Atlas Copco Air Compressor User manual

Instruction book

2920 1521 00 1

Atlas Copco Stationary Air Compressors

Instruction book

SF1 - SF2 - SF4 Skid -Tank-mounted

SF6 - SF8 Twin

SF6 - SF8 - SF11 - SF15 Multi

Any unauthorized use 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 meets the requirements for instructions specified by the machinery directive

98/37/EC and is valid for CE as well as non-CE labelled machines.

No. 2920 1521 00

Registration code: APC SF / 38 / 980

2003-10 www.atlascopco.com

Note: The PED instructions for this machine are included at the end of the book.

Instruction book

2920 1521 00 2

This instruction book describes how to handle the machines to ensure safe operation, optimum

efficiency and long service life.

Read this book before putting the machine into operation to ensure correct handling, operation

and proper maintenance from the beginning. The maintenance schedule comprises measures for

keeping the machine in good condition.

Keep the book available for the operator and make sure that the machine is operated and that

maintenance is carried out according to the instructions. Record all operating data, maintenance

performed, etc. in an operator's logbook available from Atlas Copco. Follow all relevant safety

precautions, including those mentioned on the cover of this book.

Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any

further information.

In all correspondence mention the type and the serial number, shown on the data plate.

For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal

data".

The company reserves the right to make changes without prior notice.

Instruction book

2920 1521 00 3

1 LEADING PARTICULARS................................................................................................................... 5

1.1 General description........................................................................................................................ 5

1.1.1 Compressor variants ............................................................................................................... 5

1.1.2 Compressor elements (Fig. 1.1).............................................................................................. 5

1.2 Air flow ........................................................................................................................................... 9

1.3 Cooling and condensate drain systems (Fig. 1.9) ......................................................................... 9

1.4 Regulating system on SF Skid - Tank-mounted - Twin ............................................................... 10

1.5 Regulating system on SF Multi .................................................................................................... 11

1.5.1 Controlling the compressor ................................................................................................... 11

1.5.2 Protecting the compressor .................................................................................................... 11

1.5.3 Monitoring components subject to service............................................................................ 11

1.5.4 Automatic restart after voltage failure ...................................................................................11

1.5.5 Control panel (Fig. 1.11) ....................................................................................................... 12

1.5.6 Display – keys ....................................................................................................................... 13

1.5.7 Function keys (5-Fig. 1.11) ................................................................................................... 13

1.6 Electric cabinet on SF Multi ......................................................................................................... 15

1.7 Air dryer on SF Full-Feature (Fig. 1.15)....................................................................................... 16

2 INSTALLATION ................................................................................................................................. 17

2.1 Dimension drawings (Figs. 2.1 up to 2.5) ....................................................................................17

2.2 Installation proposal (Fig. 2.6) ..................................................................................................... 22

2.3 Electrical connections .................................................................................................................. 24

2.4 Pictographs .................................................................................................................................. 27

3 OPERATING INSTRUCTIONS .......................................................................................................... 28

3.1 Initial start-up ............................................................................................................................... 28

3.2 Starting......................................................................................................................................... 28

3.2.1 Multi....................................................................................................................................... 28

3.2.2 Skid - Tank-mounted - Twin .................................................................................................. 28

3.3 During operation .......................................................................................................................... 29

3.3.1 Multi....................................................................................................................................... 29

3.3.2 Skid - Tank-mounted - Twin .................................................................................................. 29

3.4 Stopping....................................................................................................................................... 29

3.4.1 Multi....................................................................................................................................... 29

3.4.2 Skid - Tank-mounted - Twin .................................................................................................. 29

3.5 Taking out of operation at end of compressor service life........................................................... 29

4 MAINTENANCE ................................................................................................................................. 30

4.1 Compressor drive motors ............................................................................................................ 30

4.2 Preventive maintenance schedule for the compressor................................................................ 30

5 ADJUSTMENTS AND SERVICING PROCEDURES ........................................................................ 32

5.1 Air filter (1-Figs. 1.7/1.8) .............................................................................................................. 32

5.2 Belt exchange/tensioning (Fig. 5.1) ............................................................................................. 32

5.3 Coolers......................................................................................................................................... 32

5.4 Safety valve ................................................................................................................................. 33

6 PROBLEM SOLVING ........................................................................................................................ 34

7 PRINCIPAL DATA ............................................................................................................................. 35

