atlas copco - total tools

Atlas Copco

Industrial aluminium piston compressors

LE 2, LE 3, LE 5, LE 7, LE 10, LE 15, LE 20

Instruction book

Atlas Copco

Industrial aluminium piston compressors

LE 2, LE 3, LE 5, LE 7, LE 10, LE 15, LE 20

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 - 05

No. 2920 7089 82 Replaces No. 2920 7089 81

www.atlascopco.com

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Instruction book

Table of contents

Table of contents ............................................................................................................................. 2

1 Safety precautions ................................................................................................................... 4

1.1 Safety icons ...................................................................................................................................... 4

1.2 Safety precautions, general .............................................................................................................. 4

1.3 Safety precautions during installation ............................................................................................... 4

1.4 Safety precautions during operation ................................................................................................. 6

1.5 Safety precautions during maintenance or repair ............................................................................. 7

2 General description .................................................................................................................. 9

2.1 General description ........................................................................................................................... 9

2.2 Options ........................................................................................................................................... 14

2.3 Air flow ............................................................................................................................................ 15

2.4 Regulating system .......................................................................................................................... 20

3 Installation ............................................................................................................................... 22

3.1 Dimension drawings ....................................................................................................................... 22

3.2 Installation instruction ..................................................................................................................... 39

3.3 Electrical connections ..................................................................................................................... 44

3.4 Settings of overload relay and fuses ............................................................................................... 46

3.5 Cable sizes ..................................................................................................................................... 51

3.6 Pictographs ..................................................................................................................................... 51

4 Operating instructions ........................................................................................................... 52

4.1 Initial start-up .................................................................................................................................. 52

4.2 Starting ........................................................................................................................................... 52

4.3 Stopping .......................................................................................................................................... 54

4.4 Taking out of operation ................................................................................................................... 54

4.5 Storage after installation ................................................................................................................. 55

5 Maintenance ............................................................................................................................ 56

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5.1 Petrol engine maintenance ............................................................................................................. 56

5.2 Preventive maintenance schedule .................................................................................................. 56

5.3 Lubrication of compressors ............................................................................................................. 57

5.4 Service kits ..................................................................................................................................... 57

5.5 Disposal of used material ............................................................................................................... 58

6 Servicing and adjustment procedures ................................................................................. 59

6.1 Unloader or check valve ................................................................................................................. 59

6.2 Valves ............................................................................................................................................. 59

6.3 Air filter ............................................................................................................................................ 61

6.4 Adjustment MDR4 pressure switch ................................................................................................. 61

6.5 Adjustment of MDR3 pressure switch ............................................................................................. 63

6.6 Adjustment of pilot valve on Trolley ................................................................................................ 64

6.7 Safety valve .................................................................................................................................... 65

7 Problem solving ...................................................................................................................... 67

8 Technical data ......................................................................................................................... 69

8.1 Reference conditions ...................................................................................................................... 69

8.2 Limitations ....................................................................................................................................... 69

8.3 Compressor data ............................................................................................................................ 69

9 Instructions for use ................................................................................................................ 71

10 Pressure Equipment Directive (PED) ................................................................................... 72

11 Declaration of conformity ...................................................................................................... 73

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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. Installation, operation, maintenance and repair work must only be performed by authorized, trained, specialized personnel.

4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the compressed air must be adequately purified according to the applicable legislation and standards.

5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the power isolating switch must be opened and locked.

6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection.

7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation.

8. It is not allowed to walk or stand on the roof of the compressor canopy.

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.

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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. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.

3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes. 4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn

hoses. Distribution pipes and connections must be of the correct size and suitable for the working pressure. 5. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents, that can lead to

internal fire or explosion. 6. Arrange the air intake so that loose clothing cannot be sucked in. 7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat

and that it is not in contact with or close to flammable materials. 8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain. 9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is

remotely controlled and may start without warning. The operator has to make sure that the machine is stopped and that the isolating switch is open and locked before any maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the start equipment.

10. The machines must be installed in such a way that an adequate flow of cooling air is available and that the air from the exhaust does not recirculate to the compressor air inlet or cooling air inlet.

11. The electrical connections must correspond to the applicable codes. The machines must be earthed and protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor.

12. On machines with automatic start-stop system or if the automatic restart function after voltage failure is activated, a sign stating "This machine may start without warning" must be affixed near the instrument panel.

13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return valves (check valves) must not be relied upon for isolating pressure systems.

14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure-relieving device or devices as required.

15. Pipework 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 pipework must be clearly marked.

16. If the ground is not level or can be subject to variable inclinations, consult the manufacturer.

Also consult following safety precautions: Safety precautions during operation and Safety precautions during maintenance. 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.

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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. When blowing through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is fully depressurized before disconnecting it.

2. 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.

3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or particles.

4. Never operate the machine below or in excess of its limit ratings. 5. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall

wear ear protectors. 6. Periodically check that:

All guards are in place and securely fastened All hoses and/or pipes inside the machine are in good condition, secure and not rubbing There are no leaks All fasteners are tight All electrical leads are secure and in good order Safety valves and other pressure-relief devices are not obstructed by dirt or paint Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses etc. are in good repair, free of

wear or abuse 7. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take

precautions against air pollution and possible contamination of the breathing air. 8. If available, do not remove any of, or tamper with, the sound-damping material. 9. Never remove or tamper with the safety devices, guards or insulations fitted on 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.

Also consult following safety precautions: Safety precautions during installation and Safety precautions during maintenance. 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.

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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. Always wear safety glasses. 2. Use only the correct tools for maintenance and repair work. 3. Use only genuine spare parts. 4. All maintenance work shall only be undertaken when the machine has cooled down. 5. A warning sign stating "work in progress; do not start" shall be attached to the starting equipment. 6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no

one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.

7. Close the compressor air outlet valve before connecting or disconnecting a pipe. 8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and

relieve the entire system of pressure. 9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic

vapors of cleaning liquids. 10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and

exposed openings with a clean cloth, paper or tape. 11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged,

e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels.

12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.

13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel etc. 14. Make sure that no tools, loose parts or rags are left in or on the machine. 15. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They

may not be put out of action. 16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures, temperatures

and time settings are correct. Check that all control and shut-down devices are fitted and that they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled.

17. Protect the motor, air filter, electrical and regulating components etc. to prevent moisture from entering them, e.g. when steam-cleaning.

18. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork and in the air inlet and outlet systems of the compressor, are in good condition. If damaged, replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing.

19. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls. 20. The following safety precautions are stressed when handling refrigerant:

Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if required, use breathing protection.

Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid.

21. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.

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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.

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2 General description

2.1 General description

Introduction

LE are air-cooled, two cylinder, single-stage, lubricated piston compressors, built for effective working pressures up to 10 bar.

Compressor block with unloading valve

Power pack

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Power pack with unloading valve

Base mounted

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Instruction book

Tank-mounted, LE 2 up to LE 3, horizontal receiver

Tank-mounted, horizontal receiver

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Tank-mounted, Full-Feature unit, 475 l receiver

LE Trolley Petrol/Electric

Reference Description AF Air filter AR Air receiver AV Air outlet valve CV Check valve Dm Condensate drain valve Dp Oil drain plug FC Filler cap FN Fan

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Reference Description Gp Air pressure gauge M Motor MDR Air pressure switch Me Electric motor Mp Petrol engine P1 Hourmeter, running time PD Pulsation damper RV Pilot valve S1 On/off switch S2 On/off switch dryer SG Oil sight glass SV Safety valve

UA Unloader US Blow-off silencer Y1 Loading solenoid valve

Reference Description 1 Cover 2 Air inlet silencer 3 Crankcase 4 Cooling pipe 5 Left cylinder 6 Right cylinder 7 Pictograph, see Pictographs 8 Electric cabinet 9 Dewpoint indicator 10 Refrigerant dryer 11 Lifting yoke 12 Towing handle 13 Fuel tank

Compressor variants

The compressor block includes: Crankcase (3) and cylinders (5) and (6) Air inlet filter (AF) and inlet silencer (2) Fan (FN) Air cooler piping Check valve (CV) or Unloader (UA) Safety valve (SV)

The Power Pack comprises:

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For LE 2 up to LE 3: The Compressor Block as described above, with flanged-on electric motor (M),

check valve (CV) and safety valve (SV) For LE 5 up to LE 20: The Compressor Block as described above, with flanged-on electric motor (M)

and safety valve (SV)

The tank-mounted unit comprises:

For LE 2 up to LE 3: The Power pack mounted on a horizontal or vertical air receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV), air pressure switch with an on/off button (MDR) and condensate drain valve (Dm).

