Atlas Copco 8115410428, Instruction Book

Page 1: ...Atlas Copco Oil free air piston compressors LFx 0 7 LFx 1 0 LFx 1 5 LFx 2 0 Instruction book ...

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Page 3: ...ts 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 2010 04 No 2920 7002 03 www atlascopco com ...

Page 4: ...ription 9 2 1 INTRODUCTION 9 2 2 FLOW DIAGRAMS 13 3 Installation 15 3 1 DIMENSION DRAWINGS 15 3 2 INSTALLATION PROPOSAL 19 3 3 ELECTRICAL CONNECTIONS 21 4 Operating instructions 31 4 1 OPERATING PRECAUTIONS 31 4 2 OPERATING 31 5 Maintenance 33 5 1 PREVENTIVE MAINTENANCE SCHEDULE 33 5 2 SERVICE KITS 34 5 3 DISPOSAL OF USED MATERIAL 34 6 Adjustments and servicing procedures 35 6 1 PRESSURE SWITCH 35...

Page 5: ... 8 2 SETTINGS FOR OVERLOAD RELAY AND FUSES 39 8 3 REFERENCE CONDITIONS AND LIMITATIONS 40 8 4 COMPRESSOR DATA 40 9 Instructions for use 42 10 Guidelines for inspection 43 11 Pressure equipment directives 44 12 Declaration of conformity 45 Instruction book 2920 7002 03 3 ...

Page 6: ...hecks 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 the air to clean dirt from your clothes When using the air to clean equipment do so with extreme caution and we...

Page 7: ... notice shall be affixed to the start equipment 10 Air cooled machines must be installed in such a way that an adequate flow of cooling air is available and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet 11 The electrical connections must correspond to the applicable codes The machines must be earthed and protected against short circuits by fuses in al...

Page 8: ...onments or rooms where the sound pressure level reaches or exceeds 80 dB A shall wear ear protectors 8 Periodically check that All guards are in place and securely fastened All hoses and or pipes inside the machine are in good condition secure and not rubbing There are no leaks All fasteners are tight All electrical leads are secure and in good order Safety valves and other pressure relief devices...

Page 9: ...e vessels 12 Whenever there is an indication or any suspicion that an internal part of a machine is overheated the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted 13 Never use a light source with open flame for inspecting the interior of a machine press...

Page 10: ...ical first aid Also consult following safety precautions Safety precautions during installation and Safety precautions during operation 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 included herein Some precautions are general and cover several machine types a...

Page 11: ...block for open operation PWBO is provided with a fan protection and can be used for open operation The Power block for enclosed operation PWBE is not provided with a fan protection and has to be installed inside an enclosure LFx Power block Power box LFx Power box are provided with a sound insulated bodywork The Power box includes an electric motor The unit can be used to install on an air receive...

Page 12: ...er box units installed on a 20 litre 5 25 US gal 4 40 Imp gal air receiver provided with wheels Trolley units come inclusive with safety valve pressure regulator pressure switch outlet valve and pressure gauges LFx Trolley Instruction book 10 2920 7002 03 ...

Page 13: ...mp gal 1 75 cu ft or 90 litre 23 7 US gal 19 8 Imp gal 3 15 cu ft air receiver The complete units come inclusive with safety valve pressure regulator pressure switch outlet valve and pressure gauges LFx complete unit on air receiver Reference Name 1 Start stop switch AR Air receiver AV Outlet valve CV Check valve Dm Manual drain air receiver Instruction book 2920 7002 03 11 ...

Page 14: ... a programmed time interval CDXF kit An optional CDXF desiccant air dryer CDXF is available complete with inlet and outlet filters and designed for a dewpoint of 20 C 4 F This option is available for all air receiver mounted versions LFx with CDXF air dryer Manifold kit The optional manifold kit comprises a pressure regulator pressure switch pressure gauge and relief valve pre mounted on the Power...

Page 15: ...gle phase LFx 1 5 and LFx 2 0 units a vent valve 2 ensures smooth start up Air drawn through filter AF into compressor element E is compressed The air is cooled in air cooler Ca and enters air receiver AR through check valve CV The air is discharged through the pressure regulator Gpr When the pressure in the air receiver reaches the upper limit pressure switch PR stops the motor On LFx 1 5 and LFx...