7.1 Electric cable size for SF1-8 ........................................................................................................ 35

7.2 Electric cable size for SF 6-15 Multi ............................................................................................ 35

7.3 Overload relays for SF1-8............................................................................................................ 36

7.4 Overload relays for SF6-15 Multi ................................................................................................. 36

7.5 Main fuses for SF1-8.................................................................................................................... 37

7.6 Main fuses for SF6-15 Multi......................................................................................................... 37

7.7 Reference conditions/limitations .................................................................................................. 37

7.8 SF1-4 8bar 50 Hz 1) ................................................................................................................... 38

7.9 SF2-4 10 bar 50 Hz 1) ................................................................................................................ 38

7.10 SF1-4 100 psi 60 Hz 1)............................................................................................................. 38

7.11 SF2-4 145 psi 60 Hz 1)............................................................................................................. 38

7.12 SF6-15 Multi 8 bar 50 Hz 1)...................................................................................................... 39

7.13 SF6-15 Multi 10 bar 50 Hz 1).................................................................................................... 39

7.14 SF6-15 Multi 100 psi 60 Hz 1) .................................................................................................. 39

7.15 SF6-15 Multi 125 psi 60 Hz 1) .................................................................................................. 40

Instruction book

2920 1521 00 4

7.16 SF6-15 Multi 145 psi 60 Hz 1) .................................................................................................. 40

8 REGULATOR FUNCTIONS FOR SF MULTI .................................................................................... 41

8.1 Menu-driven control programs..................................................................................................... 41

8.1.1 Function of control programs ................................................................................................ 42

8.1.2 Main screen........................................................................................................................... 42

8.1.3 Calling up other menus ......................................................................................................... 44

8.2 Quick look at actual compressor status....................................................................................... 44

8.3 Status data menu......................................................................................................................... 45

8.3.1 No message exists ................................................................................................................ 45

8.3.2 A shut-down message exists ................................................................................................45

8.3.3 A warning message exists .................................................................................................... 46

8.3.4 A service warning message exists ........................................................................................ 47

8.4 Measured data menu................................................................................................................... 47

8.5 Counters menu ............................................................................................................................ 48

8.6 Test menu .................................................................................................................................... 48

8.7 Modify parameters menu ............................................................................................................. 49

8.8 Modifying parameters .................................................................................................................. 49

8.8.1 Modifying the pressure bands ............................................................................................... 50

8.9 Modifying protection settings ....................................................................................................... 51

8.9.1 Checking protections for compressor modules..................................................................... 51

8.9.2 Modifying protections for Dryer LAT on Full-Feature machines ........................................... 52

8.10 Modifying service plans ............................................................................................................. 52

8.11 Programming Clock function...................................................................................................... 54

8.11.1 Programming start/stop/pressure band commands............................................................ 54

8.11.2 To activate/deactivate the timer .......................................................................................... 56

8.11.3 To modify a command......................................................................................................... 56

8.11.4 To add a command ............................................................................................................. 57

8.11.5 To delete commands........................................................................................................... 58

8.12 Configuration menu.................................................................................................................... 59

8.12.1 Programming compressor control modes ........................................................................... 60

8.13 Service menu ............................................................................................................................. 60

8.14 Saved data menu....................................................................................................................... 63

8.15 Programmable settings.............................................................................................................. 64

8.15.1 Regulation settings.............................................................................................................. 64

8.15.2 Service settings ................................................................................................................... 65

9 CONVERSION LIST OF SI UNITS INTO US/BRITISH UNITS ......................................................... 65

Instruction book

2920 1521 00 5

1 LEADING PARTICULARS

1.1 General description

SF1 up to SF15 are stationary, oil-free compressors driven by an electric motor.

1.1.1 Compressor variants

SF Skid (Fig. 1.2)

The components of the compressor are housed in a bodywork with removable front/top panel. The

compressor is mounted on a frame designed to allow easy installation at the required spot.

SF Tank-mounted (Fig. 1.3)

The components of the compressor are housed in a bodywork with removable front/top panel. The

compressor is mounted on an air receiver.

SF Twin (Fig. 1.4)

Two compressor modules are mounted on an air receiver. Each module is provided with its own control

panel.

SF Multi Pack

The compressors have two up to four compressor modules enclosed in a sound-insulated bodywork.