For LE 5 up to LE 20: The power pack mounted on an air receiver (AR) with air outlet valve (AV), pressure gauge (Gp), safety valve (SV), and condensate drain valve (Dm). An electric cubicle (8) includes the motor starter. A separate air pressure switch (MDR) is provided.

The base-mounted unit is a fully operational unit with air pressure switch and on/off switches mounted on a frame (no air receiver).

LE Trolley units are mobile compressors. They are equipped with either a directly flanged electric motor or a petrol engine. The compressors have two outlet connections:

A connection for compressed air at working pressure. A connection for compressed air at reduced pressure via a pressure regulator.

The Full-Feature compressor is a tank-mounted compressor provided with a Refrigerant dryer with DD & PD filter. They remove moisture from compressed air by cooling the air to near freezing point. This causes water to condense. The condensate is automatically drained. The air is warmed up before leaving the dryer.

2.2 Options

The compressors are extendible with the following options. For detailed information consult Atlas Copco.

Silencing hood For 90 / 250 /475 Tank Mounted and Base Mounted Units LE15 and LE20 are not available with hood. Not as Tankmounted, Base Mounted or Sales Version

Receiver upgrade

Receiver size upgrade 90 to 250 Standard Receiver.Vertical Receiver upgrade 90 or 250 to 250. Only for 2 and 3hp 475 Receiver upgrade 90 or 250 to 475

Pneumatic drain Not available for Trolley versions

Interstage drain Not available

Transformer 100VA (for cubicle control voltage 400/3/50) YD only

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Instruction book

Motor anti-condensation heaters and thermistor protection

Used with LE 2-20 with 400V/50Hz and 460V/60Hz

CD adsorption dryer LE 2-3 on 90 and 250 receiver

Heavy duty air inlet filter For PP-BM-TM-FF versions

Oil level switch make contact (NO) break contact (NC)

Receiver wheel set Wheelset for 90/250 receiver

Power supply cable (3 m)

with red CEE 3-pole plug 16A L = 3 mtr

Auto restart offload valve (solenoid valve to make sure unit will start after power failure)

Timer drain (solenoid operated)

all Receiver Mounted units

Used For DOL 230v/50hz and 400v/50hz Units

Invalid Combinations for Any other voltages or frequencies and YD units

2.3 Air flow

LE 2 up to LE 20

Air drawn through air filter (AF) and inlet silencer (1) into cylinders (2 and 3) is compressed, then discharged through cooler piping (4) and (5)”and check valve (CV) / unloader valve (UA)” into air receiver (AR).

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Air flow and regulating system with DOL starter

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Instruction book

Air flow and regulating system with Y/D starter

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Air flow and regulating system of trolley

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Full-Feature

Air flow and regulating system, Full- Feature

References on flow diagrams

Reference Description AF Air filter AR Air receiver AV Air outlet valve AV1/AV2 Air outlet valves CV Check valve Dm Condensate drain valve FC Oil filler cap FN Fan Gp Air pressure gauge M Motor MDR Air pressure switch PD Pulsation damper S1 On/off switch

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Reference Description RV Pilot valve SV Safety valve UA Unloader UV Unloading valve US Blow-off silencer Y1 Loading solenoid valve

DP Oil drain plug SG Oil level sight-glass

Reference Description 1 Air inlet silencer 2 Left cylinder 3 Right cylinder 4 Cooler 5 Cooling pipe 6 Pressure release valve 7 Electrical cubicle 8 Plunger 9 Spring 10 Pressure regulator 11 Refrigerant dryer

2.4 Regulating system

LE 2 up to LE 20 with DOL starter

The regulating system includes:

Check valve (CV) Air pressure switch (MDR) with pressure release valve (6) and on/off button (S1). For 10 to 20 Hp also Sol valve (for quicker discharge of head)

Operation

Air pressure switch (MDR) 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 (6) are opened. The motor stops, the air at the delivery side of the compressor is vented to atmosphere and check valve (CV) closes to prevent venting of the receiver.

When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the air pressure switch close and pressure release valve (6) closes. The motor restarts and compressed air is supplied to the receiver again.

LE 5 up to LE 20 each with Y/D starter


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Instruction book

Electric cubicle Air pressure switch (MDR) On/off switch (S1) Solenoid valve (Y1) Unloader (UA) with integrated check valve (CV)

Operation

Air pressure switch (MDR) opens and closes its contacts at pre-set pressures. During loaded operation, the contacts are closed: the motor is running and solenoid valve (Y1) is energized preventing the compressed air from flowing to unloader (UA).

When the pressure in the air receiver reaches the pre-set maximum pressure, the contacts of pressure switch (MDR) open. The motor stops and solenoid valve (Y1) is de-energized. Compressed air from the receiver will flow via the solenoid valve to plunger (8) which causes unloading valve (UV) to open. The air at the delivery side of the compressor is blown through silencer (US) to atmosphere and check valve (CV) closes to prevent venting of the receiver.

When the pressure in the air receiver decreases to the pre-set minimum pressure, the contacts of the pressure switch close. The motor restarts and, after switching over from star to delta, solenoid valve (Y1) is energized. Control air from the unloader plunger chamber is vented to the atmosphere. Unloading valve (UV) closes and compressed air is supplied to the receiver again.

LE Trolley


Pilot valve (RV) Unloader (UA) with integrated check valve (CV) Electric cabinet (only on electric motor driven Trolley compressors)

Operation

Pilot valve (RV) opens and closes at pre-set pressures. During loaded operation, pilot valve (RV) is closed preventing the compressed air from flowing to unloader (UA).

When the pressure in the pulsation dampers (PD) reaches the pre-set maximum pressure, pilot valve (RV) will open. Compressed air from the pulsation dampers will flow to plunger (8) which causes unloading valve (UV) to open. The air at the delivery side of the compressor is blown through silencer (US) to atmosphere and check valve (CV) closes to prevent venting of the pulsation dampers. The compressor runs unloaded.

When the pressure in the pulsation dampers decreases to the pre-set minimum pressure, the pilot valve closes. Control air from the unloader plunger chamber is vented to the atmosphere. Unloading valve (UV) closes and compressed air is supplied to the pulsation dampers again.

