Atlas Copco SF 1, Instruction Book

Page 1: ...Atlas Copco Oil free scroll compressors SF 1 SF 2 SF 4 SF 6 Instruction book ...

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Page 3: ...ents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2015 11 No 2920 7110 11 Replaces No 2920 7110 10 www atlascopc...

Page 4: ... description 9 2 1 INTRODUCTION 9 2 2 FLOW DIAGRAM 14 2 3 REFRIGERANT DRYER 16 3 Installation 18 3 1 DIMENSION DRAWINGS 18 3 2 INSTALLATION PROPOSAL 19 3 3 ELECTRICAL CONNECTIONS 21 3 4 PICTOGRAPHS 22 4 Operation 23 4 1 INITIAL START UP 23 4 2 STARTING 24 4 3 DURING OPERATION 25 4 4 STOPPING 25 4 5 TAKING OUT OF OPERATION 26 5 Preventive maintenance 27 5 1 PREVENTIVE MAINTENANCE SCHEDULE 27 5 2 SE...

Page 5: ...F THE OUTLET PIPE 36 6 10 REFRIGERANT DRYER MAINTENANCE 37 7 Problem solving 39 8 Technical data 41 8 1 READINGS ON CONTROL PANEL 41 8 2 ELECTRIC CABLE SIZE 41 8 3 SETTINGS FOR OVERLOAD RELAY AND FUSES 42 8 4 TEMPERATURE PROTECTION AND SAFETY VALVE SETTINGS 43 8 5 REFERENCE CONDITIONS AND LIMITATIONS 43 8 6 COMPRESSOR DATA 44 9 Instructions for use 46 10 Guidelines for inspection 47 11 Pressure eq...

Page 6: ...th local legislation and standards 5 Before any maintenance repair work adjustment or any other non routine checks stop the compressor press the emergency stop button switch off the voltage and depressurize the compressor In addition the power isolating switch must be opened and locked 6 Never play with compressed air Do not apply the air to your skin or direct an air stream at people Never use th...

Page 7: ... so that loose clothing worn by people cannot be sucked in 7 Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials 8 No external force may be exerted on the air outlet valve The connected pipe must be free of strain 9 If remote control is installed the machine must bear a clea...

Page 8: ...ions When blowing through a hose or air line ensure that the open end is held securely A free end will whip and may cause injury Make sure that a hose is fully depressurized before disconnecting it 3 Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine To this end a suitable notice shall be affixed to th...

Page 9: ...ntenance and repair work 3 Use only genuine spare parts 4 All maintenance work shall only be undertaken when the machine has cooled down 5 A warning sign bearing a legend such as Work in progress do not start shall be attached to the starting equipment 6 Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machi...

Page 10: ...rial from the manufacturer to prevent the sound pressure level from increasing 19 Never use caustic solvents which can damage materials of the air net e g polycarbonate bowls 20 The following safety precautions are stressed when handling refrigerant Never inhale refrigerant vapours Check that the working area is adequately ventilated if required use breathing protection Always wear special gloves ...

Page 11: ...consists of a module with three 10 l 2 64 US gal receivers The 30 l receiver option includes an electronic drain Electronic drain on the air receiver on the receiver mounted version 270 l and 500 l Water separator on the outlet on floor mounted compressors without refrigerant dryer Prefilter mats on the air inlet Phase sequence relay on 3 phase units SF Pack The control panel comprises a pressure ...

Page 12: ...SF 6 P floor mounted general view Gp Pressure gauge Q1 H1 On off switch with lamp P1 Hour meter AV Outlet valve SF 6 P on a 270 l receiver general view Instruction book 10 2920 7110 11 ...

Page 13: ... Q1 H1 On off switch with lamp P1 Hour meter AV Air outlet valve Dm Manual drain valve SF 6 P with integrated air receivers 3 x 10 l general view R 3 x 10 l receiver AV Air outlet valve Instruction book 2920 7110 11 11 ...

Page 14: ... The compressor is controlled by a pressure switch The electric components are located in the cubicle behind the front panel door A check valve CV prevents loss of compressed air when the compressor is stopped A temperature switch and a safety valve SV protect the compressor element against overheating and too high pressure respectively The compressed air is cooled by an air cooler Ca before it en...

Page 15: ...ral view Gp Pressure gauge Q1 H1 On off switch with lamp P1 Hour meter AV Air outlet valve Dm Manual drain valve Da Automatic drain outlet Gd Dew point gauge ID Refrigerant dryer SF 6 FF details Instruction book 2920 7110 11 13 ...

