Atlas Copco SF 15+, Instruction Book

Page 1: ...INSTRUCTION BOOK OIL FREE SCROLL COMPRESSORS SF 15 SF 17 SF 22 SFD 11 SFD 15 SFD 22 ...

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Page 3: ...or copying of the contents 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 2017 06 No 2920 7140 52 www atlascopco c...

Page 4: ...ription 10 2 1 GENERAL DESCRIPTION 10 2 2 FLOW DIAGRAM 14 2 3 REGULATING SYSTEM 18 2 4 ELECTRICAL SYSTEM 19 2 5 ELECTRIC DIAGRAM 20 2 6 TEMPERATURE PROTECTION 20 2 7 AIR DRYER 22 3 Controller 24 3 1 GENERAL 24 3 2 CONTROL PANEL 26 3 3 ICONS USED 27 3 4 MAIN SCREEN 30 3 5 CALLING UP MENUS 34 3 6 SHUTDOWN WARNING 35 3 7 SHUTDOWN 39 3 8 INPUTS MENU 39 3 9 OUTPUTS MENU 42 3 10 COUNTERS 43 3 11 CONTROL...

Page 5: ... SETTINGS 73 4 Installation guidelines 76 4 1 DIMENSION DRAWING 76 4 2 INSTALLATION PROPOSAL 76 4 3 ELECTRICAL CONNECTIONS 78 4 4 PICTOGRAPHS 80 5 Operating instructions 81 5 1 INITIAL START UP 81 5 2 STARTING 81 5 3 DURING OPERATION 82 5 4 STOPPING 83 5 5 TAKING OUT OF OPERATION 83 6 Maintenance 84 6 1 PREVENTIVE MAINTENANCE SCHEDULE 84 6 2 SERVICE KITS 86 6 3 DISPOSAL OF USED MATERIAL 86 Instruc...

Page 6: ...HE COMPRESSOR ELEMENT 90 7 7 REPLACEMENT OF THE OUTLET PIPE 91 7 8 DRYER MAINTENANCE 92 8 Problem solving 94 9 Technical data 96 9 1 ELECTRIC CABLE SIZE AND FUSES 96 9 2 REFERENCE CONDITIONS AND LIMITATIONS 102 9 3 COMPRESSOR DATA 103 10 Guidelines for inspection 107 11 PED Pressure Equipment Directive 108 12 Declaration of conformity 109 Instruction book 4 2920 7140 52 ...

Page 7: ...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 8: ...ust be of the correct size and suitable for the working pressure 5 The aspirated air must be free of flammable fumes vapours and particles e g paint solvents that can lead to internal fire or explosion 6 Arrange the air intake 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...

Page 9: ...hese precautions apply to machinery processing or consuming air or inert gas Processing of any other gas requires additional safety precautions typical to the application which are not included herein Some precautions are general and cover several machine types and equipment hence some statements may not apply to your machine Precautions during operation 1 Never touch any piping or components of t...

Page 10: ...om neglecting these precautions or non observance of the normal caution and care required for installation operation maintenance and repair even if not expressly stated will be disclaimed by the manufacturer These precautions apply to machinery processing or consuming air or inert gas Processing of any other gas requires additional safety precautions typical to the application which are not includ...

Page 11: ...function correctly If removed check that the coupling guard of the compressor drive shaft has been reinstalled 17 Protect the motor air filter electrical and regulating components etc to prevent moisture from entering them e g when steam cleaning 18 Make sure that all sound damping material e g on the bodywork and in the air inlet and outlet systems of the compressor is in good condition If damage...

Page 12: ... sound insulating canopy The front door panel of each set of compressor modules houses the Elektronikon Graphic controller and the emergency stop button An electric cabinet with the electric components is located behind the front panel of each module SFD have no integrated air dryer SF SF is the type designation of the compressor variant without integrated dryer On SF the compressed air of each co...

Page 13: ...or element consists of a fixed scroll shaped housing and a scroll shaped rotor Air enters the compressor element through inlet opening 1 Once the air is drawn in the orbiting scroll 4 seals the inlet opening and forces the air into a continuously decreasing space As scroll 4 keeps orbiting this process of compression is constantly repeated resulting in discharging of oil free compressed air throug...

Page 14: ...The SF 15 has four 3 7 kW modules while the SF 17 and the SF 22 respectively have three or four 5 5 kW modules The SFD 15 has four 3 7 kW modules while the SFD 11 and the SFD 22 respectively have two or four 5 5 kW modules 3 7 kW compressor module 5 5 kW compressor module Instruction book 12 2920 7140 52 ...

Page 15: ...1 Air filter 4 Compressor element air outlet 2 Motor 5 Safety valve 3 Compressor element 6 Temperature sensor Instruction book 2920 7140 52 13 ...

