Atlas Copco Oil-free scroll compressors SF 2+, SF 4+, SF 6+ Instruction book
Atlas Copco Oil-free scroll compressors 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.
Instruction book Table of contents 1 Safety precautions..........................................................................................................6 1.1 SAFETY ICONS................................................................................................................................... 6 1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................6 1.3 SAFETY PRECAUTIONS DURING INSTALLATION.........
Instruction book 3.15 SELECTION BETWEEN LOCAL, REMOTE OR LAN CONTROL.......................................................................42 3.16 CALLING UP/MODIFYING CAN ADDRESS CONTROL.................................................................................. 43 3.17 CALLING UP/MODIFYING IP, GATEWAY AND SUBNETMASK........................................................................ 44 3.18 CALLING UP/MODIFYING PRESSURE BAND SETTINGS.......................................................
Instruction book 4.15 GENERAL SETTINGS MENU..................................................................................................................89 4.16 INFO MENU......................................................................................................................................90 4.17 WEEK TIMER MENU...........................................................................................................................91 4.18 TEST MENU.................................
Instruction book 8.4 SAFETY VALVE ..............................................................................................................................126 8.5 BELT REPLACEMENT........................................................................................................................126 8.6 TEMPERATURE PROTECTION............................................................................................................. 128 8.7 CLEANING THE COMPRESSOR ELEMENT.....................
Instruction book 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.
Instruction book 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.
Instruction book 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.
Instruction book 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.
Instruction book 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.
Instruction book 2 General description 2.1 Introduction General SF 2+, SF 4+ and SF 6+ are stationary, single stage, oil-free compressors, driven by an electric motor. The compressors are controlled by an Atlas Copco Elektronikon controller. See sections Elektronikon controller and following for details. The compressors are enclosed in a sound dampening enclosure and are air cooled.
Instruction book SF 4+ P - floor mounted - general view 12 ER Elektronikon controller AV Air outlet valve S3 Emergency stop button 2920 7110 21
Instruction book SF 6+ P on a 270 l receiver AV Air outlet valve Dm Manual drain valve SF 4+ Pack- details 2920 7110 21 13
Instruction book AF Inlet air filter AV Air outlet valve Ca Air cooler E Compressor element M Motor ER Elektronikon controller SV Safety valve TSHH Temperature sensor CV Check valve SF Full-Feature An Elektronikon controller module, fitted in the front panel, controls the compressor and the dryer. 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.
Instruction book SF 6+ FF with optional CD dryer on a 270 l receiver ER Elektronikon controller Gd Dew point gauge S3 Emergency stop button ID Refrigerant dryer AV Air outlet valve Da Automatic drain outlet Dm Manual drain valve CD Desiccant dryer 2920 7110 21 15
Instruction book SF 6+ FF - details 16 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 sensor 2920 7110 21
Instruction book 2.
Instruction book SF FF on air receiver with optional CD dryer (1) FF units on air receiver with optional CD dryer (2) To cubicle (3) 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.
Instruction book 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.
Instruction book 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.
Instruction book 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. 2.
Instruction book CD 3+ Operation Flow diagram CD 3+ 22 2920 7110 21
Instruction book Reference Designation Reference Designation 1 Compressed air inlet 7 Electrical control line 2 Dryer controller 8 Flow restriction 3 Left desiccant tower 9 Check valve 4 Right desiccant tower 10 Selector valve 5 Compressed air outlet 11 Pneumatic silencer 6 Flow line 12 Solenoid valve The operation cycle of the dryer is repetitive and is controlled by a factory set timer.
Instruction book 24 Reference Designation Reference Designation 3 LED 9 Outlet selector valve 4 LED 10 Solenoid valves 5 LED 11 Service reset 6 Air inlet 2920 7110 21
Instruction book 3 Elektronikon controller 3.1 General description Control panel Introduction The Elektronikon® controller has following functions: • • • • Controlling the compressor Protecting the compressor Monitoring components subject to service Automatic restart after voltage failure (see section Activating automatic restart for details) Controlling the compressor The regulator maintains the net pressure between programmable limits by automatically starting and stopping the compressor.
Instruction book Automatic restart after voltage failure The regulator has a built-in function to automatically restart the compressor when the voltage is restored after a voltage interruption. This function is inactive in compressors leaving the factory. If desired, the function can be activated. Consult the Atlas Copco Customer Center if a change is considered (password protected function).
Instruction book 3.3 Reference Designation Function 12 Scroll buttons Use these buttons to scroll through the menu . 13 Enter button Use this button to confirm the last action. 14 Escape button Use this button to go to the previous screen or to end the current action. Icons used on the display Function Compressor status Icon Description When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating.
Instruction book Function Units Icon Description Pressure unit (Mega Pascal) Pressure unit (pounds per square inch) Pressure unit (bar) Temperature unit (°C) Temperature unit (°F) Hours (always shown together with seconds) Percent The value shown must be multiplied by 10 to get the actual value. The value shown must be multiplied by 100 to get the actual value. The value shown must be multiplied by 1000 to get the actual value.
Instruction book Function Icon Description Dew point temperature 3.4 Main screen When the voltage is switched on, the first screen is a test screen. The next screen is the Main screen, shown automatically. Main screen The Main screen shows: • The compressor status by means of pictographs • The air outlet pressure Consult Atlas Copco if the pressure on the display is preceded by a "t". 3.