Page 16: ... air cooler Ca flows through the pre filter and enters the CDXF dryer Via the after filter and check valve CV the air enters air receiver AR and is discharged via outlet valve AV When the pressure in the air receiver reaches the upper limit pressure switch PR stops the motor On LFx 1 5 and LFx 2 0 units a quick blow off valve 1 blows off the air between element E and check valve CV and ensures smo...

Page 17: ...3 Installation 3 1 Dimension drawings Dimension drawings LFx 0 7 up to LFx 2 0 Dimension drawing LFx Power box Instruction book 2920 7002 03 15 ...

Page 18: ...Dimension drawing LFx Complete unit on air receiver Instruction book 16 2920 7002 03 ...

Page 19: ...Dimension drawing LFx Complete unit on air receiver and CDXF air dryer Instruction book 2920 7002 03 17 ...

Page 20: ...Dimension drawing LFx Trolley Ref Name 1 Cooling air outlet 2 Cooling air inlet 3 Type 4 Net mass 5 Compressed air outlet 6 Fixation holes 7 Receiver 8 Manual drain Instruction book 18 2920 7002 03 ...

Page 21: ...s of the unit free Compressor room example Description 1 The unit should be installed on a level floor capable of taking the weight of the compressor Recommended minimum distance between top of the unit and ceiling is 1100 mm 42 9 in Distances between unit and walls stated are minimum The air receiver may not be bolted to the floor 2 Position of the compressed air outlet valve Instruction book 292...

Page 22: ...r is avoided The maximum air velocity through the grids is 5 m s 16 5 ft s The maximum allowable pressure drop over the cooling air ducts depends on the ambient temperature consult your supplier The maximum air temperature at the compressor intake is 40 C 104 F minimum 0 C 32 F The ventilation capacity required to limit the compressor room temperature can be calculated as follows Qv 0 92 N dT Qv R...

Page 23: ...3 3 Electrical connections Electrical diagrams Single phase Instruction book 2920 7002 03 21 ...

Page 24: ...3 phase 230 V 50 Hz and 230 V 60 Hz Instruction book 22 2920 7002 03 ...

Page 25: ...3 phase 400 V 50 Hz and 440 460 V 60 Hz Instruction book 2920 7002 03 23 ...

Page 26: ...Single phase with CDXF air dryer Instruction book 24 2920 7002 03 ...

Page 27: ...3 phase 230 V 50 Hz and 230 V 60 Hz with CDXF air dryer Instruction book 2920 7002 03 25 ...

Page 28: ...3 phase 400 V 50 Hz and 440 460 V 60 Hz with CDXF air dryer Instruction book 26 2920 7002 03 ...

Page 29: ...Single phase with electronic drain or purge solenoid Instruction book 2920 7002 03 27 ...

Page 30: ...3 phase 230 V 50 Hz and 230 V 60 Hz with electronic drain or purge solenoid Instruction book 28 2920 7002 03 ...

Page 31: ...0 V 50 Hz and 440 460 V 60 Hz with electronic drain or purge solenoid Reference Designation 1 Customer s installation 2 Compressor 3 Motor 4 Pressure switch 5 Green yellow 6 Brown Instruction book 2920 7002 03 29 ...

Page 32: ...compressor On single phase units the overload protection is integrated in the motor and resets automatically On three phase units check the fuses and the setting of the overload relay See section Settings for overload relay and fuses For single phase units connect an electrical cable to terminals 1 3 and the earth terminal of pressure switch MDR4 See section Settings for overload relay and fuses f...

Page 33: ...tion OFF to release the pressure between compressor and check valve Switch off the voltage and remedy the trouble Allow the motor to cool down before restarting On three phase units turn the ON OFF switch on the air pressure switch to position OFF Switch off the voltage and remedy the trouble Reset the overload protection Allow the motor to cool down before restarting Take care that no dust or pai...

Page 34: ...ressure switch should be adjusted such that the following load stop times are approached Working pressure 50 Hz Normal ambient A B 50 Hz Higher ambient 30 C 86 F A B 60 Hz Normal ambient A B 60 Hz Higher ambient 30 C 86 F A B 7 bar 101 psi 80 20 70 30 70 30 60 40 10 bar 145 psi 60 40 60 40 60 40 50 50 When running single phase units at temperatures above 35 C 95 F the load cycle needs to be reduce...