The front door comprises an Elektronikon regulator including the start and stop buttons. An

emergency stop button is also provided. An electric cabinet comprising the motor starter is installed

behind the front door.

SF Multi Full-Feature (Figs. 1.5 and 1.6)

Full-Feature compressors are Pack compressors additionally provided with an air dryer integrated in

the bodywork. The dryer removes moisture from compressed air by cooling the air to near freezing

point and automatically draining the condensate. See section 1.7.

1.1.2 Compressor elements (Fig. 1.1)

Each compressor 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 through outlet opening (3).

1 Air inlet

2 Fixed scroll

3 Compressed air outlet

4 Orbiting scroll

Fig. 1.1 Compressor element

Instruction book

2920 1521 00 6

1 Control panel

2 Air outlet valve

Fig. 1.2 SF4 Skid

1 Control panel

2 Air outlet valve

1.3 SF4 Tank-mounted

Instruction book

2920 1521 00 7

1 Control panels

2 Air outlet valve

Fig. 1.4 SF Twin

1 Elektronikon regulator

2 Electric cabinet

3 Air outlet valve

4 Dryer (on Full-Feature)

5 Compressor modules

S3 Emergency stop button

Fig. 1.5 SF8FF Multi

Instruction book

2920 1521 00 8

1 Elektronikon regulator

2 Electric cabinet

3 Air outlet valve

4 Dryer (on Full-Feature)

5 Compressor modules

6 Safety valve (ASME)

S3 Emergency stop button

Fig. 1.6 SF15FF Multi

1 Air filter

2 Compressor element

3 Air cooler

4 Belts

5 Safety valve

6 Drive motor

7 Safety valve

Fig. 1.7 Details of a compressor module on SF Tank-mounted

Instruction book

2920 1521 00 9

1 Air filter

2 Drive motor

3 Compressor element

4 Compressed air outlet

5 Safety valve (CE)

Fig. 1.8 Details of a compressor module on SF Multi

1.2 Air flow

Air is drawn through the air filter into the compressor modules and is compressed. Compressed air is

discharged through the check valve and air cooler towards the air net.

1.3 Cooling and condensate drain systems (Fig. 1.9)

Each compressor element is cooled by a fan. The fan is mounted on the drive shaft of the compressor

element. The cooling air is blown over the compressor element and air cooler via a duct.

For SF Multi two fans, driven by electric motors, expel warm air from the bodywork.

SF Multi have a condensate trap, with an automatic condensate outlet (2) and a manual drain valve

(1).

1 Manual condensate drain valve

2 Automatic condensate outlet

Fig. 1.9 Condensate drains on SF Multi

Instruction book

2920 1521 00 10

1.4 Regulating system on SF Skid - Tank-mounted - Twin

The air net pressure is kept within limits by a pressure switch mounted in the cabinet below the control

panel (Fig. 1.10). The switch is connected to the air outlet and electrically connected in the circuit of

the drive motor. The switch opens and closes its contacts at pre-set pressures.

1 Pressure gauge

2 On/off switch

3 Hourmeter

4 Air pressure switch/circuit breaker

Fig. 1.10 Control panel SF Skid - Tank-mounted - Twin

When the contacts are closed, the circuit to the drive motor is made: the compressor is operating. The

air output is maximum.

When the pressure reaches the pre-set maximum, the circuit to the drive motor is broken, causing the

compressor to stop. The air output is stopped.

Protecting the compressor

The compressor will be shut down in case temperature switch (TSHH11-Fig. 2.7) trips.

Warning

Before carrying out any inspection or repair, stop the compressor, switch off the voltage, open the

isolating switch and depressurize the compressor.

Instruction book

2920 1521 00 11

1.5 Regulating system on SF Multi

SF Multi are provided with an Elektronikon® regulator (Fig. 1.11) to control the compressor.

The following is a short description of the main functions of the regulator. Consult section 8 for a

detailed description of all functions.

1.5.1 Controlling the compressor

The Elektronikon regulator keeps the net pressure within programmable limits by starting and stopping

the compressor modules, depending on the air consumption. The regulator distributes the running

time among the compressor modules, taking into account the availability and number of running hours

of each compressor module.

When the compressor has stopped automatically and the net pressure decreases, the regulator will

start a compressor module before the net pressure has dropped to the starting pressure to prevent the

net pressure from falling under the programmed minimum level.