Instruction book Compressor element temperature Press Scroll down button (12). The screen shows the compressor element temperature: Compressor element temperature: 32.8 °C It remains possible to scroll through other screens (using Scroll buttons (12)) to check the actual status of other parameters. Press the Stop button (11) to stop the compressor Switch off the voltage, inspect the compressor and remedy. The warning message will disappear as soon as the warning condition disappears.
Instruction book is flashing. Press the Scroll buttons (12) until the actual dew point temperature appears. Warning screen, dew point temperature Above screen shows that the dew point temperature is 9˚C. It remains possible to scroll through other screens (using Scroll buttons (12)) to check the actual status of other parameters. Press the Stop button (11) to stop the compressor Switch off the voltage, inspect the compressor and remedy if necessary.
Instruction book The related pictograph will appear flashing. • Press the Scroll buttons (12) until the actual compressor element temperature appears. Shutdown screen, compressor element temperature In above example, the screen shows that the compressor element temperature is 95 ˚C. In such case, • Switch off the voltage and remedy the trouble.
Instruction book Main screen with shutdown indication, motor overload In such case, • Switch off the voltage and change the phase sequence of the supply line. • Switch on the voltage and restart the compressor. 3.7 Service warning A service warning will appear when the service timer has reached the programmed time interval. Control panel • If the service timer exceeds the programmed time interval, warning LED (9) will light up. See Calling up/modifying service timer settings.
Instruction book • The long interval service actions must also include the short interval actions. • The setting of the service timer can be changed in function of the operating conditions. • After servicing, reset the service timer. See section Calling up/resetting the service timer. 3.8 Scrolling through all screens Scrolling Control panel Scroll buttons (12) can be used to scroll through all screens. The screens can be differentiated into measured data screens, digital input screens (
Instruction book Digital input screens Designation Related topic Motor starts (x 1 or x 1000) See section Calling up motor starts Module hours (hrs or x 1000 hrs) See section Calling up module hours Service timer reading (hrs or x 1000 hrs) See section Calling up/resetting the service timer Actual program version - Parameter screens Designation Related topic
Instruction book Menu flow Simplified menu flow 36 Reference Description Reference Description (1) Compressor outlet pressure (15) Service timer settings (2) Compressor element temperature (16) Temperature unit (3) Dew point temperature (17) Pressure unit 2920 7110 21
Instruction book 3.
Instruction book Compressor element temperature The screen shows that the compressor element temperature is 82 ˚C. Press Scroll button (12) again. The dew point temperature will be shown: Dew point temperature The screen shows that the dew point temperature is 3 ˚C. Press the Escape button (14) or wait a some time to return to the Main screen. 3.10 Digital inputs Control panel Starting from the Main screen, press Scroll button (12) until is shown and then press the Enter button (13).
Instruction book Digital inputs The screen shows (from left to right) the status of the emergency stop contact, the compressor motor overload protection (or incorrect phase sequence for units equipped with a phase sequence relay) and the remote start/stop contact 1 means the contact is closed, 0 means the contact is open.
Instruction book Running hours The screen shows the unit used and the value 11.25: the running hours of the compressor are 11250 hours. 3.12 Calling up motor starts Control panel Control panel Starting from the Main screen, press the Scroll button (12) until is shown and then press the Enter button (13). A screen similar to the following appears: Number of motor starts This screen shows the number of motor starts ( or - if lights up - x 1000).
Instruction book 3.13 Calling up module hours Control panel Starting from the Main screen, press the Scroll button (12) until is shown and then press the Enter button (13). A screen similar to the following appears: Module hours In the example shown, the screen shows the unit used and the value 5000: the regulator module has been in operation for 5000 hours. 3.
Instruction book Starting from the Main screen: Main screen Press the Scroll button (12) until is shown and then press the Enter button (13): Service timer reading In the example shown, the screen shows the unit used (hrs) and the value (1191). The compressor has run 1191 hours since the previous service. Resetting the service timer After servicing, see section Service warning, the timer has to be reset: • Scroll to register screen and press the Enter button (13).
Instruction book Starting from the Main screen, press the Scroll buttons (12) until is shown and then press the Enter button (13). The actually selected control mode is shown: for local control, for remote control or for LAN control. To change: press the Enter button (13) and - if necessary - enter the password (see section Activating password protection). The actually selected control mode is blinking. Use the Scroll buttons (12) to change the control mode.
Instruction book It is also possible to change the channels. The controller has four channels. When changing the channels, the controller can act as a Mk 4 controller (a previous version of the Elektronikon controller). To set the channels, go to the screen where the node ID is visible. Press the Scroll button down (12). The following screen appears: Press the Enter button (13) to modify the setting. The upmost left value will blink. Change this value by using the Scroll buttons (12).
Instruction book The next screen shows either or . If , press the Enter button (13) to modify it to . Use the Scroll buttons up or down (12) to scroll between the items in this list ( for IP address, for Subnetmask or for Gateway): Modifying Press the Enter button (13) and if necessary enter the password. The first digits are blinking. Use the Scroll buttons up or down (12) to modify the settings and press the Enter button (13) to confirm.
Instruction book 3.18 Calling up/modifying pressure band settings Calling up the settings Control panel Starting from the Main screen: Main screen • Press the Scroll button (12) until is shown and then press the Enter button (13). Pressure band 1 is shown on the display. Button (12) can be used to scroll to pressure band 2 . • Press the Enter button (13) on the desired pressure band. The motor start level of the selected pressure band appears.
