Atlas Copco SF 1 User manual

Atlas Copco
Oil-free scroll compressors
SF 1, SF 2, SF 4, SF 6
Instruction book

Atlas Copco
Oil-free scroll compressors
SF 1, SF 2, SF 4, SF 6
From following serial No. onwards: API 730 000
Instruction book
Original instructions
Copyright notice
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 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.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................4
1.1 SAFETY ICONS................................................................................................................................... 4
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................4
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................5
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 6
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 7
2 General 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 SERVICE KITS.................................................................................................................................. 29
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5.3 DISPOSAL OF USED MATERIAL............................................................................................................. 29
6 Adjustments and servicing procedures..................................................................... 30
6.1 PRESSURE SWITCH........................................................................................................................... 30
6.2 AIR FILTER......................................................................................................................................31
6.3 AIR COOLER....................................................................................................................................32
6.4 DRIVE MOTOR..................................................................................................................................32
6.5 SAFETY VALVE ................................................................................................................................32
6.6 BELT REPLACEMENT..........................................................................................................................33
6.7 TEMPERATURE PROTECTION............................................................................................................... 35
6.8 CLEANING THE COMPRESSOR ELEMENT.................................................................................................35
6.9 REPLACEMENT OF 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 equipment directives................................................................................... 48
12 Declaration of conformity............................................................................................ 49
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 Safety precautions, general
General precautions
1. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
4. Never use compressed air as breathing air without prior purification in accordance with 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 the air to clean dirt from your clothes. When using the air to clean equipment, do so with
extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the compressor or its components.
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1.3 Safety precautions during installation
All responsibility for any damage or injury resulting from 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 included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with local safety regulations.
Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or
stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe
limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction
duct. Never obstruct the air inlet. Care must be taken to minimise the entry of moisture at the inlet air.
Consult section Reference conditions and limitations.
3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must 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 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 clear sign stating "DANGER: This machine is
remotely controlled and may start without warning".
The operator has to make sure that the machine is stopped and that the isolating switch is open and
locked before any maintenance or repair. As a further safeguard, 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 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 all phases. A lockable power isolating switch must be
installed near the compressor.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure
is activated, a sign stating "This machine may start without warning" must be affixed near the
instrument panel.
13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-
return valves (check valves) must not be relied upon for isolating pressure systems.
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure relieving device or devices as required.
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15. Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high temperature
piping must be clearly marked.
16. For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet pressure.
17. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
1.4 Safety precautions during operation
All responsibility for any damage or injury resulting from 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 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 the compressor during operation.
2. Use only the correct type and size of hose end fittings and connections. 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
the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g.
to carry out routine checks. Wear ear protectors when opening a door.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 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 are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a working area,
take precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of, or tamper with, the sound dampening material.
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11. Never remove or tamper with the safety devices, guards or insulation fitted to the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
12. Be aware of possible blow off of safety valves during operation. For the location of the safety valves,
consult the description in this instruction book.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
1.5 Safety precautions during maintenance or repair
All responsibility for any damage or injury resulting from 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 included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
Precautions during maintenance or repair
1. Always use the correct safety equipment such as safety glasses, gloves, safety shoes, etc.
2. Use only the correct tools for maintenance 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 machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
7. Close the compressor air outlet valve before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near any oil system. Oil tanks must be
completely purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in
any way modify, pressure 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 to avoid spontaneous ignition of the oil vapour (if applicable) when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
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15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they 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 damaged, replace it by genuine material 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. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
21. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
22. Be aware of eventual sharp edges on certain parts of the machine.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
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2 General description
2.1 Introduction
General
SF 1, SF 2, SF 4 and SF 6 are stationary, single stage, oil-free compressors, driven by an electric motor.
The compressors are controlled by a pressure switch.
The compressors are enclosed in a sound dampening enclosure and are air cooled.
Available versions:
• The Pack version (P) comprises the motor, the compressor element, the air cooled aftercooler and the
regulation and protection components.
• The Full Feature (FF) version is a Pack version, completed with an integrated refrigerant dryer.
The basic version (referred to as the floor mounted version (FM)) does not include an air receiver.
Available options:
• Air receiver of 30 l (7.93 US gal), 270 l (71.3 US gal) or 500 l (132 US gal). The 30 l receiver
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 gauge, an hour meter and a start button. The compressor is
controlled by a pressure switch (PS).
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).
Single phase units are equipped with a vent valve for easy starting.