1.5.2 Protecting the compressor

If one or more compressor modules are shut down due to a protection function a warning message will

be shown on the display.

The compressor will be shut down in case temperature switch (TSHH20-Fig. 2.8) trips. See also

section 8.3.2.

Warning

Before carrying out any inspection or repair, stop the compressor, switch off the voltage, open the

isolating switch and depressurize the compressor.

After remedying, switch on the voltage and press the key “Reset” (F3).

1.5.3 Monitoring components subject to service

A number of service operations are grouped in plans (called Service plans I, A, B and D). Each

Service plan has a programmed time interval. If a time interval is exceeded, a message will appear on

the display to warn the operator to carry out the service actions belonging to that plan.

1.5.4 Automatic restart after voltage failure

The regulator has a built-in function to automatically restart the compressor if the voltage is restored

after voltage failure. For compressors leaving the factory, this function is made inactive. If desired,

the function can be activated. Consult Atlas Copco.

Instruction book

2920 1521 00 12

Fig. 1.11 Elektronikon regulator on SF Multi

1.5.5 Control panel (Fig. 1.11)

To control the compressor and to read and modify programmable parameters, the regulator is provided with a

control panel including:

Ref Designation Function

1 Start button

Push button to start the compressor. LED (8) lights up indicating

that the regulator is operative (in automatic operation).

2 Display

Indicates messages concerning the compressor operating

condition, a service need or a fault.

3 Scroll keys Keys to scroll through the display.

4 Tabulator key

Key to select the parameter indicated by a horizontal arrow.

Only the parameters followed by an arrow pointing to the right

are accessible for modifying.

5 Function keys Keys to control and program the compressor.

6 Voltage on LED Indicates that the voltage is switched on.

7 General alarm LED Is alight in case of a warning condition, see section 8.3.

7 General alarm LED

Blinks in case of shut-down condition, if a sensor with shut-

down function is out of order or after an emergency stop. See

section 8.3.

8 Automatic operation LED

Indicates that the regulator is automatically controlling the

compressor: the compressor is stopped and restarted

depending on the air consumption and the limitations

programmed in the regulator.

9 Stop button Push button to stop the compressor. LED (8) goes out.

10 Pictograph Voltage on.

11 Pictograph Alarm condition.

12 Pictograph Automatic operation.

S3 Emergency stop button

Push button to stop the compressor immediately in case of

emergency. After remedying the trouble, unlock the button by

pulling it out.

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2920 1521 00 13

1.5.6 Display – keys

Compressor Outlet 7.0 bar

Compressor Running

↓

Menu - - - -

F1 F2 F3

Fig. 1.12 Typical example of a display

Operating condition of a compressor module

The symbols shown above key F3 indicate the operating condition of each control module, see also section

8.1.2:

Symbol Indicates

-

that the compressor module is available (ready to run), each

symbol stands for a compressor module (the left symbol stands for

the lowest mounted module, the right symbol stands for the

highest module)

▄ that the compressor module is running

- (blinking)

that the compressor module is not available (due to minimum stop

time or too many starts)

* (blinking) that the compressor module is shut-down

Scroll keys (3-Fig. 1.11)

These keys, labelled with vertical arrows, allow to scroll through the display.

As long as a downwards pointing arrow is shown at the utmost right position of the display, the key (3) with

the same symbol can be used to see the next item.

As long as an upwards pointing arrow is shown at the utmost right position of the display, the key (3) with the

same symbol can be used to see the previous item.

Tabulator key (4-Fig. 1.11)

This key, labelled with two horizontal arrows, allows the operator to go to the next field of the display, e.g.

during modifying of programmable parameters.

1.5.7 Function keys (5-Fig. 1.11)

The keys are used:

- To call up or program settings

- To reset an active shut-down or service message, or an emergency stop

- To have access to all data collected by the regulator

The function keys allow to make the required selection from a menu of possibilities. The functions of the keys

vary depending on the displayed menu. The actual function is abbreviated and indicated on the bottom line of

the display just above the relevant key. Only the active and relevant functions at a moment are shown:

Designation Function

Back To return to a previously shown option or menu

Cancel To cancel a programmed setting when programming parameters

Delete To delete compressor start/stop commands

Extra To find the module configuration of the regulator

Help To find the Atlas Copco internet address

Limits To show limits for a programmable setting

Mainscreen To return from a menu to the main screen

Instruction book

2920 1521 00 14

Designation Function

Menu Starting from the main screen, to have access to submenus

Menu Starting from a submenu, to return to a previous menu

Modify To modify programmable settings

Program To program modified settings

Reset To reset a timer or message

Return To return to a previously shown option or menu

Selecting a menu

To facilitate controlling the compressor, menu-driven programs are implemented in the electronic module.