Instruction book Pressure band selection Motor start Motor stop Modifying the settings • Press the Enter button (13) to modify the motor start level (value starts blinking). A password may be required. Use the Scroll buttons (12) to change the loading pressure (= motor start). • Press the Enter button (13) to program the new values or press the Escape button (14) to cancel.
Instruction book 3.19 Modifying pressure band selection Control panel Starting from the Main screen: • Press the Scroll buttons (12) until is shown and then press the Enter button (13). The active pressure band 1 is shown on the display. • Press the Enter button (13) to modify the pressure band selection (a password may be required). The active pressure band starts blinking. • Press Scroll buttons (12) to modify the active pressure band.
Instruction book 3.21 Calling up/modifying unit of temperature Control panel Starting from the Main screen: • Press the Scroll buttons (12) until is shown and then press the Enter button (13). The actual used unit is shown. Possible settings are <˚C> and <˚F>. • Press the Enter button (13) (unit blinks) and use the Scroll buttons (12) to select another unit of temperature.
Instruction book 3.23 Automatic restart after voltage failure This function allows the compressor to restart automatically after a power failure. This parameter, accessible in screen , is inactive and can only be modified after entering a code. Consult Atlas Copco to activate this function. Automatic restart after voltage failure 3.24 Activating password protection Important settings such as the setting of the service timer, pressure band setting, control mode settings,...
Instruction book 3.25 Calling up/modifying protection settings Available protections The protection screens are labelled . The pictograph shown with the protection screen indicates the purpose of the protection. Possible combinations are followed by a number and one of the next pictographs: Pictograph Designation with the dew point temperature pictograph shows the dew point temperature protections. For a high warning level, shown on the display as , is available.
Instruction book Calling up / changing the settings Control panel Starting from the Main screen (the example given describes the dew point temperature protection): Press the Scroll buttons (12) until , followed by number "3" and the dew point temperature pictograph is shown and press the Enter button (13): • The warning level for the high temperature warning level becomes visible. Press the Enter button (13) to display the value.
Instruction book Display test Starting from the Main screen, press the Scroll buttons (12) until is shown and then press the Enter button (13). The display now shows all icons that can be displayed: Display test Safety valve test In the test screen , a safety valve test is provided. The safety valves can only be tested after entering a code. Consult Atlas Copco if the safety valves are to be tested. Safety valve test 3.
Instruction book USB to LAN adapter • Use a UTP cable (CAT 5e) to connect to the controller. UTP cable Configuration of the network card 1. Go to My Network Places (1). 2. Click View network connections (1).
Instruction book 3. Select the Local Area Connection (1) which is connected to the controller. 4. Click with the right-mouse button and select Properties (1) from the drop-down menu. 5. Select the checkbox Internet Protocol (TCP/IP) (1). To avoid conflicts, deselect other properties if they are selected. Click the Properties button (2) to change the settings.
Instruction book 6. Use the following settings: • IP Address 192.168.100.200 • Subnetmask 255.255.255.0 Click OK and close network connections. Configuration of the web server Configure the web interface The internal web server is designed and tested for Microsoft® Internet Explorer 6, 7 and 8. Other web browsers like Opera and Firefox do not support this internal web server. When using Opera or Firefox, a redirect page opens.
Instruction book Navigation and options • The banner shows the compressor type and the language selector. In this example, three languages are installed on the controller. • On the left side of the interface, you can find the navigation menu. If a license for ESi is foreseen, the menu contains three buttons. • Compressor: shows all compressor settings. • Es: shows the ESi status (if a license is provided). • Preferences: allows to change temperature and pressure unit.
Instruction book • Analog inputs (The units of measure can be changed via the Preferences button in the navigation menu). • Counters: Gives an overview of all actual counters from controller and compressor. • Info status: Machine status is always shown on the web interface. • Digital inputs: Gives an overview of all digital inputs and their status. • Digital outputs: Shows a list of all digital outputs and their status.
Instruction book • ES screen controller: If an ESi license is provided, the button ES is shown in the navigation menu. At the left, all compressors in the ES are shown and, at the right side, the ES status is shown. 3.28 Programmable settings Parameters: starting/stopping pressures for Pack compressors Parameter Unit Minimum setting Factory setting Maximum setting Starting pressure (8 bar compressors) bar(e) 0.5 6 8 Starting pressure (8 bar compressors) psig 7.
Instruction book Parameter Unit Minimum setting Factory setting Maximum setting Starting pressure (10 bar compressors) psig 7.2 113.1 142.1 Stopping pressure (8 bar compressors) bar(e) 0.5 7.8 7.8 Stopping pressure (8 bar compressors) psig 7.2 113.1 113.1 Stopping pressure (10 bar compressors) bar(e) 0.5 9.8 9.8 Stopping pressure (10 bar compressors) psig 7.2 142.1 142.1 Stopping pressure There will always be a difference of at least 0.1 bar (1.
Instruction book 4 Elektronikon Graphic Controller 4.
Instruction book Remedy the trouble and reset the message. See also section Inputs menu. Before remedying, consult the applicable safety precautions. Shutdown warning / shutdown If the compressor element temperature exceeds the factory set warning level, the compressor element will be stopped for a short time and a warning will appear on the controller display (1) and the general alarm LED (2) will light up.
Instruction book 4.2 Control panel Control panel Parts and functions Reference Designation Function 1 Display Shows the compressor operating condition and a number of icons to navigate through the menu. 2 Pictograph Automatic operation 3 Pictograph General alarm 4 Alarm LED Flashes in case of a shutdown, is lit in case of a warning condition.