Page 16: ...2 2 Flow diagram Flow diagram of SF 15 SF 17 SF 22 Instruction book 14 2920 7140 52 ...

Page 17: ... 3 12 Mechanical link 4 Compressor module 4 13 Electrical signal 5 To cubicle 14 Electric energy 6 Refrigerant dryer units with dryer 15 Enclosure 7 Water separator units without dryer 16 Local mounting 8 Outlet 17 On control cabinet 9 Ambient temperature sensor Instruction book 2920 7140 52 15 ...

Page 18: ...Flow diagram of SFD 11 SFD 15 SFD 22 Instruction book 16 2920 7140 52 ...

Page 19: ...er the compressed air flows through a common refrigerant dryer 300 before reaching the outlet valve 121 For details on the operation of the dryer see section Refrigerant dryer Cooling Each compressor element 102 is cooled by a radial fan 124 mounted on the drive shaft of the compressor element The cooling air is blown over the compressor element via a duct A separate electric fan 130 provides cool...

Page 20: ...Regulating system The compressor is provided with an Elektronikon controller module The controller performs following functions Monitoring the pressure Protecting the compressor Monitoring components subject to service Automatic restart after voltage failure For more details please consult the sections on the controller further in this book Instruction book 18 2920 7140 52 ...

Page 21: ... layout Electrical cabinet SF 15 SF 17 and SF 22 typical Electrical cabinet SFD 11 SFD 15 and SFD 22 typical K21 K22 Contactor 1X0 4X3 Terminals Q21 Q22 Circuit breaker T1 T4 Transformer F1 F2 Fuses Instruction book 2920 7140 52 19 ...

Page 22: ...ion The complete electrical diagram is available in the electric cubicle of the compressor For connection of the supply wires please see section Electrical connections 2 6 Temperature protection The compressor is equipped with an ambient temperature sensor The sensor creates a warning message on the controller if the ambient temperature rises above 40 C 104 F If the ambient temperature reaches 45 ...

Page 23: ...e span of 2 hours the element will be stopped during 10 minutes If the compressor element stops a third time within the 2 hours time span the element will be shut down and must be reset manually 3 7 kW compressor module 5 5 kW compressor module When the compressor is stopped due to overheating the compressor will not restart until the failure is acknowledged and the compressor is restarted manuall...

Page 24: ...t high pressure refrigerant gas which flows through condenser 6 where most of the refrigerant condenses The liquid flows through liquid refrigerant dryer filter 7 to capillary tube 8 The refrigerant leaves the capillary tube at evaporating pressure The refrigerant enters evaporator 2 where it withdraws heat from the compressed air by further evaporation at constant pressure The heated refrigerant ...

Page 25: ...ccumulates in a collector When the condensate reaches a certain level it is discharged through the drain outlet 1 The condensate can also be drained by pressing the test button 2 The drain filter can be cleaned by opening the manual drain valve 3 see section Preventive maintenance schedule Instruction book 2920 7140 52 23 ...

Page 26: ...the maximum allowed motor starting frequency and several other parameters are hereby taken into account The controller stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases A number of time based automatic start stop commands can be programmed Take into account that a start command will be executed if programmed and act...

Page 27: ...ice Plans Each Service Plan has a programmed time interval If a time interval is exceeded a message will appear on display 1 to warn the operator to carry out the service actions belonging to that Service Plan The running hours will be recalculated with respect to the ambient temperature This algorithm is activated when the compressor is operated above 30 C 86 F ambient Automatic restart after vol...

Page 28: ...matic operation LED Indicates that the regulator is automatically controlling the compressor The compressor is stopped and restarted 8 Voltage on LED Indicates that the voltage is switched on 9 Pictograph Voltage 10 Enter key Use this button to confirm the last action 11 Escape key Use this button to go to previous screen or to end the current action 12 Scroll keys Keys to scroll through the menu ...

Page 29: ...e icon is rotating Compressor status Motor stopped Motor running Machine control mode or Local start stop Remote start stop Network control Automatic restart after voltage failure Automatic restart after voltage failure is active Week timer Week timer is active Active protection functions Emergency stop Shutdown Warning Instruction book 2920 7140 52 27 ...

Page 30: ...es display icon Chart display icon General icons No communication network problem Not valid Input icons Icon Description Pressure Temperature Digital input Special protection System icons Icon Description Compressor element LP HP Dryer Fan Drain Instruction book 28 2920 7140 52 ...

Page 31: ...pressor module is running and can be stopped The compressor module is stopped and is ready to start The compressor module is awaiting the minimum stop time to expire Menu icons Icon Description Inputs Outputs Alarms Warnings shutdowns Counters or Test Settings Instruction book 2920 7140 52 29 ...