Page 16: ...V Air outlet valve Ca Air cooler E Compressor element M Motor CV Check valve SV Safety valve Dm Manual drain valve ID Refrigerant dryer TSHH Temperature switch 2 2 Flow diagram Flow diagram Instruction book 14 2920 7110 11 ...

Page 17: ... vapor condensates by cooling down The water is removed via the integrated water separator 201c and the electronic drain 210 For details on the operation of the ID dryer see section Refrigerant dryer Cooling The compressor element 101 is cooled by an integrated radial fan 102 An axial fan 107 fitted on the motor shaft provides cooling air for the air cooler 106 On compressors with integrated refri...

Page 18: ...atic drain Compressed air circuit Compressed air enters heat exchanger 1 and is cooled by the outgoing cold dried air Water in the incoming air starts to condense The air then flows through the evaporator heat exchanger 2 where the refrigerant evaporates causing the compressed air to be cooled further to close to the evaporating temperature of the refrigerant More water in the air condenses The co...

Page 19: ...tion Fan control switch P therefore stops and starts the condenser cooling fan If under partial or no load the evaporator 2 pressure drops to approximately 2 25 bar e 32 63 psig the hot gas bypass valve 5 opens and hot high pressure gas is fed to the evaporator circuit to prevent the evaporator pressure from dropping any further Electronic condensate drain The dryer is equipped with an electronic ...

Page 20: ...Electro pneumatic control CD With CD dryer EL With Elektronikon controller Hereby a list of commonly used terms with their translation Text on drawings Translation or Explanation COOLING AIR OUTLET Cooling air outlet COMPRESSED AIR OUTLET Compressed air outlet COOLING AIR INLET Cooling air inlet POWER SUPPLY CABLE Power supply cable DRYER MANUAL DRAIN Manual drain valve of the dryer AUTOMATIC DRAI...

Page 21: ...NIT Dimensions of the Full Feature units are indicated between 3 2 Installation proposal 1 Dryer service panel 5 Condensate drain 2 Service panel 6 Manual drain 3 Supply cable 7 Automatic drain 4 Minimum area to be reserved for servicing purposes Instruction book 2920 7110 11 19 ...

Page 22: ... the compressor room temperature can be calculated from Qv 1 06 N Δt for compressors without integrated dryer Qv 1 06 N 0 2 Δt for compressors with integrated dryer with Qv required ventilation capacity in m3 s N shaft input of the compressor in kW Δt temperature increase in the compressor room in C 4 Air receiver an optional air receiver can be necessary to limit the cycle frequency Recommended m...

Page 23: ...or the section of the power supply cable An electric cable is provided on the unit Fit a suitable plug on the cable Plug in the cable Three voltage units The compressors leave the factory wired for 230 V If the compressor is to be used on 460 V rewire the motor as follows 1 Take all necessary precautions 2 Change the connection in the motor terminal box according following instructions For SF 2 SF...

Page 24: ...oltage is on the unit can start and stop automatically 3 Warning rotating fan 4 Warning supply voltage 5 Warning hot surface 6 Do not adjust the pressure switch while it is depressurized because this can damage the switch only for compressors controlled by a pressure switch 7 Warning rotating fan Warning safety valve blowing 8 Warning rotating fan Warning belts 9 Warning before connecting compress...

Page 25: ...valve AV see section Introduction 3 Check the settings of overload relay F21 see section Settings of overload relay and fuses Check the drive motor connections Connect the compressor to the electricity net 4 Close the condensate drain valve s See sections Introduction and Flow diagram for their location 5 Switch on the voltage Lamp H1 alights Start the compressor and stop it immediately by means o...

Page 26: ... controller A compressor equipped with a phase sequence relay will not start if the phase sequence is wrong In that case reverse two incoming electric lines to solve the issue 4 2 Starting Control panel Gp Pressure gauge Q1 H1 On off switch with lamp P1 Hour meter Gd Dew point gauge Procedure 1 Close the manual condensate drain valve s if present 2 Open the air outlet valve AV Instruction book 24 ...

Page 27: ... the manual drain valve from time to time to remove eventual impurities see also section Preventive Maintenance schedule 3 On receiver mounted compressors open the manual drain valve of the air receiver regularly to remove the water specially in case of compressors without dryer See also section Preventive Maintenance schedule The dew point will deviate from nominal when the nominal conditions are...

Page 28: ... On compressors with refrigerant dryer and on compressors with an air receiver open the manual drain valve s Dm Dm1 4 If provided shut off and depressurize the part of the air net which is connected to the outlet valve Disconnect the compressor from the air net 5 If provided disconnect the compressor condensate piping from the local condensate drain system Instruction book 26 2920 7110 11 ...