Instruction book 4.3 Icons used Status icons Name Icon Description Stopped / Running When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating.
Instruction book Name Icon Description Service Service required Main screen display Value lines display icon Chart display icon No communication / network problem General icons Not valid Input icons Icon Description Pressure Temperature Digital input Special protection System icons Icon Description Compressor element (LP, HP, ...
Instruction book Icon Description Filter Motor Failure expansion module Network problem General alarm The compressor module is running and can be stopped The compressor module is stopped and is ready to start The compressor module is awaiting the minimum stop time to expire Menu icons Icon Description Inputs Outputs Alarms (Warnings, shutdowns) Counters Test or Settings 66 2920 7110 21
Instruction book Icon Description Service Event history (saved data) Access key / User password Network Setpoint Info Navigation arrows Icon Description Up Down 4.
Instruction book Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed. Typically, 6 different main screen views can be chosen: 1. 2. 3. 4. 5. 6.
Instruction book (2) Element 2 Outlet (3) Off, Shutdown,... (text varies upon the compressors actual condition (4) Menu (5) Element 1 Outlet (6) Ambient Air • Section A shows information regarding the compressor operation (e.g. the outlet pressure, the ambient temperature or the temperature at one of the compressor element outlets). • Section B shows Status icons.
Instruction book When Chart (High Resolution) is selected, the chart shows the variation of the selected input (in this case the pressure) per minute. Also the instantaneous value is displayed. The screen shows the last 4 minutes. The switch button (icon) for selecting other screens is changed into a small Chart and is highlighted (active). When the Chart (Medium Resolution) is selected, the chart shows the variation of the selected input per hour. The screen shows the last 4 hours.
Instruction book Selection of a main screen view To change between the different screen layouts, select the far right icon in the control icons line (see value lines display icon or chart display icon in section Icons used) and press the Enter key. A screen similar to the one below opens: Select the layout required and press the Enter key. See also section Inputs menu. 4.
Instruction book Typical Main screen (2 value lines) • To go to the Menu screen, select action button Menu (1) by means of the Scroll keys and press the Enter key. Following screen appears: Text on image (1) Menu (2) Regulation • The menu screen shows a number of icons. Each icon indicates a menu item. By default, the Regulation icon is selected. The status bar shows the name of the menu that corresponds with the selected icon. • Use the Scroll keys to select the required icon (see further).
Instruction book Element 2 is stopped during a Minimum Stop Time due to a high element temperature If the element temperature exceeds the factory set shutdown warning repeatedly, the element will shut down, alarm LED (4) (see section Control panel) will lit and following screen will appear: Element 2 is shutdown due to repeatedly high element temperature warnings If this occurs: 1. Switch off the voltage and remedy the problem cause. 2.
Instruction book Text on image (1) Element(s) (4) Problem Element (2) Warning Element 2 (5) More (3) Triggered (6) Reset Each time an element is reset manually, this will be logged in the Element Problem Reset counter: Counter screen where one element was reset manually Text on image (1) Information (4) Element Warnings (2) Trigger level (5) Element Problem Resets (3) High Temperature Warnings (6) Modify High ambient temperature If the ambient temperature is above the factory sett
Instruction book Description of high ambient alarm in the protection menu Text on image (1) General (4) Shutd. Warn.
Instruction book 4.
Instruction book Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on image (1) Menu (2) Regulation • Using the Scroll keys, move the cursor to the Inputs icon (see above, section Menu icon). • Press the Enter key.
Instruction book The first item in the list is highlighted. In this example, the Net Pressure is selected (chart icon). To change, press the Enter button again. A pop up window opens: Press Enter again to remove this input from the chart. Another confirmation pop up opens: Select Yes to remove or No to quit the current action.
Instruction book Text on image (1) 4.9 Set As Main Chart Signal Outputs menu Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan motor overload contact, the general warning contact, etc. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key.
Instruction book Text on image (1) General (4) General warning (2) General shutdown (5) Cabinet fan (3) Fan motor • The screen shows a list of all outputs with their corresponding icons and readings. If an output is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively. 4.
Instruction book Text on image (1) Counters (4) Fan starts (2) Shutdowns element 2 (5) Module hours (3) Load relay The screen shows a list of all counters with their actual readings. 4.11 Control mode selection Function To select the control mode, i.e. whether the compressor is in local control, remote control or controlled via a local area network (LAN).
Instruction book • There are 3 possibilities: • Local control (1) • Remote control (2) • LAN control (3) After selecting the required control mode, press the Enter key on the controller to confirm your selection. The new control mode selection is now visible on the main screen. 4.12 Service menu Menu icon, Service Function • • • • 82 To reset the service plans which are carried out. To check when the next service plans are to be carried out.
Instruction book Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on image (1) Menu (2) Regulation • Using the Scroll keys, move the cursor to the Service icon (see above, section Menu icon). • Press the Enter key.
Instruction book Overview Text on image (1) Overview (3) Real Time (hours) (2) Running Hours (4) Reset Example for service level (A): The figures at the left are the programmed service intervals. For Service interval A, the programmed number of running hours is 2500 hours (upper row) and the programmed number of real time hours is 8760 hours, which corresponds to one year (second row).
Instruction book Text on image (1) Service plan (4) Real time hours (2) Level (5) Modify (3) Running hours Modifying a service plan Dependant on the operating conditions, it can be necessary to modify the service intervals. To do so, use the Scroll keys to select the value to be modified. A screen similar to the one below appears: Press the Enter key. Following screen appears: Modify the value as required, using the ↑ or ↓ scroll key and press the Enter key to confirm.
