Atlas Copco OSC 35 User manual

Atlas Copco
OSC 145
AIF999999
Instruction book

Atlas Copco
OSC 145
AIF999999
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.
2012 - 11
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................3
1.1 SAFETY ICONS...................................................................................................................................3
1.2 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................3
1.3 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................4
1.4 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................4
2 General description........................................................................................................6
2.1 INTRODUCTION...................................................................................................................................6
2.2 OPERATION.......................................................................................................................................6
3 Installation.....................................................................................................................11
3.1 DIMENSION DRAWING........................................................................................................................11
3.2 INSTALLATION PROCEDURE.................................................................................................................12
4 Operating instructions.................................................................................................14
4.1 PUTTING INTO OPERATION (COMMISSIONING)..........................................................................................14
5 Maintenance..................................................................................................................15
5.1 MAINTENANCE.................................................................................................................................15
5.2 SERVICE KITS..................................................................................................................................17
5.3 DISPOSAL OF USED MATERIAL.............................................................................................................19
5.4 SPARE PARTS..................................................................................................................................19
5.5 OPTIONS........................................................................................................................................21
6 Problem solving............................................................................................................22
7 Technical data...............................................................................................................23
7.1 REFERENCE CONDITIONS AND LIMITATIONS............................................................................................23
7.2 TECHNICAL DATA..............................................................................................................................23
Instruction book
2 AIF999999

1 Safety precautions
1.1 Safety icons
Explanation
Danger for life
Warning
Important note
1.2 Safety precautions during installation
1. Place the device where the ambient air is cool and as clean as possible. Consult section Reference
conditions and limitations.
2. During installation or any other intervention on one of the connected machines, the machines must be
stopped, de-energized and the isolating switch opened 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.
3. Install the equipment in an area free of flammable fumes, vapours and particles, e.g. paint solvents, that
can lead to internal fire or explosion.
4. The electrical connections must correspond to the applicable codes. The device must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed
near the device.
5. For machines controlled by a central control system, a sign stating "This machine may start without
warning" must be affixed near the instrument panel.
6. 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.
7. Never remove or tamper with the safety devices.
Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance or repair.
These precautions apply to electrical devices.
For precautions applying to the connected equipment consult the relevant instruction book.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your device.
Instruction book
AIF999999 3

1.3 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.
1. 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.
2. Never operate the device in the presence of flammable or toxic fumes, vapours or particles.
3. Never operate the device below or in excess of its limit ratings.
4. Do not operate the device when there are flammable or toxic fumes, vapors or particles.
5. Keep all bodywork doors and panels closed during operation. The doors may be opened for short periods
only, e.g. to carry out routine checks.
6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
7. Periodically check that:
• All guards and fasteners are in place and tight
• All hoses and/or pipes are in good condition, secure and not rubbing
• There are no leaks
• All electrical leads are secure and in good order
8. Never remove or tamper with the safety devices.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance or repair.
These precautions apply to electrical devices.
For precautions applying to the connected equipment consult the relevant instruction book.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 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.
1. Use only the correct tools for maintenance and repair work.
2. Use only genuine spare parts.
3. A warning sign bearing a legend such as "Work in progress - do not start" shall be attached to the starting
equipment, including all remote start equipment.
4. 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.
5. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
6. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
7. Never use a light source with open flame for inspecting the interior of the device.
Instruction book
4 AIF999999

8. 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.
9. Before clearing the device for use after maintenance or repair, 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.
10. Make sure that no tools, loose parts or rags are left in or on the device.
11. Never use caustic solvents which can damage materials of the device.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
These precautions apply to electrical devices.
For precautions applying to the connected equipment consult the relevant instruction book.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
Units and/or used parts should be disposed of in an environmentally friendly and safe
manner and in line with the local recommendations and legislation.
Instruction book
AIF999999 5

2 General description
2.1 Introduction
Compressed air produced by oil-injected compressors contains a small quantity of oil. During the cooling of
the air in the aftercooler and in the refrigeration dryer (on compressors with built-in refrigeration dryer), oil-
containing condensate is formed.
OSC are condensate treatment devices, designed to separate the major part of this oil from the condensate
and absorb it in filters.
They are insensitive to shocks and vibration because of the use of filters and can be used with all types of
drains. The condensate meets the requirements of the environmental codes.
The number in the model designation is the air capacity of the compressor in litres per second (see section
Technical data).
OSC 35 up to OSC 145 have two towers and are called two-step units.
OSC 355 up to OSC 1200 have three towers and are called three-step units.
OSC 2400 have six towers. They consist of two three-step units.
2.2 Operation
OSC 35 up to OSC 145:
Instruction book
6 AIF999999