Page 32: ...vice Event history saved data Access key User password Network Setpoint Info Navigation arrows Icon Description Up Down 3 4 Main screen Control panel 1 Scroll keys 2 Enter key 3 Escape key Instruction book 30 2920 7140 52 ...

Page 33: ...s 2 Four value lines 3 Chart High resolution 4 Chart Medium resolution 5 Chart Low resolution 6 Scroll animation Two and four value lines screens This type of Main screen shows the value of 2 or 4 parameters see section Inputs menu Typical Main screen 2 value lines Text on image 1 Compressor Outlet 2 Ambient Air 3 Load Shutdown text varies upon the compressors actual condition 4 Menu Typical Main ...

Page 34: ...up more information about the icons shown select the icon concerned using the scroll keys and press the enter key Section C is called the Status bar This bar shows the text that corresponds to the selected icon Section D shows the Action buttons Depending on the situation these buttons are used To call up or program settings To reset a motor overload service message or emergency stop To have acces...

Page 35: ...tton icon for selecting other screens is changed into a small Chart and is highlighted active When the Chart Medium Resolution is selected the chart shows the variation of the selected input per hour The screen shows the last 4 hours When the Chart Low Resolution is selected the chart shows the variation of the selected input per day The screen shows the evolution over the last 10 days Instruction...

Page 36: ...isplay icon in section Icons used and press the Enter key A screen similar to the one below opens Select the layout required and press the Enter key See also section Inputs menu 3 5 Calling up menus Control panel 1 Scroll keys 2 Enter key 3 Escape key Procedure When the voltage is switched on the Main screen is switched on automatically Instruction book 34 2920 7140 52 ...

Page 37: ...e the Scroll keys to select the required icon see further Pressing the Escape key returns to the Main screen 3 6 Shutdown warning Description A shutdown warning will appear in the event of Too high element temperature Too high ambient temperature Too high dew point temperature on compressors with integrated refrigerant dryer High element temperature When a compressor element temperature exceeds th...

Page 38: ...ly the element will shut down alarm LED 4 see section Control panel will lit and following screen will appear Element 2 is shutdown due to repeatedly high element temperature warnings If this occurs 1 Switch off the voltage and remedy the problem cause 2 Switch on the voltage and reset the element manually by selecting the warning icon or go to warning menu elements and press Reset Warning element...

Page 39: ...ext on image 1 Information 4 Element Warnings 2 Trigger level 5 Element Problem Resets 3 High Temperature Warnings 6 Modify High ambient temperature If the ambient temperature is above the factory setting 40 C 104 F a warning is triggered and a warning icon 1 is shown on the main screen Main screen with high ambient temperature warning Text on image 1 Compressor outlet pressure 3 Load 2 Warning ic...

Page 40: ...will be lit and the related alarm icon will be flashing if the dew poin temperature exceeds the warning level Main screen with dew point exceeding the limit Text on image 1 Compressor outlet pressure 3 Load 2 Warning icon 4 Menu Go to the Input menu to see the actual dew point temperature Press the Stop button 13 see section Control panel to stop the compressor switch off the voltage inspect the c...

Page 41: ...n screen shutdown by too high ambient temperature Text on image 1 Compressor outlet 3 Shutdown 2 Stop icon 4 Menu Motor overload A motor overload relay protects the motor of each compressor module The motor is shutdown if the motor current is too high 3 8 Inputs menu Menu icon Inputs Function To display the actual value of the measured data analog inputs and the status of the digital inputs e g em...

Page 42: ...ws a list of all inputs with their corresponding icons and readings If an input is in warning or shutdown the original icon is replaced by the warning or shutdown icon respectively the Stop icon and the Warning icon in the screen shown above A small chart icon shown below an item in the list means this input signal is shown on the chart at the main screen Any analog input can be selected Selecting...

Page 43: ...ss the Enter button again A pop up window opens Press Enter again to remove this input from the chart Another confirmation pop up opens Select Yes to remove or No to quit the current action In a similar way another input signal can be highlighted and selected as Main Chart signal Instruction book 2920 7140 52 41 ...

Page 44: ...rload contact the general warning contact etc Procedure Starting from the Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on image 1 Menu 2 Regulation Using the Scroll keys move the cursor to the outputs icon see above Press the Enter key A screen similar to the one below appears Outputs screen typical Instruction book 42 2920 7140 52 ...

Page 45: ...n Counters Function To call up The running hours The loaded hours The number of motor starts The number of hours that the regulator has been powered The number of load cycles Procedure Starting from the Main screen Using the Scroll keys move the cursor to the action button Menu and press the Enter key Following screen appears Text on image 1 Menu 2 Regulation Using the Scroll keys move the cursor ...