Instruction book Next Service Text on image (1) Next service (3) Running hours (2) Level (4) Actual In the example above, the A Service level is programmed at 500 running hours, of which 0 hours have passed. History The History screen shows a list of all service actions done in the past, sorted by date. The date at the top is the most recent service action. To see the details of a completed service action (e.g.
Instruction book Text on image (1) Menu (2) Regulation • Using the Scroll keys, move the cursor to the Setpoint icon (see above, section Menu icon) • Press the Enter key. Following screen appears: Text on image (1) Regulation (4) Pressure band 2 High (2) Pressure band 1 High (5) Pressure band 2 Low (3) Pressure band 1 Low (6) Modify • The screen shows the actual stopping and starting pressure settings for both pressure bands.
Instruction book • The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the ↑ or ↓ key of the Scroll keys to modify the settings as required and press the Enter key to accept. If necessary, change the other settings as required in the same way as described above. 4.14 Event history menu Menu icon, Event History Function To call up the last shutdown and last emergency stop data.
Instruction book 4.15 General settings menu Menu icon, Settings Function To display and modify a number of settings. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on image (1) Menu (2) Regulation • Using the Scroll keys, move the cursor to the Settings icon (see above) • Press the Enter key. Following screen appears: This screen shows again a number of icons. By default, the User Password icon is selected.
Instruction book • Remote For adapting certain parameters, a password may be necessary. Example: Selecting the General Settings icon gives the possibility to change e.g. the language, the date, the date format, etc.: Text on image (1) General (4) Date (2) Language In Use (5) Date Format (3) Time (6) Modify • To modify, select the Modify button using the Scroll keys and press the Enter key. • A screen similar to the one above is shown, the first item (Language) is highlighted.
Instruction book Text on image (1) (2) Menu Regulation • Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon). • Press the Enter key. The internet address appears on the screen. 4.17 Week timer menu Menu icon, Week timer Function • • • • To program time based start/stop commands for the compressor. To program time based changeover commands for the net pressure band. Four different week schemes can be programmed.
Instruction book Text on image (1) Week Timer (4) Status (2) Week Action Schemes (5) Week Timer Inactive (3) Week Cycle (6) Remaining Running Time The first item in this list is highlighted. Select the item to be adapted and press the Enter key on the controller to modify. Programming week schemes • Select Week action schemes and press Enter. A new window opens. The first item in the list is highlighted in red. Press the Enter key on the controller to modify Week Action Scheme 1.
Instruction book Text on image (1) Week Action Scheme 1 (5) Thursday (2) Monday (6) Friday (3) Tuesday (7) Saturday (4) Wednesday (8) Sunday • A new window opens. The Modify action button is selected. Press the enter button on the controller to create an action. Text on image (1) Monday (2) Modify • A new popup window opens. Select an action from this list by using the Scroll keys on the controller. When ready press the Enter key to confirm.
Instruction book Text on image (1) Monday (5) Stop (2) Actions (6) Pressure Setpoint 1 (3) Remove (7) Modify (4) Start • A new window opens. The action is now visible in the first day of the week. Text on image (1) Monday (3) Save (2) Start (4) Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. • A new pop up window opens. Use the ↑ or ↓ key of Scroll keys to modify the values of the hours.
Instruction book Text on image (1) Monday (3) Save (2) Time (4) Modify • Press the Escape key on the controller. The action button Modify is selected. Use the Scroll keys to select the action Save. Text on image (1) Monday (3) Save (2) Start (4) Modify • A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions. Press the Enter key to confirm.
Instruction book Text on image (1) Week Action Scheme 1 (5) Thursday (2) Monday - Start (6) Friday (3) Tuesday (7) Saturday (4) Wednesday (8) Sunday Press the Escape key on the controller to leave this screen. Programming the week cycle A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week schemes can be chosen. • Select Week Cycle from the main Week Timer menu list.
Instruction book Text on image (1) Week Cycle (4) Week 3 (2) Week 1 (5) Week 4 (3) Week 2 (6) Modify Press the Enter key twice to modify the first week. • A new window opens. Select the action, example: Week Action Scheme 1 Text on image (1) Week Cycle (4) Week Action Scheme 2 (2) Week 1 (5) Week Action Scheme 3 (3) Week Action Scheme 1 (6) Modify • Check the status of the Week Timer Use the Escape key on the controller to go back to the main Week Timer menu.
Instruction book Text on image (1) Week Timer (4) Status (2) Week Action Schemes (5) Week Timer Inactive (3) Week Cycle (6) Remaining Running Time • A new window opens. Select Week 1 to set the Week Timer active. Text on image (1) Week Timer (3) Week Timer Inactive (2) Week (4) Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active.
Instruction book • This timer is used when the week timer is set and for certain reasons the compressor must continue working, for example, 1 hour, it can be set in this screen. This timer is prior to the Week Timer action. Text on image (1) Week Timer (2) Week Action Schemes (3) Remaining Running Time 4.18 Test menu Menu icon, Test or Function • To carry out a display test, i.e. to check whether the display and LED's are still intact.
Instruction book • Move the cursor to the action button Menu and press the Enter key (2). Following screen appears: • Using the scroll keys, move the cursor to the test icon (see above) • Press the Enter key, following screen appears: Text on image (1) Test (3) Not allowed (2) Safety Valve Test (4) Audit Data • The safety valve test can only be performed by authorized personnel and is protected by a security code. • Select the item display test and press the enter key.