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3 Installation

3.1 Dimension drawings

Dimension drawings

B B

A

496

40

For Dismantling Air filter

254

202

X

VIEW F G-G

Cooling Air Inlet

Compressor Air Inlet

LE/LF/LT 2-3:WITHOUT VIBRATION DAMPERLE/LF/LT 5 :WITH VIBRATION DAMPER

G

G112 20

157

100

91

30

141

368

Compressed Air outletG1/2"

26

167

Pitc

h Ø

154

H7

Ø

21

8 p9

Ø 5k 52

M8(4x)

VIEW F

M10

N e t M a s s B lo c k ( K g )

N e t M a s s P o w e r p a c k ( K g )

A B C D E

542 6 1 5943155542 6 1 5943155

T y p e

5 0 4 2 5 2

L T

3 0

3 0 5 3 3 2 7 9

L E / L F

3 6 5 7 76 8 7

6 8 7

Cooling Air Inlet

Cooling Air inlet

157

615

Compressed Air outletG1/2"

26

74 � 0,5

167

506

E

C

40

For dismantling Air filter

71

Compressed Air OutletG1/2"

VIEW H

VIEW H

D

Y

Z

9820 2239 01/0881448D

LE 2 up to LE 5, Power Pack

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Instruction book

F-F

Cooling Air Inlet

Compressor Air Inlet

LE/LT/LF 7-10

F

F

VIEW E

A

300 B

H

K

457

49,5

135

173

290

221

601

40

For Dismantling Air inlet

8,5

� hctiP 041

154

H7

Ø

M8(4x)

M10

X

VIEW E

J

10 p9

30

Ø 5K 53

25

Compressor Air OutletG1/2"

VIEW H Cooling Air inlet

C

D74 � 0,5

E

VIEW H

G

Z

Y

F

Compressor Air OutletG 1/2"

Net Mass Block (Kg)

Net Mass Power pack (Kg)

A B C D E F G H J K

06821409710 102 932

10 (60Hz) 102 929 225 109 23*7 90 412 860

10 102 453 9327 90 412 860

10 102 453 932

25

Type

LE

45

600 300453

LT 610 310

LF 600 300

187

187

71

71

15

15

177 619820 2239 02/08

81449D


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Instruction book

9820 2239 07/0281450D

Z ( 1:2 )

VIEW Y

Z

COOLING AIRINLET

AIR INLETFOR DISMANTLING AIR FILTER

B

A

394

244

60

25,5

266

99

74

228

293COMPRESSED AIROUTLET G1/2" 42

589

� 14(4x)

VIEW Y

� 270

14pg

� 45 k5M16

39,5

- 0,20

+

667

VIEW X

COOLING AIR

C

D

277

36,5

678

110

COMPRESSED AIROUTLET G1/2"

VIEW X

395 � 0,5

TYPE FRAME SIZE NET MASS BLOCK NET MASS POWERPACK A B C DLE 15 O 98 164 719 359.5 545 1067LE 20 O 98 198 719 359.5 545 1094LT 15 O 98 166 682 353 545 1067LT 20 O 98 194 713 353 545 1094


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Instruction book

9820 2239 42/0681452D

Type Net Mass (Kg) A B C D E FLE/LF 2 47 613LE/LF 3 51LE/LF 5 53 205 641 506

LT 2 47 613LT 3 51LT 5 53 205 641 506

504 252

533 279

496

496

631682

682

195

195 631

BM LE/LT/LF 2-3-5 DOL

252 B

A

10

D40

125

555

4198

395

E40

F


Compressor Cooling Air inlet

Cooling Air outlet

MotorCooling Air inlet

Compressor air Inlet

C

540166

Compressed Air ouletG 1/2"

6

LE 2 up to LE 5, Base-mounted

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9820 2239 43/0581453D

Type Net mass (Kg) A B C D

LE/LT/LF 7 92 860 322 205 721

LE/LT/LF 10 104 932 322 205 721

LE 10 (60 Hz) 104 929 360 243 759

Compressor cooling Air inlet

Cooling Air outlet

Motor cooling Air inlet

Compressor Air inlet

BM LE/LT/LF 7-10 YD300300

600

154 555

198

395

24

10

C C

D40


B

125

248 541

A

244Compressed Air outletG1/2"

LE 7 up to LE 10, Base-mounted

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Instruction book

9820 2239 41/0881454D

B

MN

K L MIN. 280

E

DA

B

COOLING AIROUTLET

COOLING AIR OUTLET

MOTOR COOLINGAIR INLET

COMPRESSOR AIR+COOLING AIR INLET

G 130 39525 540 F

TYPE SIZE NET MASS A B D E F G K L M N

LE 10 (50 Hz) 171 740 816 1180 1395 185 42.5 191.5 155 296.5 123.5

LF 10 (50 Hz) 171 740 816 1180 1395 185 42.5 191.5 155 296.5 123.5

LT 10 (50 Hz) 171 740 816 1180 1395 185 42.5 191.5 155 296.5 123.5

LE 10 (60 Hz) 240 830 880 1360 1410 369 87.5 322 194 330 82

LT 10 (60 Hz) 171 830 880 1360 1410 369 87.5 322 194 330 82

TYPE NET MASS A B D E F G K L M N

LE/LT/LF 2 101 680 731 890 1254 130 12.5 191.5 100 229.5 85.5

LE/LT/LF 3 105 680 731 890 1254 130 12.5 191.5 100 229.5 85.5

LE/LT/LF 5 107 680 731 890 1254 130 12.5 191.5 100 229.5 85.5

LE/LT/LF 7 159 740 816 1180 1395 185 42.5 191.5 155 296.5 123.5

LE/LT/LF 10 171 740 816 1180 1395 185 42.5 191.5 155 296.5 123.5

LE 2 up to LE 20, Pack with silencing hood

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9820 2239 21/0781455D

Receiver (L) Netmass (Kg) A B2 853 892 933 97

504

533 279

252LE/LF

Type

LT

90

90

TM 90L LE/LT/LF 2-3

Cooling air inlet

Cooling air outlet

Compressor air inlet

181

982

640

191600

979

� 370

40

For dismantling air filter

A

252 B

10

615

529

483

364

318

Compressed air outletG 1/2"

Manual drainG 1/4"

Slot Hole 15x25 (4x)

LE 2 up to LE 3, Tank-mounted, receiver 90 l

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Instruction book

9820 2239 23/0581456D

Cooling Air inlet

Cooling Air outlet


1149

1645

40

For DismantlingAir filter

A

252 B

2

C

140

81 Ø 006

� 500

10

Manual drainG 1/4"

Compressed Air Outlet G1/2"

622

D

Type Receiver (L) Net Mass(kg) A B C D2 2653 2695 271 687 3432 2853 2895 291 687 343

533 279

615

615

271

271

LE/LF

LT

504 252250

250

LE 2 up to LE 5, Tank-mounted, receiver 250 l

30 2920 7089 80

Instruction book

9820 2239 22/0781457D

R e c e i v e r ( L ) N e t M a s s ( K g ) A B C D E F G H E K2 1 4 73 1 4 95 1 5 02 1 6 73 1 6 95 1 7 02 1 4 73 1 4 95 1 5 0

1 0 8 2L T 5 3 3 2 7 9

L F 5 0 4 2 5 2

3 3 6 3 8 2 5 7 5 4 5 0

2 5 2

4 1 8 1 8 5 2 3 1 0

T y p e

L E

2 5 0

5 0 4

Type Receiver (L) Net Mass (Kg) A B C D E F G H J KLE 5 185 504 252LT 5 245 533 279LF 5 185 504 252

1261455 1926 395 476475 530 754 600

Cooling air Outlet

Cooling air Inlet

Compressor air inlet

LE/LT/LF 5

OPTIONAL LARGER VESSEL ON LE/LT/LF 2-3-5

C 960

Dmax

687

E

Ø J

H

G

40K

252 B

A

F

For dismantling air filter

60

Compressed Air outlet G 1/2"

365

Manual drainG 1/4"

10

LE 2 up to LE 5, Tank-mounted, horizontal receiver 250/475 l

2920 7089 80 31

Instruction book

LE/LT/LF 7-10

D

M40

C

E 960

10

62F max.

