Atlas Copco ORV 10, Instruction Manual

Page 1: ...ORV 10 ORV 12 ORX 10 ORX 12 Instruction Manual for Portable Compressors English ...

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Page 3: ...Instruction Manual for Portable Compressors ORV 10 ORV 12 ORX 10 ORX 12 Printed matter N 2954 3350 00 11 2007 ATLAS COPCO PORTABLE AIR DIVISION www atlascopco com ...

Page 4: ...g for modifications additions or conversions made without the manufacturer s approval in writing While every effort has been made to ensure that the information in this manual is correct Atlas Copco does not assume responsibility for possible errors Copyright 2007 Atlas Copco Airpower n v Antwerp Belgium Any unauthorized use or copying of the contents or any part thereof is prohibited This applies...

Page 5: ...Safety precautions 5 1 1 Introduction 5 1 2 General safety precautions 5 1 3 Safety during transport and installation 6 1 4 Safety during use and operation 6 1 5 Safety during maintenance and repair 7 1 6 Tool applications safety 7 1 7 Specific safety precautions 7 2 Leading particulars 9 2 1 Description of safety pictograms used in this manual 9 2 2 General description 9 2 3 Main Parts 10 2 4 Con...

Page 6: ... 6 Start preventing pressure switch and minimum loading pressure switch 24 6 Options 24 6 1 Oiltronix 24 7 Problem solving 25 8 Technical specifications 28 8 1 Readings on gauges 28 8 2 Settings of switches and safety valve 28 8 3 AML Data OEM ORV 10 29 8 4 AML Data OEM ORV 12 31 8 5 AML Data OEM ORX 10 33 8 6 AML Data OEM ORX 12 35 8 7 Conversion list of SI units into British units 37 9 Data plat...

Page 7: ...tances endanger the machinery due to function failures All responsibility for any damage or injury resulting from neglecting these precautions or by non observance of ordinary caution and due care required in handling operating maintenance or repair also if not expressly mentioned in this instruction manual is disclaimed by Atlas Copco The manufacturer does not accept any liability for any damage ...

Page 8: ...d sand blasting or compressed air system Observe the right mounting position direction 9 Before removing the oil filler plug ensure that the pressure is released by opening an air outlet valve 10 Never spill nor leave oil or cleansing agent in or around the unit 11 All doors shall be shut during operation so as not to disturb the cooling air flow inside the bodywork and or render the silencing les...

Page 9: ...ng heat flames or sparks on a machine the surrounding components shall first be screened with non flammable material 15 Never use a light source with open flame for inspecting the interior of a machine 16 Disconnect battery clamp before starting electrical servicing or welding evt turn battery switch in off position 17 When repair has been completed the machine shall be barred over at least one re...

Page 10: ...e of the safety valve be altered to a different pressure than that stamped on the valve without the permission of the installation designer If the set pressure must be altered then use only correct parts supplied by Seetru and in accordance with the instructions available for the valve type Safety valves must be frequently tested and regularly maintained The set pressure should be periodically che...

Page 11: ...r receiver pressure will decrease and vice versa This receiver pressure variation is sensed by the regulating valve which by means of control air to the unloader matches the air output to the air consumption The air receiver pressure is maintained between the pre selected working pressure and the corresponding unloading pressure Cooling system The compressor is provided with an oil cooler The cool...

Page 12: ... Oil filter OSV Oil stop valve OV Overpressure valve PG1 Interstage pressure gauge PG2 Working pressure gauge RV Regulating valve SDL Service door lock 4 on each side panel SP Detachable side panel TG1 Temperature gauge LP compressor element TG2 Temperature gauge HP compressor element VIS Vacuum indicator switch AI Air inlet air receiver AO Air outlet air receiver AR Air receiver FP Filler plug co...

Page 13: ...Opens when the unit is started Closes when the unit is stopped to prevent the compressor element from flooding with oil Flow restrictor FR Manages the oil flow from the air receiver oil separator AR OS to the compressor element to minimize the leaking of air to the compressor element Thermostatic by pass valve TBV Opens when oil temperature is above 70 C Oil then flows through the oil cooler OC Ov...

