Atlas Copco Industrial cast iron piston compressors CR Range Instruction book
Atlas Copco Industrial cast iron piston compressors CR Range 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. 2019 - 02 No. 2022 2096 26 www.atlascopco.
Instruction book Table of contents Table of contents .......................................................................................................................... 2 1 Safety precautions ................................................................................................................. 4 1.1 Safety icons ...................................................................................................................................... 4 1.2 Safety precautions, general .....
Instruction book 5.3 Lubrication of compressors............................................................................................................. 39 5.4 Service kits ..................................................................................................................................... 39 5.5 Disposal of used material ............................................................................................................... 39 6 Servicing and adjustment procedures .......
Instruction book 1 Safety precautions 1.1 Safety icons Explanation Danger for 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.
Instruction book Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with the applicable 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.
Instruction book 1.4 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal precautions and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. Precautions during operation 1. Use only the correct type and size of hose end fittings and connections.
Instruction book 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 precautions and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. Precautions during maintenance or repair 1. 2. 3. 4. 5. 6. Always wear safety glasses. Use only the correct tools for maintenance and repair work.
Instruction book Also consult the 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 and equipment; hence some statements may not apply to your machine.
Instruction book 2 General description 2.1 General description Introduction CR Range Compressors are air-cooled, two cylinder, single-stage and double-stage, lubricated piston compressors, built for effective working pressures up to 145-175 psi.
Instruction book Tank-mounted, vertical receiver Reference 1 2 3 4 5 6 7 8 9 10 10 Tank-mounted, vertical receiver Description Compressor Filter Air pressure switch Air receiver Air pressure gauge Crankcase Intercooler Pressure relief valve Air outlet valve Control panel 2022 2096 26
Instruction book Tank-mounted, vertical receiver Reference 1 2 3 4 5 6 7 8 9 10 11 2022 2096 26 Tank-mounted, horizontal receiver Description Compressor Pressure relief valve Air outlet valve Hour meter (option) Electric cabinet On/off switch Air receiver Air pressure switch Air pressure gauge Compressor Condensate drain valve 11
Instruction book Compressor variants The compressor block includes: • Crankcase and cylinders • Air cooler piping • Check valve • Pressure relief valve The unit comprises: • Tank-mounted CR with electric motor: The compressor on a horizontal or vertical air receiver with air outlet valve, pressure gauge, pressure relief valve, air pressure switch with an on/off button (MDR), and condensate drain valve.
Instruction book Specifications Display Reading: 9999.
Instruction book 2.3 Control piping CR 2 to 15 hp Air drawn through the air filter and inlet silencer into cylinders is compressed, then discharged through the cooler piping and “and check valve / unloader valve” into the air receiver.
Instruction book From compressor discharge Used on CR-15 units only.
Instruction book From compressor discharge Used on CR-15 units only.
Instruction book Control piping and regulating system, duplex tank mount with automatic start/stop Reference 1 2 3 4 5 6 7 8 9 2022 2096 26 Description Control panel Pressure transducer Pressure gauge Air receiver 3-way normally-open solenoid valve Vent Pressure relief valve Compressor Discharge line 17
Instruction book Control piping and regulating system, duplex tank mount with dual control and solenoid valve Reference 1 2 3 4 5 6 7 8 9 10 11 12 18 Description Control panel Pressure transducer Pressure gauge Air receiver Vent Pressure relief valve Flow from interstage Interstage dump valve (Used on CR-15 units only.
Instruction book 2.4 Regulating system Automatic Start/Stop The regulating system includes: • Check valve • Air pressure switch (MDR) with pressure release valve and on/off button (S1). Operation The air pressure switch opens and closes its contacts at pre-set pressures. During loaded operation, the contacts are closed: the motor is running. When the pressure in the air receiver reaches the pre-set maximum pressure, the contacts as well as pressure release valve are opened.
Instruction book 3 Installation 3.1 Installation instruction Install the unit in an area where the noise levels do not cause inconvenience and adequate ventilation is available for cooling purposes. Before commencing installation, check that the electrical data on the compressor specification plate/s are compatible with the local power supply. Before connecting the electricity, ensure that the power supply is off and correctly isolated.
Instruction book Installation proposal for CR with horizontal receiver 2022 2096 26 21
Instruction book CR Install the compressor horizontally, in a cool but frost-free and well-ventilated room. Place the compressor as level as possible; however, CR can be operated with a maximum inclination of 40% (22.5 degrees) in any direction. The air should be clean. It is recommended to install an automatic condensate drain (available as an option) on the air receiver to ensure continuous condensate removal. CR Contractor The compressors are equipped with a lifting eye or yoke.
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Instruction book 3.3 Fuses and wire sizes Values shown here have been determined using National Electrical Code (NFPA 70). Local electrical code requirements my differ. Refer to your local electrical code. CR_5 CR_5 CR_7.5 CR_7.
Instruction book 4 Operating instructions 4.1 Initial start-up If the compressor has not run for the past 6 months (at initial start-up check the date on the data plate), it is strongly recommended to improve the lubrication of the compressor element: drain the oil, refill the compressor with the same oil while turning the crankshaft. 1. For tank-mounted and base mounted units, remove the RED transport brackets from underneath the compressor. 2.