H

J

G

K

296 B

A

290

Ø L

21161

FOR DISMANTLING AIR FILTER

COMPRESSORCOOLINGAIR INLET

COOLINGAIR OUTLET

MOTORCOOLINGAIR INLET

COMPRESSEDAIR OUTLET

G 1/2"

COMPRESSORAIR INLET

COMPRESSORAIR INLET

MANUAL DRAINOUTLET G 1/4"

SLOT HOLE15x25 (4x)

TYPE

LE/LT/LF 7

LE /LT/LF 10

NET MASS A B C

411,5

452,5

D

859,5

931,5

E

418

F

1852

G

310

H

336

J

382

K

575

L

450

M

116208

189

201

592 296

606 310

452,5 931,5455 1926 395 476 530 754 600 1341

224

236 606 310

WITH 250L RECEIVER

TYPE

LE/LT/LF 7

LE /LT/LF 10

NET MASS A B C D E F G H J K L M

08

WITH 475L RECEIVER

411,5 859,5592 296

LE 10 (60Hz) 201 600 300 453 929

LE 10 (60Hz) 236 600 300 453 929

418 1852 310 336 382 575 450 1200

455 1926 395 476 530 754 600 1379

9820 2239 25/0881737D


32 2920 7089 80

Instruction book

9821 1041 00/1081738D

Receiver(L) Net Mass(Kg) A B BB C D E F G H J K L M N250 - 390 1793 310 336 382 554 450 1250475 - 427 1867 395 476 530 729 600 1425250 - 390 1793 310 336 382 554 450 1250475 - 427 1867 395 476 530 729 600 1425250 - 390 1793 310 336 382 554 450 1250475 - 427 1867 395 476 530 729 600 1425250 - 390 1793 310 336 382 554 450 1250475 - 427 1867 395 476 530 729 600 1425

960

Type

68715

20

LE

718

1062.5

1089.5LT

353 540

334

365

15 687 334 1062.5

20 718 365 1089.5

Air Inlet

Cooling air Inlet Electrical cable entry

(pg 21on rear side)

Gmax 60

E F

N60

BB B

A

ØM

J

K

395

H

D

Compressed AirOutlet G1/2"C

10

SLOT HOLE 15x25(4x)

L

For Dismantling Air Filter

Manual drainG 1/4"

LE/LT 15-20


2920 7089 80 33

Instruction book

9820 4496 00/0181458D


960 384

1782

� 450

1390

60

310�

3

10

605�

6

H �

6

Manual drain outlet G 1/4"

Compressed air outlet G 1/2"

Dryed compressed air outlet G 1/2"

402 � 5

352 � 585

0�

6

76For dismantlingair filter

Cooling air inlet

Cooling air outlet

40A

B C

748

28 495

1090

�6

485

326

286

Dryer cooling air outlet

Dryer cooling air inlet

D

Type Net Mass A B C D HLE/LF 2 504 252

LT2 533 279LE/LF 3 504 252

LT3 533 279LE5 504 252LT5 533 279

1072175 kg

1082

171 kg

177 kg

252 686

LE 2 up to LE 7, Tank-mounted, Full-Feature, receiver 250 l

34 2920 7089 80

Instruction book

9820 4497 00/0181459D


476 � 5

10

1888

395�

3

767�

6

1012

�6

H �

6

Compressed air outlet G 1/2"

Manual drain outlet G 1/4"

Dryed compressed air outlet G 1/2"

60

75For dismantlingair filter

Cooling air inlet

Cooling air outlet

530 � 5

� 600

1398

960 437

A

B C

40

1

1

27 495

748

1252

�6

485

327 1

287

Dryer cooling air outlet

Dryer cooling air inlet

D

Type Net Mass A B C D HLE5 225 kg 510 255 255 686 1261LT5 225 kg 533 255 279 686 1261LF5 / LE7 265 kg 592 296 296 860 1341LT/LF 7 265 kg 606 296 310 860 1341LE 10 (50Hz) 282 kg 592 296 296 932 1341LT 10 (50Hz) 277 kg 606 296 310 932 1341LF 10 / LE 15 320 kg 790 418 372 1000 1379

LE 5 up to LE 20, Tank-mounted, Full-Feature, receiver 475 l

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Instruction book

9820 2239 24/0881460D

COOLING AIR OUTLET

COOLING AIR OUTLET

COMPRESSED AIR OUTLET G1/2"

COOLING AIR INLET

L 890

100191,5680

A

B

ØK

H

G

C

254

D M

Emax 60

F

J22

9,5

N

10

Manual drain outlet G1/4"

SLOT HOLE 15x25 (4x)

Receiver Net Mass

(Kg)A B C D E F G H J K L M N

2 1933 1955 197

LF/LE 5 475 232 1340 754 1872 455 1926 395 476 530 1025 600 2302 2013 2035 205

LT 5 475 240 1340 754 1872 455 1926 395 476 530 1025 600 2302 1333 1355 1372 1413 1435 145

1852 310 336

Type

1161 1694250LF/LE 418575 846382 450 193

LT 250 1161 575 1694 418 1852 310 193336 382 846 450

960 115

LF/LE 90 1076 483 1603 191 1034 370275 318 368 761

LT 90 1076 483 1603 191 1034 275 45

600 155

318 368 761 370

45

LE 2 up to LE 5, Tank-mounted with silencing hood

36 2920 7089 80

Instruction book

9820 2239 26/0981461D

LE 7 up to LE 10, Tank-mounted with silencing hood

2920 7089 80 37

Instruction book

9820 2239 71/0781462D

1569

1131

795

A

Compressed air outlet

40 (For dismantling air filter)

AirInlet

363

220

10

311,5

375

438

1104

776

TYPERECEIVER

(lit.)NET MASS

(Kg) A

LE/LT/LF 235

LE/LT/LF

15107

LE/LT20

2 x 10 ltr.

2 x 10 ltr.

2 x 10 ltr.

9599

101140152216248

812

891

1024

LE Trolley with electrical motor

38 2920 7089 80

Instruction book

9820 2239 91/0581463D

LE Trolley with petrol engine

References of figures on dimension drawings.

Reference Description 1 Air inlet 2 Hole, 15 x 25 (4X) 3 Cooling air inlet 4 Net mass 5 Compressed air outlet, G1/2

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Instruction book

Reference Description 6 Manual condensate drain 7 Hole, 15 x 25 (3X) 8 Receiver 9 Cooling air inlet 10 Motor cooling air inlet 11 Compressed air outlet 13 Compressor cooling air and air inlet 14 For dismantling air filter 15 Compressor air outlet with flexible (2 meters) 16 Electric cable entry (on rear side) 19 Air outlet

3.2 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. The electrical power supplied to the compressor unit must be connected by a qualified electrician in accordance with the wiring diagram supplied with the plant. All wiring must be in accordance with IEE regulations. Cable sizes given in section. Electric data are recommendations only.

Installation proposal for tank-mounted unit (90 l receiver)

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Instruction book

Installation proposal for tank-mounted unit (250/475 l receiver)

2920 7089 80 41

Instruction book

Installation proposal for tank-mounted unit (vertical 250 l receiver)

42 2920 7089 80

Instruction book

Installation proposal for base-mounted unit with optional silencing hood

2920 7089 80 43

Instruction book

Installation proposal for tank mounted compressors with silencing hood

References of figures on installation drawings.

Reference Description 1 Cooling air outlet 2 Compressor air and cooling air inlet

LE

Install the compressor horizontally, in a cool but frost-free and well-ventilated room. Place the compressor as level as possible; however, LE can be operated with a maximum inclination of 40% (22.5 degrees) in any direction. The air should be clean.

A Base mounted unit with hood option must be installed away from walls to allow easy maintenance. Keep the ventilation openings free.

It is recommended to install an automatic condensate drain (available as an option) on the air receiver to ensure continuous condensate removal.