Page 29: ... environmental and working conditions of the compressor The longer interval checks and actions must also include the shorter interval checks Preventive maintenance schedule Period note 1 Running hours note 1 Operation Daily Check readings on the display Compressors with integrated air receiver and or compressors with integrated refrigerant dryer Check if condensate is discharged regularly Receiver...

Page 30: ...t and element cooling fins see note 2 Have orbiting scroll bearing and pin crank bearings greased see note 3 Replace tip seals and dust seal see also note 4 Every 4 years 10000 8 bar and 116 psi compressors Replace the element outlet pipe and the plastic insert See section Outlet pipe replacement Only on SF 1 SF 2 and SF 4 Clean fan FN1 see Flow diagram fan duct and element cooling fins see note 2...

Page 31: ...any other used material e g desiccant lubricants cleaning rags machine parts etc must be disposed of in an environmentally friendly and safe manner and in line with the local recommendations and environmental legislation Electronic components are subject to the EU Directive 2012 19 EC for Waste Electrical and Electronic Equipment WEEE As such these parts must not be disposed of at a municipal wast...

Page 32: ...he switch Adjustments may only be carried out when the switch is pressurized Pressure switch The stopping pressure is controlled by adjusting screw 2 Turn the screw clockwise to raise the stopping pressure anti clockwise to lower it The pressure difference between starting and stopping is adjusted by means of adjusting screw 1 Turn the screw anti clockwise to reduce the pressure difference clockwi...

Page 33: ... bar 116 psi units the pressure switch is factory adjusted to start the compressor at 6 5 bar e 94 psig and to stop at 7 75 bar e 112 psig 10 bar 145 psi units the pressure switch is factory adjusted to start the compressor at 8 bar e 116 psig and to stop at 9 75 bar e 141 psig 6 2 Air filter Air filter AF Instruction book 2920 7110 11 31 ...

Page 34: ...The motor bearings are greased for life and do not require special attention Keep the motor free from dust for optimal cooling 6 5 Safety valve Testing Testing shall only be carried out by competent personnel 1 Stop the compressor close the air outlet valve and switch off the voltage 2 Depressurize the compressor 3 Remove the safety valve See section Introduction for the location of the safety val...

Page 35: ...t be replaced as a set even if only one of them seems worn Use Atlas Copco belts only The number of the belt set is mentioned in the Parts list 1 Remove the service panel S 2 Loosen screw A 3 Remove the front panel 4 Remove the inlet baffle I Instruction book 2920 7110 11 33 ...

Page 36: ... new belt s in the pulley grooves 9 Set the tension of the belt s by screwing bolt C out Refer to the label on the motor plate for tensioning data 10 Tighten screws B Reinstall the inlet baffle 11 Check the belt tension after the first 500 running hours Instruction book 34 2920 7110 11 ...

Page 37: ...ment Compressor element cooling channels can be hot when the compressor has just been turned off Do not clean the cooling channels with organic solvent since this will damage the surface treatment The purpose of cleaning the cooling channels of a scroll element is to prevent the cooling channels to silt up and as such reduce the cooling efficiency A reduced cooling efficiency can lead towards a pr...

Page 38: ...he compressed air the plastic insert can become brittle after time It is recommended to replace the outlet pipe together with the insert when that is the case Both parts are available as a kit outlet pipe set Consult the Spare Parts List for part number The outlet pipe set contains two parts The plastic insert 3 The metal outlet pipe 1 Replacement procedure 1 Stop the compressor depressurize and s...

Page 39: ...ant dryer maintenance Safety precautions The dryer circuit contains refrigerant When handling refrigerant all applicable Safety precautions during maintenance or repair must be observed Specifically be aware of following points Contact of liquid refrigerant with the skin can cause freezing Wear special gloves If contacted with the skin the skin should be rinsed with water On no account may clothin...

Page 40: ...c condensate drain regularly a Functioning of the drain can be checked by pushing the TEST button of the drain consult section Air dryer b Cleaning of the drain filter can be done by opening the manual drain valve during a few seconds Device settings The regulating and safety devices are factory adjusted to obtain optimum performance of the dryer Do not alter the setting of any of the devices Conn...

Page 41: ...ns too late or not at all Readjust switch replace if necessary Safety valve SV opens too soon Have valve replaced Pressure difference between stopping and starting cannot be adjusted Air pressure switch PS out of order Replace if necessary Compressor capacity or pressure below normal Air consumption exceeds capacity of compressor Check equipment connected Choked air filter Remove and check filter ...