Page 46: ...ect the control mode i e whether the compressor is in local control remote control or controlled via a local area network LAN Procedure Starting from the Main screen make sure action button Menu 1 is selected Text on image 1 Menu Next use the scroll buttons to go to the control mode icon 2 and press the Enter key see section Icons used for the meaning of the icons Instruction book 44 2920 7140 52 ...

Page 47: ...our selection The new control mode selection is now visible on the main screen 3 12 Service menu Menu icon Service Function To reset the service plans which are carried out To check when the next service plans are to be carried out To find out which service plans were carried out in the past To modify the programmed service intervals Instruction book 2920 7140 52 45 ...

Page 48: ...lation Using the Scroll keys move the cursor to the Service icon see above section Menu icon Press the Enter key Following screen appears Text on image 1 Service 4 Next service 2 Overview 5 History 3 Service plan Scroll through the items to select the desired item and press the Enter key to see the details as explained below Instruction book 46 2920 7140 52 ...

Page 49: ...35 C 95 F is working in harder conditions than an element running at 20 C 68 F Therefore a service done earlier a time reduction of 30 is applied in this temperature zone will protect the element in a better way In the zone between 35 C 95 F and 40 C 104 F the time reduction is 60 The figures within the bars are the number of hours to go till the next service intervention In the example above the ...

Page 50: ...ntervals To do so use the Scroll keys to select the value to be modified A screen similar to the one below appears Press the Enter key Following screen appears Modify the value as required using the or scroll key and press the Enter key to confirm Note Running hours can be modified in steps of 100 hours real time hours can be modified in steps of 1 hour Instruction book 48 2920 7140 52 ...

Page 51: ...nt service action To see the details of a completed service action e g Service level Running hours or Real time hours use the Scroll keys to select the desired action and press the Enter key 3 13 Setpoint menu Menu icon Setpoint Function It is possible to program 2 different pressure bands This menu is also used to select the active pressure band Procedure Starting from the Main screen Move the cu...

Page 52: ...ressure band 2 Low 3 Pressure band 1 Low 6 Modify The screen shows the actual stopping and starting pressure settings for both pressure bands To modify the settings move the cursor to the action button Modify and press the Enter key Following screen appears The first line of the screen is highlighted Use the Scroll keys to highlight the setting to be modified and press the Enter key Following scre...

Page 53: ...ay as described above 3 14 Event history menu Menu icon Event History Function To call up the last shutdown and last emergency stop data Procedure Starting from the Main screen Using the Scroll keys move the cursor to the action button Menu and press the Enter key Following screen appears Text on image 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Event History icon see above Pr...

Page 54: ...emergency stop occurred 3 15 General settings menu Menu icon Settings Function To display and modify a number of settings Procedure Starting from the Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on image 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Settings icon see above Press the Enter key Following screen appears...

Page 55: ...ary Example Selecting the General Settings icon gives the possibility to change e g the language the date the date format etc Text on image 1 General 4 Date 2 Language In Use 5 Date Format 3 Time 6 Modify To modify select the Modify button using the Scroll keys and press the Enter key A screen similar to the one above is shown the first item Language is highlighted Use the key of the Scroll keys t...

Page 56: ...see above section Menu icon Press the Enter key The internet address appears on the screen 3 17 Week timer menu Menu icon Week timer Function To program time based start stop commands for the compressor To program time based changeover commands for the net pressure band Four different week schemes can be programmed A week cycle can be programmed a week cycle is a sequence of 10 weeks For each week...

Page 57: ...o select the Timer icon Text on image 1 Menu 2 Regulation Press the Enter key on the controller Following screen appears Text on image 1 Week Timer 4 Status 2 Week Action Schemes 5 Week Timer Inactive 3 Week Cycle 6 Remaining Running Time The first item in this list is highlighted Select the item to be adapted and press the Enter key on the controller to modify Programming week schemes Select Week...

Page 58: ...matically selected and highlighted in red Press the Enter key on the controller to set an action for this day Text on image 1 Week Action Scheme 1 5 Thursday 2 Monday 6 Friday 3 Tuesday 7 Saturday 4 Wednesday 8 Sunday A new window opens The Modify action button is selected Press the enter button on the controller to create an action Instruction book 56 2920 7140 52 ...

Page 59: ...Enter key to confirm Text on image 1 Monday 5 Stop 2 Actions 6 Pressure Setpoint 1 3 Remove 7 Modify 4 Start A new window opens The action is now visible in the first day of the week Text on image 1 Monday 3 Save 2 Start 4 Modify To adjust the time use the Scroll keys on the controller and press the Enter key to confirm Instruction book 2920 7140 52 57 ...