Use the function keys (5) to select the menus in order to program and monitor the compressor. See also

section 8.

Fig. 1.13 Menu flow, SF Multi

Instruction book

2920 1521 00 15

1.6 Electric cabinet on SF Multi

F1/8 Fuses

K11 Auxiliary contactor, dryer

K21/24 Contactors

Q21/24 Circuit breakers

T1/2 Transformers

1X0 Terminal strip, mains supply

1X2 Terminal strip, dryer

1X3/6 Terminal strips

Fig. 1.14 Electric cabinets, SF Multi

Instruction book

2920 1521 00 16

1.7 Air dryer on SF Full-Feature (Fig. 1.15)

Compressed air circuit

Wet compressed air enters heat exchanger (13) and is cooled by the outgoing, cold, dried air. Water in the

incoming air starts to condense. The air then flows through heat exchanger (11) where the refrigerant

evaporates and withdraws heat from the air. More water in the air condenses. The cold air then flows

through condensate separator (3) where the condensate is separated from the air. The condensate is

automatically drained through outlet (5). The cold, dried air then flows through heat exchanger (13), where it

is warmed up by the incoming air.

Refrigerant circuit

Compressor (M1) delivers hot, high-pressure refrigerant gas which flows through condenser (9) where most

of the refrigerant condenses.

The liquid flows through liquid refrigerant dryer/filter (12) to capillary tube (7). The refrigerant leaves the

capillary tube at evaporating pressure.

The refrigerant enters evaporator (11) where it withdraws heat from the compressed air by further evaporation

at constant pressure. The heated refrigerant leaves the evaporator and is sucked in by the compressor.

AO

AI

5

6

4

3

2

1

13

11

12

REFRIGERANT LIQUID (3)

REFRIGERANT GAS (2)

AIR (1)

50972D

7

10

S3

9

8

M2

M1

Text on Fig. 1.15

(1) Air

(2) Refrigerant gas

(3) Refrigerant liquid

AI Wet air inlet 5 Automatic condensate drain

AO Dry air outlet 6 Manual condensate drain valve

M1 Refrigerant compressor 7 Capillary tube

M2 Condenser fan motor 8 Condenser cooling fan

S3 Fan control switch 9 Refrigerant condenser

1 Pressure dewpoint sensor 10 Hot gas by-pass valve

2 Insulating block 11 Air/refrigerant heat exchanger/evaporator

3 Condensate separator 12 Liquid refrigerant dryer/filter

4 Condensate trap 13 Air/air heat exchanger

Fig. 1.15 Dryer on SF Full-Feature

Instruction book

2920 1521 00 17

2 INSTALLATION

2.1 Dimension drawings (Figs. 2.1 up to 2.5)

9820 4052 00/1

55100D

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Fig. 2.1 Dimension drawing, SF 1-4 Skid

9820 4053 00/1

55101D

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Fig. 2.2 Dimension drawing, SF 1-4 Tank-mounted

Instruction book

2920 1521 00 18

9820 4054 00/1

55102D

(1)

(2)

(1)

(3)

(4)

(5)

(6)

(7) (8)

Fig. 2.3 Dimension drawing, SF 6-8 Twin

Text on Figs.2.1/2.3

1 Motor cooling air outlet 5 Electrical supply

2 Element cooling outlet 6 Type

3 Cooling air inlet 7 Pressure

4 Compressed air outlet 8 Mass, approx.

Instruction book

2920 1521 00 19

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(8)

(9)

(12)

(13)

(14)

(15)

9820 4027 00

55098D

Fig. 2.4 Dimension drawing, SF 6-8 Multi

Instruction book

2920 1521 00 20

9820 4026 00

55099D

(1)

(16)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(8)

(9)

(12)

(13)

(14)

(15)

Fig. 2.5 Dimension drawing, SF 11-15 Multi

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Atlas Copco Air Compressor User manual

Atlas Copco Air Compressor User manual

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