Instruction book CR Contractor with electrical motor 1. Check the oil level, which must be near the top of the red circle of the sight-glass. The minimum level is the lower part of the red circle. 2. Set the pilot valve in the unload position by turning the red handle 90 degrees. Refer to Adjustment of pilot valve. 3. Attach the air lines to the air outlets. 4. Plug in and switch on the voltage at the main circuit breaker. Warning: Never move the compressor after plugging it in. 5.
Instruction book 4.3 Stopping CR 1. Turn the switch to position 0 (Off), or push switch (S1) to position 0. 2. Close air outlet valve. 3. Switch off the voltage. If a compressor with pressure switch stops during operation because of a power failure, the pressure from the air outlet pipe must be released by moving the switch on top of the air pressure switch to 0 to prevent the compressor from restarting against back-pressure when the power becomes live again. CR Contractor with Pilot Valve 1.
Instruction book 5 Maintenance 5.1 Gas engine maintenance Consult the engine “Owner’s manual”. 5.2 Preventive maintenance schedule The schedule contains a summary of the maintenance instructions. Read the respective section before taking maintenance measures. When servicing, replace all disengaged packing components, e.g. gaskets, O-rings, washers. The “longer interval” checks must also include the “shorter interval” checks.
Instruction book 5.3 Lubrication of compressors It is strongly recommended to use the Piston Fluid compressor oil to keep the compressor in excellent operating condition. Traditional lubricants cannot cope with the extreme conditions of piston compressors, resulting in fast oil degradation, overheating and potentially irreversible damage and high repair costs. Therefore, high performing lubricants increase the equipment lifetime.
Instruction book 6 Servicing and adjustment procedures Warning Release the pressure from the compressor before starting repair or maintenance works. Switch off the voltage and isolate the compressor from the mains. 6.1 Air filter To replace the air filter, follow these steps: 1. Stop the compressor. 2. Unscrew the cap on top of the cover. Lift off the cover and the filter element. Take care that no dirt drops inside the suction silencer. 3. Using a damp cloth, clean the filter chamber and cover.
Instruction book Adjustment • • Adjust the air pressure switch while it 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. The maximum pressure is controlled by adjusting screw (4). Turn the screw clockwise to raise the maximum or stopping pressure, counter-clockwise to lower it. The pressure difference is adjusted by means of screw (5).
Instruction book Adjustment • Adjust the air pressure switch while it 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. The stopping pressure is controlled by adjusting screw (2). Turn the screw clockwise to raise the stopping pressure, counter-clockwise to lower it. The pressure difference between starting and stopping is adjusted by means of adjusting screw (3).
Instruction book Unload mechanism The pilot valve is equipped with a hand-operated unload mechanism: by turning the red handle (1) 90 degrees, the plunger of the valve will be lifted, releasing the spring force. The air pressure from the pulsation dampers will force down unloader plunger (8) and the compressor will run unloaded. By turning handle (1) 90 degrees further, the plunger returns to its original position so that the pilot valve will again unload and load the compressor at the pre-set pressures.
Instruction book 7 Problem solving Condition Low discharge pressure Water in the crankcase (lubricant appears milky) Rusty valves and/or cylinders Excessive vibration Excessive drive belt wear 44 Fault Restricted inlet Defective compressor valves or valve unloading mechanism Leaks in the compressed air distribution system at fittings, connections, etc.
Instruction book Condition Low oil pressure Compressor loads and unloads excessively Defective pressure switch Excessive air pressure in air receiver Excessive intercooler pressure Intercooler pressure Compressor overheats 2022 2096 26 Fault Oil sump strainer plugged Excessive leakage at crankshaft seals Low oil level Oil pump incorrectly assembled to the bearing carrier (“o” ring not properly located between oil pump body & bearing carrier) Oil pressure adjusting screw not set properly Defective oi
Instruction book Condition High discharge temperature Compressor knocks Excessive oil consumption Excessive current draw (To determine maximum amperage allowed, multiply the FLA on the motor nameplate by the service factor.) CAUTION ! Motor surface temperature normally exceeds 170° F. Failure to start CAUTION! Overload relays are designed to protect the motor from damage due to motor overload.
Instruction book 8 Technical data 8.1 Reference conditions Inlet pressure (absolute) psi 14.5 Relative air humidity % 0 Air inlet temperature ºF 68 Working pressure: psi 145-175* * 145 psi for single stage units, 175 for two-stage units 8.2 Limitations Minimum inlet temperature °F 32 Maximum inlet temperature ºF 104 Maximum working pressure psi See below Only applicable for Full Feature variants. (with refrigerant dryer) Minimum ambient air temperature 8.
Instruction book 9 Instructions for use Air receiver (tank-mounted units) 48 1 Corrosion must be prevented: depending on the conditions of use, condensate may accumulate inside the tank and must be drained every day. This may be done manually, by opening the drain valve, or by means of the automatic drain, if fitted to the tank. Nevertheless, a weekly check of correct functioning of the automatic valve is needed. This has to be done by opening the manual drain valve and checking for condensate.
Instruction book ATLAS COPCO STANDARD TERMS AND CONDITIONS LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an authorized representative of Seller, the following terms and conditions shall apply to and form a part of this order and any additional and/or different terms of Buyer’s purchase order or other form of acceptance are rejected in advance and shall not become a part of this order.
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In order to be First in Mind-First in Choice® for all your quality compressed air needs, Atlas Copco delivers the products and services that help to increase your business’ efficiency and profitability. No. 2022 2096 26 / 2019 - 02 - Printed in U.S.A. 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.