Page 14: ...l cooler OF Oil filter OLG Oil level gauge OS Oil separator OSV Oil stop valve OV Overpressure valve PM Prime mover PS1 Maximum loading pressure switch PS2 Minimum loading pressure switch RV Regulating valve SL Scavenge line SV Safety valve TBV Thermostatic by pass valve TG1 Temperature gauge LP compressor element TG2 Temperature gauge HP compressor element TS1 Temperature switch LP compressor ele...

Page 15: ... compressor is stopped 2 6 OIL SYSTEM SEE FIG 2 3 The lower part of the air receiver AR serves as oil tank Air pressure forces the oil from the air receiver oil separator AR OS through the oil filters OF and oil stop valve OSV to the compressor element The thermostatic by pass valve TBV opens when the oil temperature is above 70 C Then the oil flows through the oil cooler OC before it is filtered ...

Page 16: ...ller plug oil compressor element FR Flow restrictor LV Loading valve MPV Minimum pressure valve OC Oil cooler OF Oil filter OLG Oil level gauge OSE Oil separator element OSV Oil stop valve PS Pressure sensor RV Regulating valve SC Safety cartridge SL Scavenge line SV Safety valve TBV Thermostatic By Pass valve TG Temperature gauge TS Temperature sensor UA Unloader assembly WPG Working pressure gau...

Page 17: ...ir and pressure builds up in the receiver The throttle valve is closed The air output is controlled from maximum output 100 to no output 0 by air inlet throttling If the air consumption is equal to or exceeds the maximum air output the throttle valve is fully open If the air consumption is less than the maximum air output the regulating valve supplies control air to the throttle valve to reduce th...

Page 18: ...nal H40 Lamp Ready To Start Indicator S60 Switch Engine Start Signal H50 Lamp Engine Shutdown Indicator Override Indicator S70 Switch Override Switch H60 Lamp Oiltronix Failure Indicator Option S80 Switch Draining Acknowledged Option H70 Lamp Oiltronix Warning Indicator Option TS10 Temperature Switch H80 Lamp Oiltronix Draining Indicator Option X1 Connector K10 Relay Starter Motor Activation Y10 S...

Page 19: ...um Switch Airfilter Warning 11 Oiltronix Failure Signal Option TS1 Temperature Switch LP Element Temperature Shutdown 12 Oiltronix Warning Signal Option TS2 Temperature Switch HP Element Temperature Shutdown 13 Oiltronix Draining Signal Option X1 Connector 14 Not used Y1 Loading Valve 15 Oiltronix Test Input Option 16 Oiltronix Draining Acknowledged Input Option 12 24VDC 24 24 30 87a 28 33 34 36 3...

Page 20: ...at Electrocution hazard Atlas Copco synthetic compressor oil Atlas Copco synthetic compressor oil Manual Reset fuse Prohibition to open air valves without connected hoses Compressor loaded Airfilter Compressor temperature too high Rotation direction Inlet Outlet Compressor oil drain Read the instruction manual before starting Service every 24 hours Warning Part under pressure ...

Page 21: ...smoothly energize the loading solenoid valve Fig 2 3 LV by pressing the loading push button 2 As soon as the unloading pressure registers on working pressure gauge the unit runs unloaded 3 Open the outlet valve s Fig 2 3 AOV 3 5 DURING OPERATION Regularly carry out following checks 1 If the vacuum indicator switch Fig 2 3 VIS gives a warning signal stop the unit and service the air filters Fig 2 3...

Page 22: ...very 1000 hours Compressor oil level Check Check Check Interstage pressure Check Check Check Air filter dust traps Empty Empty Empty Air filter elements 1 Replace Oil cooler Clean Clean Air filter vacuum indicator switch Test Temperature shutdown switches Test Minimum loading pressure switch Test Start preventing pressure switch Test Temperature shutdown switches Test Compressor oil filters Replac...

Page 23: ...iller plug to speed up draining Tighten the plugs after draining Close the air receiver drain valve 3 Remove the oil filters 1 e g by means of a special tool Catch the oil in a drain pan 4 Clean the filter seats on the manifold taking care that no dirt drops into the system Oil the gaskets of the new filter elements Screw the elements into place until the gaskets contact their seats then tighten o...