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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
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Gp Pressure gauge 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
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SF 4 P - details
AF Inlet air filter AV Air outlet valve
Ca Air cooler E Compressor element
M Motor PS Pressure switch
SV Safety valve TSHH Temperature switch
CV Check valve
SF Full-Feature
The control panel comprises a pressure gauge, an hour meter, a start button and a temperature gauge
indicating the dew point (Gd). 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 enters the dryer.
Single phase units are equipped with a vent valve for easy starting.
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SF 6 FF floor mounted - general 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
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AF Inlet air filter AV 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
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(1) Compressor module (5) Units with dryer on air receiver
(2) Units without dryer and air receiver (6) Refrigerant dryer
(3) Units with dryer, without receiver (7) To cubicle
(4) Units without dryer on air receiver (8) Compressed air outlet
Air flow
Air is drawn through air filter (100) and is compressed by the compressor element (101). Next, the
compressed air flows through the check valve (105) and the air cooler (106).
Single phase units are equipped with a solenoid valve (109) and a silencer (110) for easy starting at low
voltage.
On floor mounted versions without refrigerant dryer, the air flows then directly to the outlet valve (121).
On receiver mounted units, the compressed air flows into the air receiver (120), onto which the outlet valve
AV (121) is fitted.
On compressors with refrigerant dryer, the compressed air flows to the refrigerant dryer (ID), where the
water 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 refrigerant dryer, a separate fan (204) delivers cooling air for the dryer.
Condensate management
Floor mounted compressors without refrigerant dryer have no drain. A water separator is available as
option.
The dryer of compressors equipped with a refrigerant dryer has an integrated water separator (201c) and an
electronic water drain (210). The water separator has a manual drain valve (211) and a connection for the
automatic drain. For more details, consult section Refrigerant dryer.
The receiver of receiver mounted compressors has a manual drain valve (122) at the bottom. An electronic
condensate drain is available as option.
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Regulating system and protection
The compressor is started and stopped automatically by a pressure switch (PS). A pressure gauge (PI)
indicates the pressure. A temperature switch (TSHH) protects the compressor element from too high
temperatures.
A safety valve (108) protects the compressor element against too high pressure.
2.3 Refrigerant dryer
Operation
The refrigerant dryer removes moisture from the compressed air by cooling it down to near freezing
temperature. The water is removed via an automatic 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 cold air then flows through water
separator (3), where the condensate is separated from the air. The condensate is automatically drained by
the electronic condensate drain (9).
The cold, dried air flows through heat exchanger (1) where it is warmed up by the incoming air.
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Refrigerant circuit
Compressor (4) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most
of the refrigerant condenses.
Next, the liquid refrigerant flows through 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 leaves the evaporator and is sucked in again by the
compressor.
The condenser (6) pressure must be kept as constant as possible to obtain stable operation. 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 condensate drain. The condensate, separated by the condensate
trap, accumulates inside the drain. Once 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.
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3 Installation
3.1 Dimension drawings
The dimension drawings can be found on the DVD or the USB, supplied with the compressor.
Model Dimension drawing number
SF 1-6 P FM EP metric 9820 6376 02-01
SF 1-6 P FM EP imperial 9820 6376 02-04
SF 1-6 FF FM EP metric 9820 6376 03-01
SF 1-6 FF FM EP imperial 9820 6376 03-04
SF 1-6 P TM EP metric 9820 6376 04-01
SF 1-6 P TM EP imperial 9820 6376 04-04
SF 1-6 FF TM EP metric 9820 6376 05-01
SF 1-6 FF TM EP imperial 9820 6376 05-04
SF 1-6 P-FF 30 l EP metric 9820 6376 06-01
SF 1-6 P-FF 30 l EP imperial 9820 6376 06-04
Legend
P Without refrigerant dryer FF With integrated refrigerant dryer
FM Floor mounted TM On air receiver
30 l With integrated 30 l air receiver EP 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 DRAIN Automatic drain outlet
CENTRE OF GRAVITY Location of centre of gravity
DRYER SERVICE PANEL Service panel for the dryer
DOOR FULLY OPEN Dimensions with fully open door
COOLING AIR INLET OF
DRYER
Cooling air inlet for the dryer
ANCHOR POINTS Location of anchoring points
AIR RECEIVER MANUAL
DRAIN
Manual drain of the air receiver
THE DIMENSIONS FOR 500 L
VESSEL...
Dimensions of the 500 l vessel are indicated between ( ) where they are
different from the dimensions of the 270 l vessel.
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