Page 60: ...nday 3 Save 2 Time 4 Modify Press the Escape key on the controller The action button Modify is selected Use the Scroll keys to select the action Save Text on image 1 Monday 3 Save 2 Start 4 Modify A new pop up window opens Use the Scroll keys on the controller to select the correct actions Press the Enter key to confirm Instruction book 58 2920 7140 52 ...

Page 61: ... Wednesday 8 Sunday Press the Escape key on the controller to leave this screen Programming the week cycle A week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed week schemes can be chosen Select Week Cycle from the main Week Timer menu list Text on image 1 Week Timer 4 Status 2 Week Action Schemes 5 Week Timer Inactive 3 Week Cycle 6 Remaining Running Time A ...

Page 62: ...s Select the action example Week Action Scheme 1 Text on image 1 Week Cycle 4 Week Action Scheme 2 2 Week 1 5 Week Action Scheme 3 3 Week Action Scheme 1 6 Modify Check the status of the Week Timer Use the Escape key on the controller to go back to the main Week Timer menu Select the status of the Week Timer Instruction book 60 2920 7140 52 ...

Page 63: ...Inactive 2 Week 4 Week 1 Press the Escape key on the controller to leave this window The status shows that week 1 is active Text on image 1 Week Timer 4 Status 2 Week Action Schemes 5 Remaining Running Time 3 Week Cycle Press the Escape key on the controller to go to the main Week Timer menu Select Remaining Running Time from the list and press the Enter key on the controller to Modify Instruction...

Page 64: ...et in this screen This timer is prior to the Week Timer action Text on image 1 Week Timer 3 Remaining Running Time 2 Week Action Schemes 3 18 Test menu Menu icon Test or Function To carry out a display test i e to check whether the display and LED s are still intact Procedure Starting from the Main screen Instruction book 62 2920 7140 52 ...

Page 65: ...ormed by authorized personnel and is protected by a security code Select the item display test and press the enter key A screen is shown to inspect the display at the same time all LED s are lit 3 19 User password menu Menu icon Password Function If the password option is activated it is impossible for not authorized persons to modify any setting Procedure Starting from the Main screen Move the cu...

Page 66: ... This allows to consult certain data and settings via a PC instead of on the display of the controller Getting started If the compressor is equipped with a SMARTBOX the network connection of the Elektronikon is already in use To allow the web server functionality the network cable that is connected to the SMARTBOX should be unplugged and replaced by the cable of the company network If both the web...

Page 67: ...apter Use a UTP cable CAT 5e to connect to the controller see picture below Configuration of the network card in Windows Go to My Network places 1 Click on View Network connections 1 Instruction book 2920 7140 52 65 ...

Page 68: ... with the right button and select properties 1 Use the check box Internet Protocol TCP IP 1 see picture To avoid conflicts uncheck other properties if they are checked After selecting TCP IP click on the Properties button 2 to change the settings Instruction book 66 2920 7140 52 ...

Page 69: ...k OK and close network connections Configuration of the web server Configure the web interface for Internet Explorer Open Internet Explorer and click on Tools Internet options 2 Click on the Connections tab 1 and then click on the LAN settings button 2 Instruction book 2920 7140 52 67 ...

Page 70: ... controller Multiple IP addresses can be given but they must be separated with semicolons Example Suppose that you already added two IP addresses 192 168 100 1 and 192 168 100 2 Now you add 192 168 100 100 and separate the 3 IP addresses by putting semicolons between them 1 see picture Instruction book 68 2920 7140 52 ...

Page 71: ...en shots are indicative The number of displayed fields depends on the selected options Open your browser and type the IP address of the controller you want to view in your browser in this example http 192 168 100 100 The interface opens Instruction book 2920 7140 52 69 ...

Page 72: ...ettings All compressor settings can be displayed or hidden Put a check mark in front of each point of interest and it will be displayed Only the machine status is fixed and can not be removed from the main screen Analog inputs Lists all current analog input values The measurement units can be changed in the preference button from the navigation menu Instruction book 70 2920 7140 52 ...

Page 73: ...ts all current counter values from controller and compressor Info status Machine status is always shown on the web interface Digital inputs Lists all Digital inputs and their status Instruction book 2920 7140 52 71 ...

Page 74: ... Lists all special protections of the compressor Service plan Displays all levels of the service plan and their status This screen shot underneath only shows the running hours It is also possible to show the current status of the service interval Instruction book 72 2920 7140 52 ...