LE trolley

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Instruction book

The compressors are equipped with a lifting eye or yoke. When running, the compressor must be installed as level as possible; however, it can be operated temporarily in an inclined plane of maximum 25% (or 20 degrees). Keep the compressor in a frost-free and well-ventilated place.

3.3 Electrical connections

Warning

The electrical connection must be carried out by an electrician and corresponds to the local codes. The indications on the motor data plate must correspond to the power supply voltage and frequency. The installation must include an isolating switch in the power line near to the unit and be protected against short-circuits by fuses for each phase refer section Overload relays and fuses or Cable sizes. The power supply and earthing lines must be of suitable size. refer section Overload relays and fuses or Cable sizes. For DOL starters, connect the power supply cables as shown in the electrical diagrams. For Y/D starters, connect the power supply cables to terminal board (X1) as shown in the picture. Check the setting of the overload relay. refer section Overload relays and fuses or Cable sizes.

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Instruction book

Electric cabinet

Example of an electrical cubicle

Reference Description F1 Fuse

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Instruction book

Reference Description F4 Overload relay K1 Line contactor with integrated Y-D timer K2 Star contactor K3 Delta contactor P Hourmeter, running hours X1 Terminal board S1 On/off switch

Electrical diagram with direct-on-line starter

3.4 Settings of overload relay and fuses

Settings of overload relay - fuses of compressors with DOL starter

50 Hz

Type Voltage (V)

Overload relay (A)

Fuses (A)

LE 2 230 MONO 10 16

LE 2 230 7 10

LE 2 400 4 6

LE 2 500 3 6

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Instruction book

Type Voltage

(V) Overload relay (A)

Fuses (A)

LE 3 230 MONO 14 20

LE 3 230 10 16

LE 3 400 5.2 10

LE 3 440 5 10

LE 3 500 4 6

LE 3 550 3 6

LE 3 660 2.8 6

LE 3 1000 2 4

LE 5 230 16 25

LE 5 400 10 16

LE 5 690 5 10

LE 5 1000 4 6

LE 7 230 22 32

LE 7 400 14 20

LE 7 550 9 16

LE 7 690 6 10

LE10 400 15 20

LE10 690 9 16

LE15 400 21.5 32

LE20 400 30 50

60 Hz

Type voltage (V)

overload relay (A)

fuses (A)

LE2 230 MONO 10 16

LE2 230 7 10

LE2 380 4 6

LE2 460 3.4 6

LE2 575 3 6

LE2 690 2 4

LE3 230 MONO 14 20

LE3 230 10 16

LE3 380 6.5 10

LE3 460 5.5 10

48 2920 7089 80

Instruction book

Type voltage (V)

overload relay (A)

fuses (A)

LE3 575

LE5 230 MONO 29 40

LE5 230 16 25

LE5 380 11 16

LE5 460 9 16

LE5 575

LE7 230 22 32

LE7 380 15 20

LE7 460 12 20

LE7 575 10 16

LE10 230 30 50

LE10 380 18 32

LE10 460 15 25

LE10 575 11 20

LE15 230 47 63

LE15 460 23 40

LE15 575 18 32

LE20 230 58 80

LE20 460 29 50

LE20 575 23 32

Settings of overload relay and fuses of compressors with Y-D starter

50 Hz

Type voltage

(V) overload relay (A)

fuses (A)

LE5 230 10.5 25

LE5 400 6 16

LE5 500 4 10

LE5 550 5 10

LE7 230 14 32

LE7 400 8 20

LE7 440 7 16

LE7 500 6 16

2920 7089 80 49

Instruction book

Type voltage (V)

overload relay (A)

fuses (A)

LE7 550 5 16

LE7 575 4.8 12

LE7 660 4 12

LE7 1000 2.5 6

LE10 230 16 40

LE10 400 10.5 25

LE10 440 9 25

LE10 500 7 20

LE10 550 6 16

LE10 660 5 16

LE10 690 5 16

LE10 1000 4 10

LE15 230 25 63

LE15 400 15 40

LE15 500 12 32

LE15 550 10 25

LE20 230 34 80

LE20 400 20 50

LE20 500 14 32

LE20 550 13 32

60 Hz

Type voltage (V)

overload relay (A)

fuses (A)

LE5 230 10.5 25

LE5 380 6.5 16

LE5 460 5.5 16

LE7 230 14 32

LE7 380 8.5 20

LE7 460 7 16

LE7 575 5.5 16

LE10 230 16 40

LE10 380 10.5 25

LE10 460 9 20

LE10 575 7 20

50 2920 7089 80

Instruction book

Type voltage (V)

overload relay (A)

fuses (A)

LE15 230 25 50

LE15 380 15 40

LE15 460 13 32

LE20 230 31 80

LE20 380 20 50

LE20 460 15 40

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Instruction book

3.5 Cable sizes

Starter Cable size

mm² LE 2 and LE 3 DOL 2.5 LE 5 and LE 7 DOL 4 LE 10 DOL 6 LE 5 Y/D 2.5 LE 7 Y/D 4 LE 10 and LE 15 Y/D 6 LE 20 Y/D 10

3.6 Pictographs

10

Reference Description 1 Temperature 2 Pressure 3 On 4 Off 5 Warning: voltage 6 Switch off voltage and depressurize before maintenance or repair 7 Read Instruction book before starting 8 Consult Instruction book for correct rotation direction 9 Do not adjust switch if it is depressurized

10 Drain label - drain out the tank daily - annually have the thickness of the tank walls checked by a competent body, recording the date of the service task on the label.

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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. Check the electrical installation, which must be in accordance with the instructions given in Electrical connection.

3. LE are filled with Piston Fluid compressor oil. Check that the oil level is still at the top of the red circle of sight-glass (SG).

4. Switch on the voltage. Start the motor. 5. Check the operation of the air pressure switch. See section Adjustment of pressure switch Check the

operation of pilot valve (RV) on LE Trolley. See section Adjustment of pilot valve. 6. On LE 15 and 20 compressors, check for correct direction of rotation, as indicated by the arrow on the fan

housing

4.2 Starting

LE

1. On LE check the oil level, which must be at the top of the red circle of sight-glass (SG). The minimum level is the lower part of the red circle.

2. Switch on the voltage. 3. Turn the switch to position I (Auto), or turn switch (S1) to position I.

4. For the full feature units, also push the switch to position I to start up the refrigerant dryer. Approximately 10 minutes later, the nominal dewpoint will be reached.

2920 7089 80 53

Instruction book

To ensure optimum operational efficiency, do not use dryer on/switch repeatedly within a short time period. Wait at least 5 minutes to start the dryer again after stopping to allow pressure equalization.

5. Open the air outlet valve (AV).

Regularly drain condensate

LE Trolley with electrical motor

1. On LE check the oil level, which must be near the top of the red circle of sight-glass (SG). The minimum level is the lower part of the red circle.

2. Set pilot valve (RV) in the unload position by turning the red handle 90 degrees. See section 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. Move switch to position I or push switch (S1) to position I. 6. Open the outlet valves (AV1 and AV2). 7. Set pilot valve (RV) in the load position by turning the red handle 90 degrees. See section Adjustment of

pilot valve. 8. Turn the regulating knob of the pressure regulator (10) clockwise or counter-clockwise to increase or

decrease the pressure at the outlet of the pressure regulator.

Regularly drain condensate (Dm).

LE Trolley with petrol engine

1. On LE check the oil level, which must be near the top of the red circle of sight-glass (SG). The minimum level is the lower part of the red circle.

2. Check the engine oil level as follows: Remove the oil filler cap and wipe the dipstick clean. Insert the dipstick into the filler neck, but do not screw it in. The oil level must show between the minimum and maximum marks on the dipstick.