OSC 145
1 Condensate outlet (at rear side)
2 Condensate inlet
3 Service indicator
4 Test outlet
Instruction book
AIF999999 7

Flow diagram (OSC 35 up to OSC 145)
1 Condensate inlet
2 Service indicator (oleophilic filter)
3 Mufflers
4 Oleophilic filter
5 First tower
6 Condensate outlet
7 Activated carbon filter
8 Second tower
9 Protector
The condensate, containing fine oil droplets, enters the unit via mufflers (3) and is depressurised. The
condensate flows to the first tower and seeps through an oleophilic filter (4), which absorbs most of the oil.
The water from the first tower, still containing a small quantity of oil, gradually flows to a second tower (8),
where an activated carbon filter (7) is fitted. This filter absorbs almost all of the remaining oil.
The clean condensate is drained to the condensate outlet (.
The oleophilic filter floats on the water. The more oil the filter absorbs, the deeper it will sink, and service
indicator (2) will move downwards with the filter. The filter must be replaced when the service indicator is
down.
OSC 355 up to OSC 2400:
Instruction book
8 AIF999999

OSC 355
1 Condensate outlet (at rear side)
2 Service indicator (unit clogged)
3 Condensate inlet
4 Service indicator (oleophilic filter)
5 Mufflers
6 Oleophilic filters
7 Activated carbon filters
8 First tower
9 Second tower
10 Third tower
11 Test outlet
12 Diffuser
The condensate, containing fine oil droplets, enters the unit via mufflers (5) and is depressurised. The
condensate flows to the first tower and seeps through an oleophilic filter, which absorbs most of the oil.
Instruction book
AIF999999 9

The water from the first tower, still containing a small quantity of oil, gradually flows to a second tower (9),
where two filters are fitted: a small oleophilic filter, which absorbs some more oil from the condensate, and
an activated carbon filter (7). The activated carbon filter starts to absorb the remaining oil in the condensate.
The condensate gradually flows to a third tower (10), where another activated carbon filter is fitted, which
absorbs almost all of the remaining oil.
The clean condensate is drained to the condensate outlet (1).
The oleophilic filter floats on the water. The more oil the filter absorbs, the deeper it will sink, and service
indicator (2) will move downwards with the filter. The filter must be replaced when the service indicator is
down.
Instruction book
10 AIF999999

3 Installation
3.1 Dimension drawing
OSC 35 OSC 95 OSC 145 OSC 355 OSC 600 OSC 825 OSC 1200 OSC 2400
A (mm) 470 680 680 750 750 945 945 945
B (mm) 165 255 255 546 546 650 695 1185
C (mm) 745 940 940 1100 1330 1450 1450 1450
Shipping
weight (kg)
4 13 15 25 26 28 30 60
Operating
weight (kg)
16 51 53 80 103 151 164 324
Model Connections
Inlet
BSP/NPT
Outlet
BSP/NPT
1 x 1/2 " 1 x 1/2 "
2 x 1/2 " 1 x 1/2 "
OSC 145 2 x 1/2 " 1 x 1/2 "
2 x 3/4 " 1 x 3/4 "
2 x 3/4 " 1 x 3/4 "
2 x 3/4 " 1 x 3/4 "
2 x 3/4 " 1 x 3/4 "
2 x 3/4 " 1 x 1 "
Instruction book
AIF999999 11

3.2 Installation procedure
OSC 35 up to OSC 145 (left), OSC355 and OSC 600 (right)
OSC 825 and OSC 1200
Reference Description
1 Service indicator (unit clogged)
2 Condensate inlet
3 Service indicator (oleophilic filter)
Instruction book
12 AIF999999