Page 75: ... psig 58 101 5 116 Starting pressure 10 bar compressors bar e 4 9 10 Starting pressure 10 bar compressors psig 58 130 5 145 Minimum setting Factory setting Maximum setting Stopping pressure Stopping pressure 8 bar compressors bar e 4 8 8 Stopping pressure 8 bar compressors psig 58 116 116 Stopping pressure 10 bar compressors bar e 4 10 10 Stopping pressure 10 bar compressors psig 58 145 145 Instru...

Page 76: ...tting Factory setting Maximum setting Allowed number of motor starts per day 72 720 720 Power recovery time Automatic restart function s 60 60 3600 Restart delay s 0 0 1200 Communication time out s 10 30 60 Protections Minimum setting Factory setting Maximum setting Ambient temperature warning level C 0 40 40 Ambient temperature warning level F 32 104 104 Ambient temperature shutdown level C 0 45 ...

Page 77: ...he signal must exist before the compressor is shut down If it is required to program this setting to another value consult your supplier Minimum stop time Once the compressor has automatically stopped it will remain stopped for the minimum stop time whatever happens with the net air pressure Consult your supplier if a setting lower than 20 seconds is required Starting stopping pressure The regulat...

Page 78: ...ilation outlet opening for cabinet COMPRESSED AIR OUTLET Compressed air outlet ELECTRIC CABLE PASSAGE POWER SUPPLY CABLE Opening for power supply cable MANUAL DRAIN Manual drain valve AUTOMATIC DRAIN Automatic drain outlet CENTER OF GRAVITY Location of center of gravity COOLING AIR INLET OF AFTERCOOLER AND DRYER Cooling air inlet of aftercooler and dryer COOLING AIR INLET OF COMPRESSOR AND CABINET...

Page 79: ...the compressor in a frost free and preferably low dust location 2 Compressed air outlet valve 3 Delivery pipe The pressure drop over the air delivery pipe can be calculated as follows Δp L x 450 x Qc 1 85 d5 x P with d inner diameter of the pipe in mm Δp pressure drop in bar recommended maximum 0 1 bar 1 5 psi L length of the pipe in m P absolute pressure at the compressor outlet in bar Instructio...

Page 80: ...utlet valve e g A DD filter for general purpose filtration The filter traps solid particles down to 1 micron A PD filter for filtration down to 0 01 micron A PD filter must always be installed downstream a DD filter It is recommended to provide bypass pipes and valves across the filters in order to isolate the filters during maintenance without disturbing the compressed air delivery 8 Safety valve...

Page 81: ... the supply cable to terminals L1 L2 and L3 of terminal strip 1X0 connect the neutral conductor to terminal N if applicable and the earthing conductor to the earthing bolt 1X3 Instruction book 2920 7140 52 79 ...

Page 82: ...Instruction book for motor rotation direction 3 Consult the specific instructions before greasing 4 Manual condensate drain 5 Torques for steel Fe or brass CuZn bolts 6 Switch off the voltage and depressurize the compressor before maintenance or repair 7 Warning voltage 8 Warning hot surface 9 Rotation direction of fan Instruction book 80 2920 7140 52 ...

Page 83: ...e section Electrical connections 4 Close the condensate drain valve See chapter Condensate management in section Flow diagram 5 Switch on the voltage Start and stop the compressor On 3 phase compressors check for correct direction of rotation direction arrows are provided on the motors If the rotation direction is wrong switch off the voltage and reverse two incoming electric lines 5 2 Starting Pr...

Page 84: ...also section Programmable settings 5 3 During operation Control panel Procedure 1 If the automatic operation LED 3 is alight the regulator is automatically controlling the compressor modules starting stopping 2 Check the readings on the display 1 In case of a warning or shutdown condition see section Problem solving or Event history menu 3 Check that condensate is discharged automatically from the...

Page 85: ...the compressor and close the air outlet valve 2 Switch off the voltage and disconnect the compressor from the mains 3 Depressurize the compressor Open the condensate drain valve 4 Shut off and depressurize the part of the air net which connected to the outlet valve Disconnect the compressor from the air net 5 Disconnect the condensate piping from the local condensate drain system Instruction book ...

Page 86: ... Customer Centre may overrule the specified maintenance schedule especially the service intervals depending on the environmental and operating conditions of the compressor The longer interval checks must always include the shorter interval checks Preventive maintenance schedule A number of service operations are grouped in plans called Service plans I A B or D See the table below A message will ap...

Page 87: ...otor overload tested Check tension and condition of the V belts Every 2 years 5000 A Replace V belt s Replace the check valves Every 2 years 5000 B 8 bar and 116 psi compressors Clean fan ref 124 on Flow diagram fan duct and element cooling fins see note 2 See section Cleaning cooling fins Have orbiting scroll bearing greased see note 3 Every 2 years 5000 B 10 bar and 145 psi compressors Replace t...

