting from
failure to observe the present safety rules or from carelessness during operation, work and
maintenance, even in circumstances not expressly mentioned in this Operating and Maintenance
Manual.
In order to ensure fault-free operation of the compressor, observe the following instructions
relating to periodic inspections and maintenance operations.
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),
- check the condition of the elastic coupling,
- clean the air and oil cooler ribs if necessary.

7.2.4 Warranty and post-warranty checks

- change the filter mat at the cooling air inlet,

- change the air filter cartridge,
- check electric clamp terminals, fasten if necessary,
- clean the air and oil cooler ribs,
every 2000 work - test the non-return valve for proper functioning,
hours - check the condition of elastic coupling,
or after 1 year - check the tubing for leaks, mend if any,
- test the pressure switch for proper functioning,
- check the oil temperature indicator,
- check the condition of safety valve,
- check the motor thermal protection setting.
In addition to the activities required after 2000 work hours:
- change the filter mat at the cooling air inlet,
every 8000 work
- change the air filter cartridge,
hours
- change oil filter,
or after 1 year
- change oil,
- inspect the electric system and check it for proper functioning.

During the warranty period, the checks must be performed only by one of the servicing
companies listed in the Warranty Book
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.
- Purging: purge the external surface of the cartridge with dry compressed air, at the
pressure up to 0.5 MPa, askew from the inside and outside.
- Replace the filter cover taking care to position it properly.
- Start the compressor and check for correct operation.

No particles of dirt or dust should get from the suction side into the screw stage.

7.3.2 Cleaning or replacing the filter mats.

Filter mat is placed at the inlet into the housing. If the filter mat get dirty, cooling of the
compressor may be insufficient.
Maintenance operations:
- Carefully, without tools, remove the filter mat from the housing.
- Thoroughly vacuum or flick the mat. In case of heavy dirtiness, the mat can be
washed in water with detergent.
- If it’s impossible to clean the mat or the mat is damaged, it should be completely
replaced.
- Carefully placed the filter mat in the housing.

Filtration mat exchange

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!
- 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 tank. Then screw the filter in by hand,
without using any tool.
- Start the compressor and check for leaks.
7.3.4. Oil level
Sufficient oil level in the oil receiver is of critical importance for trouble-free performance of the
compressor.
Oil check intervals:
- after prolonged compressor off-time,
- every 100 hours.

Procedure:
- check oil level after 1 minute from the compressor stop,
- the oil should be above the middle line of the sight glass (during normal use when the cooler is
full of oil at all times).
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).
- Unscrew the compressor crankcase ventilation hose on the compressor stage body (see Fig. 11).
- Place a suitable container and carefully unscrew the oil drain plug located under the oil reservoir
on the hose.
- Drain the oil from the stage body completely and screw in the drain plug again.
- Pour new oil through the filler neck to the max.level Close the bleeder hose.
- Switch on the screw compressor and leave it working for approx. three minutes (the oil cooler
should be completely full).
- Check the oil level: top up with the missing amount of oil up to max.
- Used oil should be disposed of in accordance with applicable regulations.

Oil dedicated for oil free screw compressors has been used.
oil cap

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

Kinematic viscosity at 40C 41,4-50,6

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).

7.3.6. Handling wastes produced while operating the compressor

The condensate (condensed water from the compressor, tank or compressed air purification
equipment) may not be drained directly to sewer. It should be disposed of according to the valid
legislation on handling wastes; waste code 12 01 09.
Used oil should be disposed of according to the valid legislation on handling wastes; waste code 13 02
05.
Oil filters and oil filter cartridges 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 regular radiator cleaning. The cooling ribs of the radiator
should be kept clean. Only in this way is full cooling possible. Sufficient cooling means lower oil
temperature and thus longer durability. It is advisable to clean the radiator fins with compressed air, a
steam jet or a detergent solution. If this method of cleaning does not cause a decrease in the working
temperature, the elements of the radiator through which the oil flows should be cleaned inside from the
carbon deposit (nagar) using available means for removing carbon deposits (nagar). To do this, the
radiator should be removed. In case of strong contamination of the intake air (cooling air) it is necessary
to more frequently clean the radiator, especially when the temperature at the compressor outlet is
more than approx. 10 to 150C above ambient temperature.
 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.