3. Fill the fuel tank with unleaded or low-leaded petrol (gasoline).

54 2920 7089 80

Instruction book

4. Start the engine, consult the engine "Owner's manual". 5. Attach the air lines to the air outlets. 6. Open the outlet valves (AV1/2). 7. Set pilot valve (RV) in the load position by turning the red handle 90 degrees. See section Adjustment of

pilot valve. 8. Turn the regulating knob of the pressure regulator (10) clockwise or counter-clockwise to increase or

decrease the pressure at the outlet of the pressure regulator.

Regularly drain condensate (Dm)

4.3 Stopping

LE

1. Turn the switch to position 0 (Off), or push switch (S1) to position 0. 2. Close air outlet valve (AV) 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.

LE Trolley

1. Set pilot valve (RV) in the unload position by turning the red handle 90 degrees. See section Adjustment of pilot valve.

2. On LE Trolley with electrical motor, move switch to position 0 or push switch (S1) to position 0.If the compressor is not required for immediate further use, switch off the voltage at the main circuit breaker and unplug.

3. On LE Trolley with petrol engine Stop the engine, consult the engine "Owner's manual". 4. Close the air outlet valves (AV1 and AV2). Depressurize and disconnect the air lines from the outlet valves.

4.4 Taking out of operation

At the end of the service life of the compressor, proceed as follows:

1. Stop the compressor and close the air outlet valve(s). 2. Switch off the voltage and disconnect the compressor from the mains. 3. Depressurize the compressor. 4. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the

compressor from the air net. 5. Drain the oil.

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Instruction book

4.5 Storage after installation

Procedure

If the compressor is going to be stored without running from time to time, protective measures must be taken.

Protect the machine against dust and moisture, if possible in a clean, cool, dry and well ventilated area. Make sure that the machine is not subject to vibration. If the machine is stored in packing, put some vapor corrosion inhibitor (VCI) paper into the packing. Store the machine in its normal position, not upside down or on its side. If the machine is stored for 1 year or more, rotate the bearings once a month to change the position of the

roller balls in the bearings. Consult Atlas Copco Service.

56 2920 7089 80

Instruction book

5 Maintenance

5.1 Petrol 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.

Period Running hours

Operation Consult section See notes below table

Preventive maintenance kit

Weekly Check oil level. Starting 1 - Daily

Drain condensate from air receiver or pulsation damper.

Air receiver instructions

- -

6-monthly

Test safety valve.

Safety valve Relief valve

1 -

6-monthly

Inspect air filter. Air filter 3/4 2

Yearly 500 On LE 15 and LE 20, replace air filter.

Air filter 3/4 2


Air filter 3/4 2


Air filter 3/4 2

Yearly 2000 Change blow-off silencer, if provided.

- - 2

Yearly 2000 If mineral oil is used, change oil.

Lubrication of compressor

- -

2-yearly 3000 If Piston Fluid oil is used, change oil.

Lubrication of compressor

- -

3000 to 4000 Replace check valve or unloader.

Valves - 3/4

4000 On LE 2 up to 5 and LE 15 up to 20 replace valve discs.

Valves - 1

5000 On LE 7 up to 10 replace valve discs.

Valves - 1

2920 7089 80 57

Instruction book

Notes:

1. Maintain the level in the red circle of the sight-glass. 2. Wear gloves and safety glasses. 3. For normal operation in clean surroundings. More frequently when operating in a dusty environment. 4. In a dusty environment, a heavy-duty filter (available as an option) is essential.

Preventive maintenance schedule Full Feature units

Only applicable on the refrigerant dryer.

Period Operation Daily Inspect and clean the filter of the steam trap. Weekly Brush or blow off the finned surface of the condensor.

Note (Full Feature units):

Regularly check that the condensate is discharged via the condensate outlet of the refrigerant dryer. The amount depends on the operation conditions.

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 a fast oil degradation, overheating and potentially irreversible damage and high repair costs. Therefore, high performing lubricants increase the equipment lifetime.

Considering the low oil content in piston compressors, often less than 2 liters, the economy of lesser quality oils simply is not worth the risk.

Piston Fluid oil can be ordered in different quantities: a 1-liter can and 5-liter can.

5.4 Service kits

Service kits are available, offering the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. The kits comprise all parts needed for servicing. Consult the Parts list for the contents of all kits.

58 2920 7089 80

Instruction book

Reference Description 1 Valve kit 2 Filter kit 3 Check valve 4 Unloader 5 Piston Fluid

Notes:

1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized

parts is not covered by Warranty or Product Liability. 2. Whichever interval comes first. The local Sales Company may overrule the maintenance

schedule, especially the service intervals, depending upon the environmental and working conditions of the compressor.

3. For the contents of all kits, consult the Parts list.

5.5 Disposal of used material

Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation.

2920 7089 80 59

Instruction book

6 Servicing and adjustment procedures

6.1 Unloader or check valve

Warning

Release the pressure from the compressor before starting repair or maintenance works. Switch off the voltage and isolate the compressor from the mains.

Unloader or check valve

It is recommended to replace the unloader or check valve as indicated in section Preventive maintenance schedule.

Dirt, condensate, coke formation and oxidation influence the proper operation of the valve. Depending on the environmental and working conditions (ambient temperature, working pressure, load cycle, oil type), the local Atlas Copco customer center or authorized distributor may overrule the maintenance schedule (consult Atlas Copco).

6.2 Valves

A faulty valve must be replaced immediately. A faulty valve can be discovered as stated in section Problem solving Consult Atlas Copco.

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Instruction book

It is highly recommended to replace the valve discs, O-rings and gaskets if disassembling the cylinder heads.

Cylinder heads, low pressure variants

10 97

654

3

2

11 1213 1

16

15

17

1820

1921

8

1414

81615D

Reference Description

1 Pin

2 Suction disc

3 Seat

4 O-ring

5 Delivery disc

6 Valve guard

7 Spring

8 Head

9 Bolt

10 Washer

11 Stud

12 Washer

13 Nut

14 O-ring

15 Cylinder

16 O-ring

17 Gasket

18 Bolt

19 Washer

20 Washer

21 Nut

2920 7089 80 61

Instruction book

Replacement of valve discs

Operation sequence

Remove the fan guard, unscrew the cap and remove the cover, air filter and cover of the air inlet silencer(1).

Disconnect cylinder head cover (12) from the inlet and outlet pipe flanges. Remove cylinder head cover.

Remove spring (3), outlet valve guard (4) and outlet valve disc (5). Lift off valve seat (6) and remove inlet valve disc (7). Do not remove guide pins (8). Remove and discard all O-rings. If necessary, remove the carbon deposits from the inlet valve guard at the cylinder top. Take care that

no dirt drops into the cylinder. Clean and inspect all parts. Fit a new O-ring (11). Do not stretch the cord while inserting it in its groove; the ends should meet. Put a new inlet valve disc (7) into place and install valve seat (6). Fit new O-rings (9) and (10). Install a new outlet valve disc (5), guard (4) and spring (3). Reinstall cylinder head cover (12). Fit new O-rings/gaskets (2) for the pipe flanges. Fit the flange and

cylinder head bolts and tighten them alternately. Reinstall the fan guard, cover of the air inlet silencer, air filter, cover (1).and cap.

Torque value Torque value Torque value M6: 10 Nm ±2 M8: 23 Nm ±2 M10: 46 Nm ±5

6.3 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. Discard damaged elements. 4. Install the new element, cover and cap.