Page 88: ...pecial grease gun and according a specific procedure In high ambient conditions the bearings must be greased more frequently for every 5 C 9 F increase above 30 C 86 F the maintenance interval should be reduced with 30 Contact your supplier for details Check more frequently if operating in a dusty atmosphere Check for cleanness and damage Replace a dirty or damaged filter by a new one 4 In extreme...

Page 89: ...aste Electrical and Electronic Equipment WEEE As such these parts must not be disposed of at a municipal waste collection point Refer to local regulations for directions on how to dispose of this product in an environmental friendly manner Instruction book 2920 7140 52 87 ...

Page 90: ...3 Fit the new element and reinstall the filter cover 7 2 Air cooler Cleaning Keep the cooler clean to maintain cooling efficiency If necessary remove any dirt with a fibre brush Never use a wire brush or metal objects Next clean by air jet in reverse direction of normal flow If it is necessary to wash the cooler with a cleansing agent consult Atlas Copco 7 3 Drive motor Instructions The motor bear...

Page 91: ... can be tested on a separate compressed air line If the safety valve does not open at the specified pressure it must be replaced No adjustments are allowed Never run the compressor without safety valve 7 5 Belt set exchange and tensioning Important The belts must 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...

Page 92: ...r the first 500 running hours 7 6 Cleaning the compressor element 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 ...

Page 93: ...F 15 and the SFD 15 This new element does no longer have a plastic insert in the outlet pipe and replacement is no longer required Description The element outlet pipe 1 of the 3 7 kW element contains a plastic insert 3 Due to the heat of the compressed air the plastic insert can become brittle after time Therefore it is recommended to replace the outlet pipe together with the insert when that is t...

Page 94: ...TFE tape Warning If the outlet pipe is tightened too hard the thread of the element can get damaged or the insert can break resulting in overheating of the compressor element 6 Fasten coupling 3 while holding nipple 2 with a wrench Note The outlet pipe of the 5 5 kW element and the new 3 7 kW element see above does not contain an insert Please do not exceed a torque of 15 Nm hand tightened plus ma...

Page 95: ...e voltage and close the air outlet valve Local legislation may stipulate that Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function must be undertaken by an authorized control body The installation should be checked once a year by an authorized control body General The following remarks should be kept in mind Keep the dryer clean Brush or blow off t...

Page 96: ...ter Replace if necessary Safety valve leaking Replace valve Compressor element out of order Consult your supplier Compressor module overheating or compressor shutdown on high air temperature Insufficient compressor cooling Improve ventilation of compressor room Clean compressor element fins and fan see Cleaning the compressor element Cooling fan out of order Check and correct Condensate trap conti...

Page 97: ...ed 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 circuit repaired or recharged Hot gas bypass valve incorrectly set or out of order Have the valve adjusted or replaced Condensate trap continuously discharging air an water Automat...

Page 98: ... cable size If required reduce fuse size or enlarge cable size Cable length should not exceed the maximum length according to IEC 60204 table 10 Currents and fuses Compressor type Itot 1 Max fuse 1 Itot 2 Max fuse 2 Q21 Q2 2 Q23 Q24 Q15 SF 15 IEC 50 Hz 230 V 55 A 63 A 60 A 80 A 15 0 A SF 15 IEC 60 Hz 380 V 32 A 40 A 37 A 50 A 8 9 A SF 15 IEC 50 Hz 400 V 32 A 35 A 35 A 50 A 8 7 A SF 15 IEC 50 Hz 40...

Page 99: ... 60 A 12 0 A 0 43 A SF 22 UL cUL 60 Hz 575 V 35 A 40 A 38 A 40 A 9 6 A 0 44 A Compressor type Itot 1 Max fuse 1 Q21 Q2 2 SFD 11 IEC 50 Hz 230 V 21 A 25 A 22 3 A SFD 11 IEC 60 Hz 380 V 14 A 16 A 14 5 A SFD 11 IEC 50 Hz 400 V 12 A 16 A 12 8 A SFD 11 UL cUL 60 Hz 200 V 26 A 30 A 21 9 A SFD 11 UL cUL 60 Hz 230 V 22 A 30 A 19 0 A SFD 11 UL cUL 60 Hz 460 V 11 A 15 A 9 5 A SFD 11 UL cUL 60 Hz 575 V 9 A 1...

Page 100: ...use 2 maximum fuse size in case of compressors with integrated dryer IEC fuses class gL gG UL fuses class K5 CSA HRC form II Possible configurations There are 3 possible cabling layouts 1 Single supply cables for DOL variants only K21 is used 2 Parallel supply cables for DOL variants only K21 is used 3 is only valid for Y D versions Cable sizing according IEC The tables below indicate the current ...