Page 35: ...vals Carry out maintenance at the interval which comes first The local Atlas Copco Customer Centre may overrule the maintenance schedule especially the service intervals depending on the environmental and working conditions of the compressor The longer interval checks must also include the shorter interval checks Preventive maintenance schedule Running hours Operation Daily Drain the condensate fr...

Page 36: ...rvicing Service kits Service kits Ordering number Air filter kit inlet filter 2901 0498 00 5 3 Disposal of used material Used filters or 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 Instruction book 34 2920 7002 03 ...

Page 37: ...h also controls the pressure difference between the maximum pressure stopping pressure and the pressure at which compression is resumed starting pressure Caution Adjust the air pressure switch while the switch is pressurized Switch off the voltage before removing the cover of the switch reinstall it after an adjustment has been made and before the voltage is switched on again Instruction book 2920...

Page 38: ...er it The pressure difference is adjusted by means of screw 3 To reduce the difference between the stopping and starting pressure increase the starting pressure by turning the screw anti clockwise To increase the pressure difference turn the screw clockwise The adjustment range is shown on the diagram 6 2 Vent valve Vent valve Single phase LFx 1 5 and LFx 2 0 are equipped with a vent valve for smo...

Page 39: ...using and use the precision shim to measure the distance between the nuts and the vent valve housing If this distance is larger than 0 5 mm tighten the nuts until the distance becomes 0 5 mm This will result in a venting time of 5 to 25 seconds in case of a unit connected to an empty vessel The smaller the piston stroke the smaller the venting flow and venting time If the stroke of 0 5 mm is too m...

Page 40: ... with air receiver open the manual condensate drain valve Compressor problems Condition Fault Remedy The machine does not start No power Check power supply Fuse blown Replace fuse The main motor thermal protection has tripped On single phase units check and let the motor cool down move compressor start stop switch to 0 then to I The main motor thermal protection has tripped On three phase units ch...

Page 41: ...y and fuses Compressor type Voltage V Frequency Hz Overload relay A Main fuses compressor supply A LFx 0 7 230 single phase 50 10 LFx 0 7 230 50 3 1 10 LFx 0 7 400 50 2 0 10 LFx 0 7 115 single phase 60 16 LFx 0 7 230 single phase 60 10 LFx 0 7 440 460 60 2 0 10 LFx 1 0 230 single phase 50 10 LFx 1 0 230 50 4 0 10 LFx 1 0 400 50 2 5 10 LFx 1 0 115 single phase 60 16 LFx 1 0 230 single phase 60 10 L...

Page 42: ...bar e See Compressor data Working pressure psi See Compressor data Limitations Maximum working pressure bar e See Compressor data Maximum working pressure psig See Compressor data Minimum working pressure bar e 1 Minimum working pressure psig 14 5 Maximum air inlet temperature C 40 Maximum air inlet temperature F 104 Minimum ambient temperature C 0 Minimum ambient temperature F 32 Safety valve set...

Page 43: ...ts kW 0 53 0 63 0 97 1 30 Power input 50 Hz units hp 0 71 0 84 1 30 1 74 Power input 60 Hz units kW 0 75 0 77 1 49 Power input 60 Hz units hp 1 01 1 03 2 0 Opening pressure of the safety valve bar e 11 11 11 11 Opening pressure of the safety valve psig 160 160 160 160 Maximum sound pressure level 50 Hz trolley version dB A 64 62 62 64 Maximum sound pressure level 50 Hz complete unit dB A 67 65 65 ...

Page 44: ...ectly to the vessel and the discharge capacity should be higher than the air intake of the compressor See also Reference Conditions and Limitations 6 Do not store the vessel near heating sources and inflammable substances and avoid storing the vessel in badly ventilated rooms 7 Use vibration dampers to reduce the vibration during operation as this can cause failure Do not mount the vessel on the g...

Page 45: ...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 7002 03 43 ...

Page 46: ...Directive greater than or equal to category II Compressor type Part number Description PED Class LFx 0 7 up to LFx 2 0 0830 1007 68 Safety valve IV 0830 1008 57 Safety valve IV 2235 3772 80 Vessel 24 litre II 2235 3534 56 Vessel 50 litre II Overall rating The compressors conform to PED smaller than category II Instruction book 44 2920 7002 03 ...

Page 47: ...2 Declaration of conformity 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 Instruction book 2920 7002 03 45 ...

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Page 50: ...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 ...