6.4 Adjustment MDR4 pressure switch

Views of air pressure switch MDR4

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Instruction book

Ref Name 1 Air pressure switch 2 Solenoid valve 3 Pressure release valve 4 Adjusting screw, stopping pressure 5 Adjusting screw, pressure difference

Function

The adjustment of the maximum or stopping pressure of the compressor is effected by means of the air pressure switch. The switch also controls the pressure difference between the maximum pressure (stopping pressure) and the pressure at which compression is resumed (starting pressure).

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). To reduce the difference between the stopping and starting pressures, i.e. to increase the starting pressure, turn the screw counter-clockwise. To increase the pressure difference, turn the screw clockwise. The adjustment range is shown on the pressure difference diagram below.

Pressure difference diagram MDR4 - 11 bar

Ref Name (1) Starting pressure - bar(e) (2) Stopping pressure - bar(e)

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Instruction book

Example: Stopping pressure: 7 bar(e) Starting pressure: adjustable between 3 and 5.7 bar(e)

6.5 Adjustment of MDR3 pressure switch

Views of air pressure switch MDR3 with ON/OFF switch

This pressure switch has a cover with rotary knob (4) for manual On/Off (Auto/Off).

Reference Description 1 Dial, overload relay 2 Adjusting screw, stopping pressure 3 Adjusting screw, pressure difference 4 On/off switch (Auto/Off)

Function

The switch allows the operator to select the stopping pressure and the pressure difference between stopping and starting pressures. The stopping and starting pressures are the opening and closing pressures of the switch.

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). The adjustment range is shown in the graph below. Turn the screw counter-clockwise to reduce the pressure difference, clockwise to increase it.

64 2920 7089 80

Instruction book

Pressure difference diagram, MDR3/11 (10 bar units)

Example:

Stopping pressure: 7 bar(e) Starting pressure: adjustable between 3 and 5.7 bar(e)

Ref Name (1) Starting pressure - bar(e) (2) Stopping pressure - bar(e)

6.6 Adjustment of pilot valve on Trolley

The adjustment of the maximum or unloading pressure of the compressor is effected by means of pilot valve (RV) The valve also controls the difference between the preset maximum pressure and that at which compression is resumed.

Pilot valve on Trolley

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Instruction book

Reference Description A Control air to unloader R Vent hole 1 Unloading handle 2 Pressure adjusting screw 3 Nuts 4 Shims

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.

Setting of the pilot valve

The maximum pressure is controlled by adjusting screw (2): 1. Loosen handle (1) and the two nuts (3) 2. Turn the adjusting screw (2) clockwise to increase the maximum pressure. 3. The pressure difference can be increased by removing one or more shims (4). 4. Fit the two nuts (3) and handle (1) in their original position.

6.7 Safety valve

Replace the valve if it does not open at the correct pressure. No adjustment is allowed. Testing: Testing as described below shall only be carried out by competent personnel.

If safety valve is not used for longer than 6 months, pressurize for 4h to have working pressure.

Testing

1. Close the air outlet valve, depressurize and disconnect the hose or pipe from the valve 2. Start the compressor and run it until it stops automatically. 3. Switch off the voltage.

Remove the cover from the air pressure switch and, with the air receiver now under pressure, turn the adjusting screw one turn clockwise to increase the stopping pressure Adjustment of MDR4S pressure switch and Adjustment of MRD3 pressure switch. Reinstall the cover.

4. Switch on the voltage, slightly open the outlet valve and start the compressor 5. Gradually close the outlet valve while checking the air pressure gauge. If the safety valve has not

opened at the pressure specified in Compressor data, it must be replaced by a new one. If the compressor unloads before the specified opening pressure is reached, repeat the procedure as mentioned from step 3.

6. Readjust the unloading pressure as described in sections Adjustment of MDR4S pressure switch and Adjustment of MRD3 pressure switch

7. Reconnect the hose or pipe to the closed air outlet valve

66 2920 7089 80

Instruction book

Testing on Trolley

1. Close the air outlet valves, depressurize and disconnect the hoses from the valves. 2. Loosen the red handle of the pilot valve (1) and the two nuts (3) 3. Open outlet valve (AV1) a fraction. Start the compressor. 4. Gradually turn adjusting screw (2) clockwise while checking pressure gauge (Gp). If the safety

valve has not opened at the pressure specified in Compressor data, it must be replaced by a new one.

5. Readjust the normal working pressure after testing. Consult section Adjustment of pilot valve 6. Fit nuts (3) and handle (1) in their original positions.

2920 7089 80 67

Instruction book

7 Problem solving

Condition Fault Remedy Insufficient air pressure Air leak Check and correct as

necessary Air filter choked Replace filter Air pressure switch incorrectly

set Adjust switch

Air consumption exceeds maximum output of compressor

Check equipment connected

Damaged valve Inspect valves and replace parts where necessary

Unloader malfunctioning Inspect and replace parts where necessary

Solenoid valve out of order Remove and check. Replace if necessary

Unit does not speed up Voltage drop at motor terminals Consult power supplier. Use correct size of cable


Solenoid valve out of order Remove and check. Replace if necessary

Blow-off silencer choked Replace Air receiver pressure rises above maximum and causes safety valve to blow

Air pressure switch or pilot valve incorrectly set or out of order

Check. Replace switch or valve, if necessary

Solenoid valve defective Remove and check. Replace if necessary


Blow-off silencer choked Replace Receiver does not hold pressure Check valve leaks Check for broken valve and

springs Air leaks Check and correct as

necessary Too frequent starting/too short operating periods

Air pressure switch or pilot valve incorrectly set

Increase pressure difference

Check valve leaks Check for broken valve and springs

High oil consumption on LE/LT compressors

Oil level too high Do not overfill crankcase. Keep level in red circle of sight-glass

Piston ring(s) worn or broken Have condition of piston rings checked

Unit does not start Electrical failure Have electrical system checked. Check fuses and line terminals for tightness

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Instruction book

Condition Fault Remedy Overload relay cut out Reset overload relay. If the

relay cuts out again after starting, see "Overload relay cuts out"

Air pressure above pre-set starting pressure

Compressor will start when air pressure is lower than pre-set starting pressure of air pressure switch

Overload relay cuts out Overload relay incorrectly set Check and adjust. Reset relay Solenoid valve out of order Remove and check. Replace if

necessary Unloader plunger jammed Inspect and replace parts

where necessary Blow-off silencer choked Replace Ambient temperature too high Improve ventilation of room Motor stops and starts too

frequently See "Too frequent starting/too short operating periods"

Overcurrent due to motor or compressor failure

Consult Atlas Copco

2920 7089 80 69

Instruction book

8 Technical data

8.1 Reference conditions

Inlet pressure (absolute) bar 1 Relative air humidity % 0 Air inlet temperature ºC 20 Working pressure: for LE 10 bar bar(e) 7

8.2 Limitations

Minimum inlet temperature °C 0 Maximum inlet temperature ºC 40 Maximum working pressure bar(e) See below Only applicable for Full Feature variants. (with refrigerant dryer) Minimum ambient air temperature °C 5

8.3 Compressor data

50 Hz (10 bar)

Compressor type LE 2 LE 3 LE 5 LE 7 LE 10 LE 15 LE 20 Maximum working pressure

bar(e) 10 10 10 10 10 10 10

Maximum working pressure for Trolley

bar(e) 9.5 9.5 9.5 9.5 9.5 9.5 9.5

Pre-set pressure difference for Trolley

bar 1 1 1 1 1 1 1

Temperature at outlet valve, approx. - Unsilenced compressor

ºC 40 44 66 59 80 70 89

- Silenced compressor ºC 48 52 74 67 88 78 97 Power input at max. working pressure

kw 1.82 2.54 4.57 6.11 8.28 12.14 16.02

Motor shaft speed r/min 1500 1500 1500 1500 1500 1500 1500 Free air delivery (Note 1)

l/s 3.4 4.4 8.4 11.7 15.7 23.9 31.7

Oil capacity l 0.8 0.8 0.8 1.4 1.4 5.4 5.4 Opening pressure of safety valve

bar(e) 11 11 11 11 11 11 11

Maximum sound pressure level (Note 2)