Page 24: ...e same time which improves the uptime of the unit The order numbers of the Service Kits are listed in the Atlas Copco Parts List ASL 4 8 COMPRESSOR ELEMENT OVERHAUL When a compressor element is due for overhaul it is recommended to have it done by Atlas Copco This guarantees the use of genuine parts and correct tools with care and precision 4 9 LIABILITY The manufacturer does not accept any liabil...

Page 25: ...ns apply to one air filter and should be repeated for both air filters of the compressor 1 Release the snap clips 1 and remove the dust trap cover 2 Clean the inside of the cover 2 Withdraw the filter element 4 and the safety cartridge 3 from the housing 5 Discard the filter element when damaged A dirty safety cartridge 3 is an indication of a malfunctioning filter element 3 Reassemble in reverse ...

Page 26: ...and remove the switch with its coupling from the air intake manifold 2 Fit the switch to a tee with a female leg of M10x1 5 Connect a vacuum gauge and a hose or pipe to the other legs 3 Connect an ohmmeter or a test lamp with battery to the switch 4 Create a vacuum with the mouth through the hose while observing the vacuum gauge and the ohmmeter or test lamp The lamp should light up when the vacuu...

Page 27: ... a Membrane of regulating valve RV cracked b Air intake throttle valve TV stuck in closed position c Loading solenoid valve LV defective a If air blows from venting device remove and dismantle regulating valve Replace membrane b See corrective action 1b c Check loading solenoid valve correct or replace if necessary 3 Excessive compressor oil consumption Oil mist being discharged from air outlet va...

Page 28: ...rises above maximum and causes safety valve SV to blow a Regulating valve RV opens too late or its ball valve spring is broken b Air leaks in regulating system c Air intake throttle valve TV does not close for some reason d Minimum pressure valve MPV malfunctioning e Bleed off valve BOV malfunctioning a Adjust regulating valve Dismantle and inspect parts if valve does not respond Replace where nec...

Page 29: ...emove and inspect oil stop valve Replace if necessary i Replace oil separator element j Remove and inspect by pass valve Replace if necessary k Consult Atlas Copco l Consult Atlas Copco 8 Interstage pressure below normal a Choked air filter elements b Leak between LP and HP compressor elements c LP compressor element CEL not in order a Clean or renew air filter elements b Remove interconnecting pi...

Page 30: ...30 C 8 2 SETTINGS OF SWITCHES AND SAFETY VALVE Switch Makes at Breaks at Shutdown switch LP compressor element air outlet temperature TS1 adjustable up to 1 130 C HP compressor element air outlet temperature TS2 adjustable up to 1 130 C Alarm switch Air filter vacuum indicator switch VIS 50 mbar Start preventing pressure switch 0 5 0 4 1 5 0 3 bar e Safety valve SV Opening pressure 30 bar e ORV 34...

Page 31: ...e male rotor speed 2000 rpm 2000 rpm 4 Maximum allowable male rotor speed 4000 rpm 4000 rpm Performance data 1 2 1 Free air delivery 3 see diagram 2 Shaft input at reference conditions 3 see diagram 3 Compressed air temperature at minimum pressure valve approx 100 C 212 F Design data Compressor 1 Number of compression stages 2 2 2 Gear ratio s 1 569 1 569 1 723 1 723 1 844 1 844 2 195 2 195 2 474 ...

Page 32: ...tional standards British BSI 1571 part 1 German DIN 1945 Part 1 Swedish SS ISO 1217 American ANSI PTC9 3 Effect on environmental conditions Power derates with approximately 6 3 kW 8 4 BHP per 1000 m 3281 ft above sealevel at 2000 MRS derates with approximately 16 3 kW 21 8 BHP per 1000 m 3281 ft above sealevel at 4000 MRS derates with 1 per 10 C 20 F above 20 C 68 F Free air delivery derates with ...

Page 33: ...le male rotor speed 2000 rpm 2000 rpm 4 Maximum allowable male rotor speed 4000 rpm 4000 rpm Performance data 1 2 1 Free air delivery 3 see diagram 2 Shaft input at reference conditions 3 see diagram 3 Compressed air temperature at minimum pressure valve approx 100 C 212 F Design data Compressor 1 Number of compression stages 2 2 2 Gear ratio s 1 569 1 569 1 723 1 723 1 844 1 844 2 195 2 195 2 474...