Instruction book Text on image (1) (2) Menu Regulation • Using the Scroll keys, select the Settings icon (see section General settings menu). • Press the Enter key. Following screen appears: • Move the cursor to the Password icon (see above, section Menu icon) • Select Modify, using the Scroll keys and press the Enter key. Next, modify the password as required. 4.
Instruction book USB to LAN adapter • Use a UTP cable (CAT 5e) to connect to the controller (see picture below). Configuration of the network card (in Windows) • Go to My Network places (1). • Click on View Network connections (1).
Instruction book • Select the Local Area connection (1), which is connected to the controller. • Click with the right button and select properties (1). • Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked. After selecting TCP/IP, click on the Properties button (2) to change the settings.
Instruction book • Use the following settings: • IP Address 192.168.100.200 • Subnetmask 255.255.255.0 Click OK and close network connections. Configuration of the web server Configure the web interface (for Internet Explorer) • Open Internet Explorer and click on Tools - Internet options (2). • Click on the Connections tab (1) and then click on the LAN settings button (2).
Instruction book • In the Proxy server Group box, click on the Advanced button (1). • In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given but they must be separated with semicolons (;).
Instruction book Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture). Click OK (2) to close the window. Viewing the controller data All screen shots are indicative. The number of displayed fields depends on the selected options. • Open your browser and type the IP address of the controller you want to view in your browser (in this example http://192.168.
Instruction book Screen shot (typical) Navigation and options • The banner shows the compressor type and the language selector. In this example, three languages are available on the controller. Compressor settings All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen. Analog inputs Lists all current analog input values.
Instruction book Counters Lists all current counter values from controller and compressor. Info status Machine status is always shown on the web interface. Digital inputs Lists all Digital inputs and their status.
Instruction book Digital outputs Lists all Digital outputs and their status. Special protections Lists all special protections of the compressor. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours. It is also possible to show the current status of the service interval.
Instruction book 4.21 Programmable settings Compressors without built-in refrigeration dryer Minimum setting Factory setting Maximum setting Starting pressure Starting pressure (8 bar compressors) bar(e) 4 7 8 Starting pressure (8 bar compressors) psig 58 101.5 116 Starting pressure (10 bar compressors) bar(e) 4 9 10 Starting pressure (10 bar compressors) psig 58 130.
Instruction book Compressors with built-in refrigeration dryer Minimum setting Factory setting Maximum setting Starting pressure Starting pressure (8 bar compressors) bar(e) 4 6.8 7.8 Starting pressure (8 bar compressors) psig 58 98.6 113.1 Starting pressure (10 bar compressors) bar(e) 4 8.8 9.8 Starting pressure (10 bar compressors) psig 58 127.6 142.1 Minimum setting Factory setting Maximum setting Stopping pressure Stopping pressure (8 bar compressors) bar(e) 4 7.8 7.
Instruction book Terminology 112 Term Explanation ARAVF Automatic Restart After Voltage Failure. See section General. Power recovery time Is the period within which the voltage must be restored to have an automatic restart. Is accessible if the automatic restart is activated. To activate the automatic restart function, consult your supplier. Restart delay This parameter allows to programme that not all compressors are restarted at the same time after a power failure (ARAVF active).
Instruction book 5 Installation 5.1 Dimension drawings The dimension drawings can be found on the DVD or the USB, supplied with the compressor.
Instruction book Text on drawings Translation or Explanation 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. THE DIMENSIONS FOR FULL Dimensions of the Full Feature units are indicated between ( ) FEATURE UNIT... 5.
Instruction book 1 Dryer service panel 5 Condensate drain 2 Service panel 6 Manual drain 3 Supply cable 7 Automatic drain 4 Minimum area to be reserved for servicing purposes Recommendations 1. Install the compressor on a level horizontal industrial floor, suitable for taking the weight of the compressor. The location must be frost-free and preferably low dust location. The compressor unit must be installed on a level floor. 2. Delivery pipe.
Instruction book 12. All piping to be connected free of stress. 5.3 Electrical connections Attention The electrical installation must correspond to the applicable codes. The mains supply and earthing lines must be of suitable size. The installation must be earthed and protected by fuses in each phase. Install an isolating switch near the compressor. Make sure that this switch is open to isolate the compressor from the mains before carrying out any connection.
Instruction book 5.4 Pictographs Pictographs Reference Designation 1 Warning: the compressor starts and stops automatically. Do not perform service when pressurized and when the voltage is on. Read the instruction book, switch off the power and depressurize the compressor before maintenance or repair. 2 Warning: when the voltage is on, the unit can start and stop automatically. 3 Warning: rotating fan. 4 Warning: supply voltage. 5 Warning: hot surface.
Instruction book 6 Operation 6.1 Initial start-up Safety The operator must apply all relevant Safety precautions during operation. The maximum recommended motor starting frequency is starts is 20 starts per hour. In order to keep the number of starts at an acceptable level, the compressor must be connected to an air receiver with a suitable size. Initial start-up 1. Remove the yellow painted transport brackets (E, F) (if applicable) Transport brackets on SF 6 and SF 6+ 2.
Instruction book blown upwards. If the direction is wrong, stop the compressor immediately and reverse two incoming electric lines. (1) Rotation control check (2) Electropneumatic controlled compressors (3) Compressors with Elektronikon controller A compressor equipped with a phase sequence relay will not start if the phase sequence is wrong. In that case, reverse two incoming electric lines to solve the issue.