Reference Description
4 Condensate outlet
5 Tower 1
6 Tower 3
7 Tower 2
8 Diffuser
9 Condensate outlet (test)
10 Protector
A Housing part 1
B Housing part 2
Procedure
1. Install the OSC on a level floor, suitable for taking its weight.
Keep in mind to reserve sufficient free space for replacement of the filters (see section Maintenance).
2. On OSC 355 and OSC 600:
If the three towers stand in one line, rotate the third tower to the front.
It is possible to operate the unit with the three towers in line. However, it is recommended to
rotate the third tower as described above for easy change of the activated carbon filter in the
third tower. When the unit is operated with the towers in line, they have to be rotated in order
to change the filter. Keep in mind that the unit in operation can be heavy. (See the operating
weight in section Dimension drawing).
3. Stop the compressor and close the air outlet valve. Switch off the voltage. Depressurise the outlet piping
by opening the manual condensate drain.
4. Connect the automatic drain of the compressor condensate trap to the condensate inlet of the OSC.
The connection can be made using one or both condensate inlets. The piping diameter must be at least 6
mm . The flexible must be laid out in such a way that no pockets are formed where condensate can collect.
5. Connect the condensate outlet of the OSC to the sewer.
The outlet piping should have a section, sufficient to allow the condensate to flow without building up
pressure. An inner diameter of 19 mm (3/4 ") or larger is recommended. See section Dimension
drawing for the connection dimensions.
The OSC must be positioned higher than the sewer and the OSC outlet piping must be
installed with a slight downward slope to the sewer.
Instruction book
AIF999999 13

4 Operating instructions
4.1 Putting into operation (commissioning)
•The plastic bag of the filters must be removed. Do not remove the net around the filters.
•The activated carbon filter in the second tower must be placed on the flow plate.
On OSC 355 and OSC 600,
do not remove the flow plate. On all other models, the flow plate is not removable.
•Check that the activated carbon filters do not float. If necessary, hold them submerged
until they remain down.
Procedure
OSC 35 up to OSC 145:
1. Remove the lid of the first tower. Take out the oleophilic filter.
2. Remove the lid of the second tower and take out the activated carbon filter. Remove the plastic bag and
put the filter back. Check that the top of the filter is just below the condensate outlet. If not, check that the
filter is resting on the flow plate.
3. Pour clean water into the unit until the water comes out of the condensate outlet.
4. Put the oleophilic filter on the water surface in the first tower. Do not push the filter down.
5. Put back the lids.
OSC 355 up to OSC 1200:
1. Remove the lids. Take the oleophilic filter out of the first tower.
2. Remove the plastic bag from the activated carbon filter in the third tower. Put the filter back and check
that the top of the filter is just below the condensate outlet. If not, check that the filter rests on the bottom
of the vessel.
3. Take the small oleophilic filter and the activated carbon filter out of the second tower. Remove their bags.
First put back the activated carbon filter, then the small oleophilic filter. Fit the lid and check that the
service indicator is free to move.
4. Pour clean water into the unit until the water comes out of the condensate outlet.
5. Put the oleophilic filter back on the water surface of the first tower. Do not push the filter down.
6. Refit the lids.
OSC 2400:
The steps in section OSC 355 up to OSC 1200 must be done for the left side and for the right side.
Instruction book
14 AIF999999

5 Maintenance
5.1 Maintenance
Check the filters regularly as explained below in order to prevent untreated condensate from
entering the sewer.
Sample the condensate weekly.
•If the filters are not installed properly, oil-containing condensate can leave the OSC.
•When new activated carbon filters are placed, the outgoing water may initially look black
(caused by carbon dust). This is not harmful.
•Each new filter is provided with a label. The correct position is marked on the label.
•Used filters can be heavy.
•See to it that no condensate comes into contact with eyes, mouth, …
Checking the condensate
Every week, a test sample should be collected during compressor operation.
1. Open the test valve and collect the condensate in the test bottle.
2. Compare the turbidity of the sample with the 15 ppm turbidity reference bottle.
Test/sample bottle (1) and turbidity reference bottle (2)
Oleophilic filter
If the activated carbon filter has to be replaced, do this first (see section Activated carbon
filters).
Initially, the oleophilic filter will float almost completely on the condensate and only the bottom part will act
as filtration medium. By sorbing more and more oil, the filter will sink and new filter material will be exposed
to the condensate.
Instruction book
AIF999999 15