Page 42: ...nser Motor of refrigerant compressor stops or does not start The internal thermal protection of the motor has tripped Compressor will restart when the motor windings have cooled down Electric power supply to refrigerant compressor interrupted Check and correct as necessary Evaporator pressure is too high or too low Condenser pressure too high or too low See above Shortage of refrigerant Have circu...

Page 43: ...unning time Q1 H1 On off switch with lamp 8 2 Electric cable size Attention Local regulations remain applicable if they are stricter than the values proposed below The voltage drop must not exceed 5 of the nominal voltage It may be necessary to use cables of a larger size than those stated to comply with this requirement Cable size SF 1 SF 2 SF 4 SF 6 Frequency Voltage Cable size Cable size Cable ...

Page 44: ...C gL gG Fuse specifications CSA HRC Form II UL Class 5 Settings SF 1 SF 1 SF 2 SF 2 Frequency Voltage Overload relay Maximum fuse Overload relay Maximum fuse IEC 50 Hz 230 V 1 12 6 A 25 A 16 2 A 25 A 230 V 3 9 7 A 40 A 400 V 3 5 6 A 10 A 400 V N 3 5 6 A 10 A 60 Hz 380 V 3 5 8 A 10 A UL CUL 60 Hz 200 V 3 10 1 A 15 15 20 A 230 V 1 10 6A 15 15 20 A 16 3 A 25 25 30 A 230 V 3 9 1 A 15 15 15 A 460 V 3 4...

Page 45: ...lass K5 for units without refrigerant dryer and according Class K5 for units with refrigerant dryer respectively 8 4 Temperature protection and safety valve settings Temperature shut down switch settings TSHH Compressor element outlet temperature Opens at SF 1 8 bar 116 psi 70 C 158 F SF 1 10 bar 145 psi 80 C 176 F SF 2 8 bar and 10 bar 116 and 145 psi 70 C 158 F SF 4 8 bar and 10 bar 116 and 145 ...

Page 46: ...si g 116 145 116 145 Maximum working pressure Full Feature bar e 7 75 9 75 7 75 9 75 Maximum working pressure Full Feature psi g 112 141 112 141 Reference working pressure bar e 7 10 7 10 Reference working pressure psi g 100 145 100 145 Air temperature at outlet valve SF Pack approx C 25 25 25 25 Air temperature at outlet valve SF Pack approx F 77 77 77 77 Air temperature at outlet valve SF FF app...

Page 47: ...temperature at outlet valve SF Pack approx C 32 32 35 35 Air temperature at outlet valve SF Pack approx F 90 90 95 95 Air temperature at outlet valve SF FF approx C 21 21 22 22 Air temperature at outlet valve SF FF approx F 70 70 72 72 Motor shaft speed 50 Hz r min 2900 2900 2905 2905 Motor shaft speed 60 Hz r min 3510 3510 3515 3515 Nominal motor power kW 3 7 3 7 5 5 5 5 Nominal motor power hp 5 ...

Page 48: ...every day to prevent corrosion This may be done manually by opening the drain valve or by means of the automatic drain if fitted to the vessel Nevertheless a weekly check of correct functioning of the automatic valve is needed This has to be done by opening the manual drain valve and check for condensate Yearly service inspection of the air receiver is needed as internal corrosion can reduce the s...

Page 49: ...or the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this compressor Local legal requirements and or use outside the limits and or conditions as specified by the manufacturer may require other inspection periods as mentioned below Instruction book 2920 7110 11 47 ...

Page 50: ...EC 2014 68 EU Pressure Equipment Directive greater than or equal to category II Pressure version Part number Description PED Class 8 bar 0830 1008 54 Safety valve IV 116 psi 0830 1008 49 Safety valve IV 10 bar 0830 1007 68 Safety valve IV 145 psi 0830 1008 35 Safety valve IV Overall rating The compressors conform to PED smaller than category I Instruction book 48 2920 7110 11 ...

Page 51: ...formity Typical example of a Declaration of Conformity document 1 Contact address Atlas Copco Airpower n v P O Box 100 B 2610 Wilrijk Antwerp Belgium 2 Applicable directives 3 Standards used Instruction book 2920 7110 11 49 ...

Page 52: ...rer the harmonized and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this device Instruction book 50 2920 7110 11 ...

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Page 54: ...s the products and services that help to increase your business efficiency and profitability Atlas Copco s pursuit of innovation never ceases driven by our need for reliability and efficiency Always working with you we are committed to providing you the customized quality air solution that is the driving force behind your business www atlascopco com ...