Instruction book Procedure 1. 2. 3. 4. 5. 6. Close the manual condensate drain valve(s) if present. Open the air outlet valve (AV). Switch on the voltage. Press the start button on the Elektronikon® controller. The motor starts and stops automatically depending on the air pressure. On compressors equipped with a refrigerant dryer, the dew point of the refrigerant dryer will be reached after a few minutes. 7.
Instruction book ER Elektronikon® controller Gd Dew point gauge S3 Emergency stop button Procedure 1. Press the stop button on the Elektronikon® controller. 2. Switch off the voltage. 3. Close air outlet valve (AV - see section Introduction). The refrigerant air dryer and the air receiver remain under pressure. If it is necessary to depressurize, open the manual drain valve(s). 6.5 Taking out of operation Procedure 1. Stop the compressor and close the air outlet valve. 2.
Instruction book 7 Preventive maintenance 7.1 Preventive maintenance schedule Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Switch off the voltage and open the isolating switch. Press the emergency stop button (S3) • Close the air outlet valve. • Depressurize the compressor by opening the manual drain valve(s). The operator must apply all relevant Safety precautions during maintenance or repair.
Instruction book Period (note 1) Running hours (note 1) Operation Every 6 months -- Every 6 months (note 2) -- Yearly 2500 • Replace the air inlet filter(s) (AF) and the prefilter mats on the cooling air intake openings (if fitted) (note 2). • Test the safety valve. • Have temperature protection and motor overload tested. • Check tension and condition of the V-belt(s). • Compressors with CD dryer: Replace the PD 20+ filter cartridge. Every 2 years 5000 • Replace the V-belt(s).
Instruction book In high ambient conditions, the bearings must be greased more frequently: for every 5 °C (9 °F) increase above 30 °C (86 °F), the maintenance interval should be reduced with 30 %. Contact your supplier for details. 4. In extremely dry conditions (relative humidity below 15 %), the tip seals and dust seals need to be replaced more frequently. 7.2 Service kits Service kits For overhauling and for preventive maintenance, a wide range of service kits is available.
Instruction book 8 Adjustments and servicing procedures 8.1 Air filter Air filter (AF) Procedure 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove the filter cover and the filter element. Discard damaged or clogged elements. Clean the cover. 3. Fit the new element and reinstall the filter cover. SF 6+ has 2 air filters. 8.2 Air cooler Cleaning Keep the cooler clean to maintain cooling efficiency. If necessary, remove any dirt with a fibre brush.
Instruction book 8.4 Safety valve Testing Testing shall only be carried out by competent personnel 1. 2. 3. 4. Stop the compressor, close the air outlet valve and switch off the voltage. Depressurize the compressor. Remove the safety valve. See section Introduction for the location of the safety valve (SV). Test the safety valve on a separate compressed air circuit by gradually increasing the pressure. If the safety valve does not open at the specified pressure, it must be replaced.
Instruction book 3. Remove the front panel. 4. Remove the inlet baffle (I) 5. Loosen screws (B). 6. 7. 8. 9. Loosen screw (C). Use slot (D) to lift the motor plate. Install the new belt(s) in the pulley grooves. Set the tension of the belt(s) by screwing bolt (C) out.
Instruction book 10. Tighten screws (B). Reinstall the inlet baffle. 11. Check the belt tension after the first 500 running hours. 8.6 Temperature protection Description The compressor element is protected by a PT 1000 sensor in the element outlet. The sensor is connected to the Elektronikon controller. When the maximum temperature is exceeded, the compressor is stopped. It will restart automatically if the temperature drops again and if pressure is required.
Instruction book • Remove clip (2) (if applicable). • Remove fan duct (3). 4. Clean cooling channels: • Remove dust from the cooling channels (1) by means of air jet (see next figure). • Clean the fan duct (2). 5. Reassemble the fan duct: • Put the fan duct in place. • Fit the 3 bolts and the clip. The unit is now again ready for use. 8.8 Replacement of the outlet pipe (only applicable to SF 2+ and SF 4+) Description The element outlet pipe (1) of the 2.2 kW and the 3.
Instruction book Replacement procedure 1. Stop the compressor, depressurize and switch off the voltage. 2. Loosen coupling (3) while immobilizing nipple (2) with a wrench. 3. Remove the outlet pipe together with the nipple. 4. Fit the nipple to the new outlet pipe and tighten. Use only PTFE tape. 5. Fit the plastic insert in place as indicated on the drawing and assemble the outlet pipe with a maximum torque of 5 Nm (3.7 lbf.ft). Do not end turning counterclockwise in order to avoid leaks.
Instruction book 8.9 Refrigerant dryer maintenance Safety precautions The dryer circuit contains refrigerant. When handling refrigerant, all applicable Safety precautions during maintenance or repair must be observed. Specifically be aware of following points: • Contact of liquid refrigerant with the skin can cause freezing. Wear special gloves. If contacted with the skin, the skin should be rinsed with water. On no account may clothing be removed. • Fluid refrigerant can also cause freezing of the eyes.
Instruction book • Switch off all electrical power. • Depressurize the compressor. Leave the dryer operating during 15 minutes to fully depressurize. • Use original spare parts only. Consult the Parts List for part numbers. For preventive maintenance, dedicated service kits are available. • Check for correct operation after maintenance. Under no circumstances must compressed air be allowed to flow through the dryer when the electrical power is switched off.