The filter must be replaced when the service indicator (see section Introduction) approaches the lid of the
tower.
The lifetime of the filter depends on the amount of oil in the condensate.
Replacement instructions
1. Stop the compressor and close the air outlet valve. Switch off the voltage. Depressurise the outlet piping
by opening the manual condensate drain.
2. Remove the lid of the first tower and take out the oleophilic filter (4 - Flow diagram of OSC 35 up to OSC
145). On OSC 355 up to OSC 1200, remove also the lid of the second tower and remove also the small
oleophilic filter (6 - View of OSC 355).
3. Only if necessary (see Problem solving, item 1), clean the inside of the OSC with water and tissue.
Do not use any form of soap or detergents as they could contain dispersants which deteriorate the ability
to break oil/water emulsions.
4. Fit the new filter (white label), observing the position. Do not push the filter below the water surface.
5. Fit the lid(s).
6. Remove the diffuser and pull out the mufflers. See section Introduction.
7. Fit the new mufflers and diffuser.
On OSC 2400: Repeat the instructions for OSC 355 up to OSC 1200 once for the left side of the unit and
once for the right side of the unit.
Activated carbon filter(s)
The activated carbon filters must be replaced when:
• The oleophilic filters are changed for the second time.
• The filters get clogged.
On OSC 355 up to OSC 2400, replace the filters when the service indicator (2 - View of OSC 355) is
rising.
• The condensate from the test outlet is less transparent than in the reference glass.
Replacement instructions
1. Stop the compressor and close the air outlet valve. Switch off the voltage. Depressurise the compressor
by opening the manual condensate drain.
2. Remove the lid of the second tower.
Take out the activated carbon filter (7 - Flow diagram of OSC 35 up to OSC 145). On OSC 355 up to
OSC 1200, take out the small oleophilic filter and replace also the activated carbon filter in the third tower.
3. Clean out the vessels with water and tissue. Do not use any form of soap or detergents as they could
contain dispersants which deteriorate the ability to break oil/water emulsions.
4. Fit the new filter in the tower (activated carbon = black label), observing its position.
On OSC 355 up to OSC 1200, put a new small oleophilic filter on top of the activated carbon filter (see
section Oleophilic filter).
5. Refill with clean water until it comes out of the condensate outlet.
On OSC 2400: Repeat the instructions for OSC 355 up to OSC 1200 once for the left side of the unit and
once for the right side of the unit.
Instruction book
16 AIF999999

5.2 Service kits
Atlas Copco has a complete range of service kits available. Service kits comprise all parts needed for servicing
components and offer the benefits of using genuine Atlas Copco parts while keeping the maintenance budget
low.
Service kits
1 Activated carbon filters
2 Oleophilic filters
3 Diffuser
4 Mufflers
For each type of OSC, three service kits are available:
•Service kit A comprises the material to change the oleophilic filter(s) once. It is a kit for the first service
after installation when the condensate is in normal condition. After this, service kit B can be used.
• Service kit B comprises the material to change the oleophilic filter(s) twice and the activated carbon filter(s)
once. This kit is also intended for use when the condensate is in normal condition. The lifetime of the
carbon filter is twice as long as that of the oleophilic filter.
• Service kit D comprises the material to change the oleophilic filter(s) as well as the activated carbon
filter(s) once. This kit should be used when the condensate contains a lot of oil, so that all the filters will
be saturated at the same time.
Part Number
Service kit A 2901 1400 00
Service kit B 2901 1400 01
Service kit D 2901 1575 00
Instruction book
AIF999999 17

Part Number
Service kit A 2901 1401 00
Service kit B 2901 1401 01
Service kit D 2901 1576 00
OSC 145 Part Number
Service kit A 2901 1402 00
Service kit B 2901 1402 01
Service kit D 2901 1577 00
The service kits for OSC 35 up to OSC 145 comprise:
Quantity, service kit A Quantity, service kit B Quantity, service kit D
Oleophilic filter 1 2 1
Activated carbon filter 0 1 1
Diffuser 1 2 1
Mufflers 1 2 1
Part Number
Service kit A 2901 1403 00
Service kit B 2901 1403 01
Service kit D 2901 1578 00
Part Number
Service kit A 2901 1404 00
Service kit B 2901 1404 01
Service kit D 2901 1579 00
Part Number
Service kit A 2901 1408 00
Service kit B 2901 1408 01
Service kit D 2901 1581 00
Part Number
Service kit A 2901 1409 00
Service kit B 2901 1409 01
Service kit D 2901 1582 00
The service kits for OSC 355 up to OSC 1200 comprise:
Instruction book
18 AIF999999