Page 101: ... A 91 A 95 mm 179 A 156 A 141 A 127 A 109 A 120 mm 206 A 179 A 163 A 146 A 126 A Installation method C according table B 52 1 Single core or multicore cable on a wooden wall Maximum allowed current in function of the ambient temperature for installation method C Ambient temperature Cable section 30 C 40 C 45 C 50 C 55 C 4 mm 32 A 28 A 25 A 23 A 20 A 6 mm 41 A 36 A 32 A 29 A 25 A 10 mm 57 A 50 A 45...

Page 102: ... as in 3 Add 10 to the total current Itot from the tables and divide by 3 Multiply the ampacity of the cables with 0 8 see table A 52 17 52 E1 Fuse size the recommended maximum fuse size divided by 3 on each cable Size of the PE cable use following rule of thumb For supply cables up to 16 mm same size as supply wires For supply cables between 16 mm and 35 mm 16 mm For supply cables larger than 35 ...

Page 103: ...ction factor 21 25 C 70 77 F 1 05 26 30 C 78 86 F 1 00 31 35 C 87 95 F 0 94 36 40 C 96 104 F 0 88 Calculation method for UL Single supply cables 3 phases 1 PE configuration 1 Add 25 to the total current Itot from the tables see UL 508A 28 3 2 Ampacity shall have 125 of the full load current Install the prescribed maximum fuse on each cable Parallel supply cable 2 x 3 phases 2 PE configuration 2 Ad...

Page 104: ...cable Parallel supply cable 2 x 3 phases 2 PE configuration 2 I 28 A 25 2 28 x 1 25 2 17 5 A For a AWG14 the maximum current at 40 C is 20 A x 0 88 x 0 8 14 1 A which is insufficient For an AWG14 the maximum current is 25 x 0 88 x 0 8 17 6 A So 2 parallel cables of 3 x AWG12 2 x AWG12 are sufficient Install 20 A fuses on each cable 9 2 Reference conditions and limitations Reference conditions Air ...

Page 105: ...01 5 Reference working pressure compressors with integrated dryer bar e 6 75 6 75 6 75 Reference working pressure compressors with integrated dryer psi g 98 98 98 Air temperature at outlet valve compressors without integrated dryer C 32 30 30 32 30 30 Air temperature at outlet valve compressors without integrated dryer F 90 86 86 90 86 86 Air temperature at outlet valve compressors with integrated...

Page 106: ...ference working pressure compressors with integrated dryer bar e 8 75 8 75 8 75 Reference working pressure compressors with integrated dryer psi g 127 127 127 Air temperature at outlet valve compressors without integrated dryer C 32 30 30 30 28 30 Air temperature at outlet valve compressors without integrated dryer F 90 86 86 86 84 86 Air temperature at outlet valve compressors with integrated dry...

Page 107: ...pressors with integrated dryer bar e 6 75 6 75 6 75 Reference working pressure compressors with integrated dryer psi g 98 98 98 Air temperature at outlet valve compressors without integrated dryer C 30 28 30 30 28 30 Air temperature at outlet valve compressors without integrated dryer F 86 82 86 86 82 86 Air temperature at outlet valve compressors with integrated dryer C 25 28 30 Air temperature a...

Page 108: ...yer bar e 8 75 8 75 8 75 Reference working pressure compressors with integrated dryer psi g 127 127 127 Air temperature at outlet valve compressors without integrated dryer C 32 30 30 32 30 30 Air temperature at outlet valve compressors without integrated dryer F 90 86 86 90 86 86 Air temperature at outlet valve compressors with integrated dryer C 25 30 55 Air temperature at outlet valve compresso...

Page 109: ...r 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 7140 52 107 ...

Page 110: ... than or equal to category II Part number Description Medium Pressure 0830 1009 17 Safety valve Air 9 3 bar 0830 1008 49 Safety valve Air 9 3 bar 0830 1009 18 Safety valve Air 11 5 bar 0830 1008 35 Safety valve Air 11 bar Volume P x V or P Life cycle PED class NA NA 2 x 106 IV NA NA 2 x 106 IV NA NA 2 x 106 IV NA NA 2 x 106 IV Overall rating The compressors conform to PED category I or smaller Ins...

Page 111: ...um 2 Applicable directives 3 Standards used On the Declaration of Conformity Declaration by the Manufacturer 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 2920 7140 52 109 ...

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Page 114: ...vironment and the people around us We make performance stand the test of time This is what we call Sustainable Productivity www atlascopco com No 2920 7140 52 2017 06 Printed in Belgium Atlas Copco Airpower NV All rights reserved Designs and specifications are subject to change without notice or obligation ...