7.3.8. . Electric motor

When the compressor is running, check the motor operation by paying attention to the following:
- Operating noise,
- Excessive vibration,
- Excessive current consumption – protection activation in the electrical cabinet,
- The condition of the fixing screws,
- A degree of fouling.
The motor (compressor) should be stopped immediately in case of:
- Overheating,
- Smoke or burningsmell,
- Excessive vibration,
- Bearing noise.

The machine can be 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 personnel or properly qualified personnel
from specialized companies.
Any repairs or special inspections should be performed by the specialised workshop or the
manufacturer service.

Replacement or lubrication of the motor bearings must be performed in accordance with the
manufacturer’s recommendations. The permissible hours of the bearing operation to the
replacement or lubrication are presented in the table below. When any symptoms indicating the
bearing damage occur (unusual noise or increased temperatures), contact the service
immediately.

Hours of operation until the performance of service operations

Motor power Bearing type Hours of operation Operations
3-22 kW Maintenance-free 40000 h Replacement
30-55 kW Maintenance-free 20000 h Replacement
75-90 kW Requiring maintenance 4000 h Lubrication
110-200 kW Requiring maintenance 3000 h Lubrication

7.3.9 Safety valve

The safety valves fulfil an important function in pressure equipment and systems. They require
particularly careful and professional service. Any operational shortcomings may damage the
 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,
- Periodic inspections of the valve for correct operation according to the requirements of the office
of technical inspection regulations.

The safety valve operation inspection involves blowing the valve by pulling the handle (wheel)
upwards. The pin, lifted by pulling the wheel up, releases the pressure of the valve spring and
moves the head a little up and allows the compressed air to flow through the valve.
The handle can be loosened at the pressure equal at least 50% of the operating pressure.

The valves 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. Keep away from the stream of air blown out (caution – the air may be
hot!).
In case of the valve leaks, contact the manufacturer service to arrange its repair. The valve
cannot be repaired by the user itself.
Blocking the pin, tightening the adjustment nut or covering the valve outlets is not allowed.
In addition to the guidelines and requirements listed in this paragraph, the user is obliged to
observe the regulations being in force in the country in which the equipment is operated.

The safety valves are intended only for protection of: pressure tanks, conduits for
compressed air or other neutral gases, sources of compressed air from overpressure
(above the limit for that type of equipment).
The safety valves may not be used as relief valves for pressure adjustment.

8. Troubleshooting

Symptom Cause Remedy

the compressor power failure check for supply voltage in the power supply
will not start terminals
 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 > 40°C
compressor does
not start contaminated cooler clean the cooler (exchanger)
operating pressure above adjust the pressure switch or enter correct
the set value settings in the controller
oil level too low top oil up as required

oil thermostat malfunction replace the entire thermostat or its cartridge

lack of cooling water provide water to compressor
damaged temperature replace with a new one
transducer
other causes call service
forcing pressure wrong pressure switch or adjust the pressure switch or enter correct
too low microprocessor controller settings in the controller
setting
insufficient compressor install additional source of compressed air
capacity in relation to air
requirement
leak in the system check the tubing for leaks, remove leaks if any

air filter contaminated change air filter cartridge (during the warranty
period to be replaced obligatorily by the
service staff only)
damaged pressure replace with a new one
transducer
damaged suction regulator call the service staff
activation of ambient temperature too improve room ventilation
motor protection high
failure of one phase in motor check motor leads, contactor and protection
power supply
supply voltage too low ensure correct supply voltage

discharge pressure higher adjust the correct settings in the controller

than specified on the
nameplate
 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
9. Consumables for one year guarantee

No. Name Part number 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 BÖ 480001 1
4. Coupling insert BS 480165 1
5. Oil Öl 480069* 40 l
6. Thermostat cartridge BS 488580 1
* package of 10 L

10. Electrical scheme