70 2920 7089 80

Instruction book

Compressor type LE 2 LE 3 LE 5 LE 7 LE 10 LE 15 LE 20 - Tank-mounted dB(A) 78 79 79 80 81 84 85 - Tank-mounted with hood

dB(A) 65 66 66 70 70 73 73

- Base-mounted with hood

dB(A) 63 64 64 68 68 70 70

60 Hz (10 bar)

Compressor type LE 2 LE 3 LE 5 LE 7 LE 10 LE 15 LE 20 Maximum working pressure

bar(e) 10 10 10 10 10 10 10

Maximum working pressure for Trolley

bar(e) 9.5 9.5 9.5 9.5 9.5 9.5 9.5

Pre-set pressure difference for Trolley

bar 1 1 1 1 1 1 1

Temperature at outlet valve, approx. - Unsilenced compressor

ºC 49 54 80 74 80 70 89

- Silenced compressor ºC 57 62 88 82 88 78 97 - Power input at max. working pressure

kw 2.36 3.38 6.36 7.57 10.81 14.32 18.98

Motor shaft speed r/min 1800 1800 1800 1800 1800 1800 1800 Free air delivery (Note 1)

l/s 3.9 5.1 9.7 13.6 18.2 28.7 37.2

Oil capacity L 0.8 0.8 0.8 1.4 1.4 5.4 5.4 Opening pressure of safety valve

bar(e) 11 11 11 11 11 11 11

Maximum sound pressure level (Note 2) - Tank-mounted dB(A) 80 81 81 82 83 84 85 - Tank-mounted with hood

dB(A) 67 68 68 72 74 75 75

- Base-mounted with hood

dB(A) 65 66 66 70 70 72 73

Notes:

1) At reference conditions 2) According to ISO 2151 and Pneurop/Cagi PN8NTC2; tolerance 3dB(A)

2920 7089 80 71

Instruction book

9 Instructions for use

Air receiver (tank-mounted units)

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.

2 Periodical service inspection of the air receiver is needed, as internal corrosion can reduce the steel wall thickness with the consequent risk of bursting. Local rules need to be respected, if applicable. The use of the air receiver is forbidden once the wall thickness reaches the minimum value as indicated in the service manual of the air receiver (part of the documentation delivered with the unit).

3 Lifetime of the air receiver mainly depends on the working environment. Avoid installing the compressor in a dirty and corrosive environment, as this can reduce the vessel lifetime dramatically.

4 Do not anchor the vessel or attached components directly to the ground or fixed structures. Fit the pressure vessel with vibration dampers to avoid possible fatigue failure caused by vibration of the vessel during use.

5 Use the vessel within the pressure and temperature limits stated on the nameplate and the testing report.

6 No alterations must be made to this vessel by welding, drilling or other mechanical methods.

72 2920 7089 80

Instruction book

10 Pressure Equipment Directive (PED)

Components subject to the 97/23/EC Pressure Equipment Directive

The following table contains the necessary information for the inspection of all pressure equipment of category II and higher according to the Pressure Equipment Directive 97/23/EC and all pressure equipment according to the Simple Pressure Vessel Directive 2009/105/EC.

Part number Description PED Class 0830 1007 42 Safety valve IV 0830 1010 34 Safety valve IV 0830 1010 17 Safety valve IV 0830 1010 18 Safety valve IV 0830 1007 70 Safety valve IV 0830 1010 19 Safety valve IV 0830 1010 32 Safety valve IV 0830 1007 73 Safety valve IV 0830 1010 33 Safety valve IV 0830 1009 54 Safety valve IV 0832 1001 10 Safety valve IV

Overall rating

The compressors conform to PED smaller than category II.

2920 7089 80 73

Instruction book

11 Declaration of conformity

1 EC DECLARATION OF CONFORMITY2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product

3 Machine name

4 Machine type

5 Serial number

Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements of this directive.

The machinery complies also with the requirements of the following directives and their amendments as indicated.

Directive on the approximation of laws of the Member States relating to

Harmonized and/or Technical Standards used

Att’mnt

a. CE/32/79 tnempiuqe erusserP

b. CE/24/6002 ytefas yrenihcaMEN ISO 12100 – 1 EN ISO 12100 – 2

EN 1012 – 1 c. CE/501/9002 lessev erusserp elpmiS

d. Electromagnetic compatibility 2004/108/EC EN 61000-6-2 EN 61000-6-4

e. Low voltage equipment 2006/95/EC EN 60034

EN 60204-1 EN 60439

f. CE/41/0002 noissime esion roodtuO

6

7

8.a The harmonized and the technical standards used are identified in the attachments hereafter

8.b Atlas Copco Airpower n.v. is authorized to compile the technical file. 9

10 Conformity of the specification to the directives

Conformity of the product to the specification and by implication to the

directives11

12

13

gnirutcafunaM gnireenignE yb deussI

14 Name Ferdinando MARCHETTI

RikVAN DE VELDE

15 Signature

16 Date

Typical example of a Declaration of Conformity document

(1): Contact address:

Atlas Copco Airpower n.v.

P.O. Box 100

B-2610 Wilrijk (Antwerp)

Belgium

74 2920 7089 80

Instruction book

DECLARATION OF INCORPORATION

2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product

3 Machine name

4 Machine type

5 Serial number

6

7

must not be put into service until the machine in which it is intended to be incorporated into or assembled with, is in conformity with the relevant Essential Health and Safety Requirements of the EC-Directive 2006/42/EC and its amendments on the approximation of the laws of the Member States relating to Machinery.

EC DECLARATION OF CONFORMITY

We, Atlas Copco Airpower n.v., hereby declare that the product which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, as a component/quasi machine is in conformity with the relevant Essential Health and Safety Requirements of this directive.We, Atlas Copco Airpower n.v., undertakes, in response to a reasoned request by the national authorities, to transmit the relevant information on the partly completed machinery. The information on the relevant parts can be obtained prejudice to the intellectual property rights of Atlas Copco Airpower N.V.




Att’mnt

a. Pressure equipment 97/23/EC

b. Machinery safety 2006/42/EC EN ISO 12100 – 1 EN ISO 12100 – 2

EN 1012 – 1 EN 60204-11

c. Simple pressure vessel 2009/105/EC d. Electromagnetic compatibility 2004/108/EC EN 61000-6-2

EN 61000-6-4


EN 60204-1 EN 60439

f. Outdoor noise emission 2000/14/EC

8

9

10





directives14

15

16

Issued by Engineering Manufacturing


RikVAN DE VELDE

18 Signature

19 Date

Typical example of a Declaration of incorporation for block document



P.O. Box 100


Belgium

2920 7089 80 75

Instruction book

1 EC DECLARATION OF CONFORMITY2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product

3 Machine name

4 Machine type

5 Serial number

Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements of this directive.




Att’mnt

a. Pressure equipment 97/23/EC

b. CE/24/6002 ytefas yrenihcaMEN ISO 12100 – 1 EN ISO 12100 – 2

EN 1012 – 1 c. Simple pressure vessel 2009/105/EC

d. Electromagnetic compatibility 2004/108/EC EN 61000-6-2 EN 61000-6-4


EN 60204-1 EN 60439

6

7





directives11

12

13

Issued by Engineering Manufacturing


RikVAN DE VELDE

15 Signature

16 Date

Typical example of a Declaration of conformity for petrol document



P.O. Box 100


Belgium

76 2920 7089 80

Instruction book

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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.

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.

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