Page 34: ...andard ISO 1217 corresponds to following national standards British BSI 1571 part 1 German DIN 1945 Part 1 Swedish SS ISO 1217 American ANSI PTC9 3 Effect on environmental conditions Power derates with 4 per 1000 m 3281 ft above sealevel derates with 1 per 10 C 20 F above 20 C 68 F Free air delivery derates with approximately 1 5 l s 3 2 cfm per 1000 m 3281 ft at 15 bar 217 psi eff working pressur...

Page 35: ...le male rotor speed 2000 rpm 2000 rpm 4 Maximum allowable male rotor speed 4000 rpm 4000 rpm Performance data 1 2 1 Free air delivery 3 see diagram 2 Shaft input at reference conditions 3 see diagram 3 Compressed air temperature at minimum pressure valve approx 100 C 212 F Design data Compressor 1 Number of compression stages 2 2 2 Gear ratio s 1 569 1 569 1 723 1 723 1 844 1 844 2 195 2 195 2 474...

Page 36: ...nternational standard ISO 1217 corresponds to following national standards British BSI 1571 part 1 German DIN 1945 Part 1 Swedish SS ISO 1217 American ANSI PTC9 3 Effect on environmental conditions Power derates with 4 per 1000 m 3281 ft above sealevel derates with 1 per 10 C 20 F above 20 C 68 F Free air delivery derates with approximately 1 5 l s 3 2 cfm per 1000 m 3281 ft at 15 bar 217 psi eff ...

Page 37: ... male rotor speed 2000 rpm 2000 rpm 4 Maximum allowable male rotor speed 4000 rpm 4000 rpm Performance data 1 2 1 Free air delivery 3 see diagram 2 Shaft input at reference conditions 3 see diagram 3 Compressed air temperature at minimum pressure valve approx 100 C 212 F Design data Compressor 1 Number of compression stages 2 2 2 Gear ratio s 1 569 1 569 1 723 1 723 1 844 1 844 2 195 2 195 2 474 2...

Page 38: ...dard ISO 1217 corresponds to following national standards British BSI 1571 part 1 German DIN 1945 Part 1 Swedish SS ISO 1217 American ANSI PTC9 3 Effect on environmental conditions Power derates with 4 per 1000 m 3281 ft above sealevel derates with 1 per 10 C 20 F above 20 C 68 F Free air delivery derates with approximately 1 5 l s 3 2 cfm per 1000 m 3281 ft at 15 bar 217 psi eff working pressure ...

Page 39: ...0 401 in wc 1 N 0 225 lbf 1 Nm 0 738 lbf ft t F 32 1 8 x t C t C t F 32 1 8 A difference of 1 C a difference of 1 8 F 9 DATA PLATE 1 Company code 2 Product code 3 Unit serial number 4 Name of manufacturer 5 EEC or national type approval number 6 Vehicle identification number 7 Weight of unit 8 Model 9 Working pressure 10 Speed 11 Engine power 12 Manufacturing year 13 CE mark in accordance with Mac...

Page 40: ...r ORX 10 4 PARTS SUBJECTED TO CAT I AND COVERED BY THE MACHINE DIRECTIVE 89 392 EC All other parts 10 5 PARTS SUBJECTED TO ART I PARAGRAPH 3 3 All other parts ORV 10 ORV 12 ORX 10 ORX 12 Set pressure bar e 30 34 Design temperature C 130 130 Standard Cold start equipment Design pressure bar e 30 30 Design temperature max C 130 130 Design temperature min C 10 25 Volume l 143 143 Standard Cold start ...

Page 41: ...of the materials for recycling in the future is forseen Note 11 2 DISPOSAL OF MATERIALS Dispose contaminated substances and material separately according to local applicable environmental legislations Before dismantling a machine at the end of its operating lifetime drain all fluids and dispose of according the applicable local disposal regulations Remove the batteries Do not throw batteries into ...

Page 42: ...40 ORV 10 ORV 12 ORX 10 ORX 12 MAINTENANCE LOG Compressor Customer Serial number Service hours Maintenance action Date By initials ...

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Page 44: ...Printed in Belgium 11 2007 2954 3350 00 ...