Instruction book 9 Problem solving Before carrying out any maintenance or repair, perform following steps: • Stop the compressor and switch off the voltage. • Open and lock the isolating switch to prevent an accidental start. • Isolate the compressor by closing the outlet valve. • Depressurize the system by opening the drain valve(s). Compressor Condition Fault Remedy The compressor does not start. Pressure too high. Compressor will start again when the pressure drops to the starting pressure.
Instruction book Condition Fault Remedy Condenser pressure too high or too low Fan control switch out of order Have switch replaced Condenser fan motor out of order Have fan motor inspected Ambient temperature too high Improve ventilation of compressor room, see section Installation proposal Condenser externally clogged Clean condenser Motor of refrigerant compressor stops or does not start The internal thermal protection of the motor has tripped Compressor will restart when the motor winding
Instruction book Symptom Possible cause Corrective action High dew point The dryer has not had the time to regenerate completely. Close the valve installed between the dryer and the application (if permitted) and have the desiccant regenerated. Liquid water at dryer inlet Check PD filter and the drains. Fit an extra water separator if required. Excessive flow Check actual flow against maximum specified.
Instruction book 136 Symptom Possible cause Corrective action Low outlet pressure Blocked filter Check/replace filter elements. Blocked filter desiccant cartridge Check/replace desiccant cartridge. Excessive purge air flow See excessive purge air flow. Dryer won't pressurize Incorrect start-up Keep downstream isolation valve closed. Open upstream valve slowly. Power the dryer once pressurized. Package won't electrically energize Faulty wiring to controller Check electrical wiring.
Instruction book 10 Technical data 10.1 Readings on control panel Description The readings mentioned below are valid under the reference conditions (see section Reference conditions and limitations). ER Elektronikon® controller Gd Dew point gauge S3 Emergency stop button Regularly check the Elektronikon® display. Important information can be found here, like the working pressure, starting and stopping pressure, dew point, hour meter and service messages.
Instruction book SF 2+ SF 4+ SF 6+ Frequency Voltage Cable size Cable size Cable size 60 Hz 380 V 3~ 1.5 mm2 1.5 mm2 2.5 mm2 60 Hz 200 V 3~ AWG 12 AWG 10 AWG 8 60 Hz 230 V 1~ -- -- -- 60 Hz 230 V 3~ AWG 12 AWG 10 AWG 8 60 Hz 460 V 3~ AWG 12 AWG 10 AWG 8 60 Hz 575 V 3~ AWG 14 AWG 14 AWG 14 UL/CUL 10.3 Settings for overload relay and fuses Attention The indicated fuse value is the maximum value with regard to the short circuit protection of the starter.
Instruction book SF 4+ SF 4+ SF 6+ SF 6+ Frequency Voltage Overload relay Maximum fuse Overload relay Maximum fuse 50 Hz 200 V 3~ 17.3 A 50A 25.7A 50 A 50 Hz 230 V 3~ 15.0 A 40 A 22.3 A 40 A 50 Hz 400 V 3~ 8.7 A 16 A 12.8 A 25 A 50 Hz 400 V + N 3~ 8.7 A 16 A 12.8 A 25 A 60 Hz 380 V 3~ 8.7 A 16 A 12.8 A 25 A 60 Hz 200 V 3~ 16.6 A 25/25/30 A* 25.2 A 40/40/45 A* 60 Hz 208 V -- -- 24.3 A 40/40/45 A* 60 Hz 230 V 3~ 15.2 A 25/25/30 A* 24.
Instruction book 10.5 Reference conditions and limitations Reference conditions Air inlet pressure (absolute) bar 1 Air inlet pressure (absolute) psi 14.5 Air inlet temperature ˚C 20 Air inlet temperature ˚F 68 Relative humidity % 0 Working pressure See section Compressor data. Limits Maximum working pressure See section Compressor data.
Instruction book Compressor type SF 2+ SF 2+ 8 bar 10 bar 116 psi 145 psi Sound pressure level dB(A) Refrigerant type (Full-Feature) 56 56 R134a R134a Dew point (refrigerant dryer) ˚C 4 4 Dew point (refrigerant dryer) ˚F 39 39 SF 4+ SF 6+ SF 6+ Compressor type SF 4+ 8 bar 10 bar 8 bar 10 bar 116 psi 145 psi 116 psi 145 psi Maximum working pressure (Pack) bar(e) 8 10 8 10 Maximum working pressure (Pack) psi(g) 116 145 116 145 Maximum working pressure (Full-Feature) bar(e)
Instruction book 11 Instructions for use Air receiver This section applies to compressors including air receiver(s). 142 - The vessel can contain pressurized air; this can be potentially dangerous if the equipment is misused. - The vessel shall only be used to store compressed air and shall not be subject to rapid fluctuation of pressure. - The vessel shall only be used within the pressure and temperature limits stated on the data plate and the testing report, which should be kept in a safe place.
Instruction book 12 Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.
Instruction book 13 Pressure equipment directives Components subject to Pressure Equipment Directive 97/23/EC (until 20/07/2016) or 2014/68/EU (from 20/07/2016 onwards) Components subject to 97/23/EC / 2014/68/EU Pressure Equipment Directive greater than or equal to category II Pressure version Part number Description PED Class 8 bar 0830 1008 54 Safety valve IV 116 psi 0830 1008 49 Safety valve IV 10 bar 0830 1007 68 Safety valve IV 145 psi 0830 1008 35 Safety valve IV Overall rating
Instruction book 14 Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Atlas Copco Airpower n.v. P.O.
Instruction book On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this device.
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. 2920 7110 21 / 2015 - 11 - Printed in Belgium 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.
