Atlas Copco CR Series Instruction Book Download | Manualshive

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Atlas Copco

Industrial cast iron piston compressors

CR Range

Instruction book

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Summary of Contents for CR Series

Page 1: ...Atlas Copco Industrial cast iron piston compressors CR Range Instruction book ...

Page 2: ......

Page 3: ...struction book Original instructions Copyright Notice Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings 2019 02 No 2022 2096 26 www atlascopco com ...

Page 4: ...or repair 7 2 General description 9 2 1 General description 9 2 2 Hour meter option 12 2 3 Control piping 14 2 4 Regulating system 19 3 Installation 20 3 1 Installation instruction 20 3 2 Electrical connections 22 3 3 Fuses and wire sizes 34 4 Operating instructions 35 4 1 Initial start up 35 4 2 Starting 35 4 3 Stopping 37 4 4 Taking out of operation 37 4 5 Storage after installation 37 5 Mainten...

Page 5: ...g and adjustment procedures 40 6 1 Air filter 40 6 2 Adjustment of MDR4 pressure switch 40 6 3 Adjustment of MDR3 pressure switch 41 6 4 Adjustment of pilot valve 42 6 5 Pressure relief valve 43 7 Problem solving 44 8 Technical data 47 8 1 Reference conditions 47 8 2 Limitations 47 8 3 Compressor data 47 9 Instructions for use 48 ...

Page 6: ...tment 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 d...

Page 7: ...s 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 connection...

Page 8: ...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 Pressure relief 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 repa...

Page 9: ...perations 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 f...

Page 10: ...ring 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 ...

Page 11: ... Compressors are air cooled two cylinder single stage and double stage lubricated piston compressors built for effective working pressures up to 145 175 psi Compressor block Compressor block Reference Description 1 Cylinder 2 Crankcase 3 Oil drain 4 Intercooler 5 Cylinder head 6 Pressure relief valve ...

Page 12: ...unted vertical receiver Tank mounted vertical receiver Reference Description 1 Compressor 2 Filter 3 Air pressure switch 4 Air receiver 5 Air pressure gauge 6 Crankcase 7 Intercooler 8 Pressure relief valve 9 Air outlet valve 10 Control panel ...

Page 13: ... Tank mounted horizontal receiver Reference Description 1 Compressor 2 Pressure relief valve 3 Air outlet valve 4 Hour meter option 5 Electric cabinet 6 On off switch 7 Air receiver 8 Air pressure switch 9 Air pressure gauge 10 Compressor 11 Condensate drain valve ...

Page 14: ...eceiver CR Contractor units are mobile compressors They are equipped with a gas 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 2 2 Hour meter option The hour meter is triggered by the motor s magnetic field so the hours display actual operation When the motor is on t...

Page 15: ...999 9 Hour meter Digit Height 5 digits 8MM LCD Operating Voltage Internal lithium battery 15 000 hours continuous running Temperature Standard 40 C to 85 C 40 F to 185 F Vibration Resistance Withstands 10 to 75Hz 1 to 8 g s Mounting Configuration Two hole base mount ...

Page 16: ...scharged through the cooler piping and and check valve unloader valve into the air receiver Control piping and regulating system with automatic start stop Reference Description 1 Pressure relief valve 2 Air receiver 3 Discharge line check valve 4 Vent 5 Pressure switch 6 Pressure release valve on pressure switch 7 Pressure gauge From compressor discharge ...

Page 17: ...load Reference Description 1 Pressure relief valve 2 Air receiver 3 Discharge line check valve 4 Vent 5 Pressure gauge 6 Pilot valve 7 Flow to head unloaders 8 Flow from compressor interstage 9 Electronic drain 10 Vent to atmosphere From compressor discharge Used on CR 15 units only ...

Page 18: ... 1 Pressure relief valve 2 Air receiver 3 Discharge line check valve 4 Vent 5 Pressure switch 6 Pressure release valve on pressure switch 7 Pressure gauge 8 Pilot valve 9 Flow to head unloaders 10 Flow from compressor interstage 11 Electronic drain 12 Vent to atmosphere From compressor discharge Used on CR 15 units only ...

Page 19: ... regulating system duplex tank mount with automatic start stop Reference Description 1 Control panel 2 Pressure transducer 3 Pressure gauge 4 Air receiver 5 3 way normally open solenoid valve 6 Vent 7 Pressure relief valve 8 Compressor 9 Discharge line ...

Page 20: ...lenoid valve Reference Description 1 Control panel 2 Pressure transducer 3 Pressure gauge 4 Air receiver 5 Vent 6 Pressure relief valve 7 Flow from interstage 8 Interstage dump valve Used on CR 15 units only 9 Flow to compressor head unloaders 10 Discharge line 11 Compressor 12 3 way normally open solenoid valve ...

Page 21: ...starts and compressed air is supplied to the receiver again CR Contractor The regulating system includes Pilot valve Unloader with integrated check valve Operation The pilot valve opens and closes at pre set pressures During loaded operation the pilot valve is closed preventing the compressed air from flowing to the unloader When the pressure in the pulsation dampers reaches the pre set maximum pr...

Page 22: ...or 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 UL regulations Cable sizes given in secti...

Page 23: ...2022 2096 26 21 Instruction book Installation proposal for CR with horizontal receiver ...

Page 24: ...rated temporarily in an inclined plane of maximum 25 or 20 degrees Keep the compressor in a frost free and well ventilated place 3 2 Electrical connections Warning The electrical connection must be carried out by an electrician and must correspond 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 is...

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Page 36: ...200 45 10 230 40 12 460 20 14 575 20 14 CR_10 200 60 10 230 50 10 460 25 14 575 20 14 CR_15 200 90 6 230 80 8 460 40 12 575 30 14 Motor Amperage This is the maximum Full Load Three Phase Standard Motors 1 15 SF NEC Table 430 250 Single Phase Full Load Motor Amps are from NEC Table 430 248 NEC Table 430 52 used for calculating Fuse size NEC 240 6 Used to select Standard Fuse Sizes 15 20 25 30 35 40...

Page 37: ...ns given in Electrical connections 3 CR units are filled with Piston Fluid compressor oil Check that the oil level is still at the top of the red circle of sight glass 4 Switch on the voltage Start the motor 5 Check the operation of the air pressure switch Refer to Adjustment of pressure switch Check the operation of the pilot valve when equipped Refer to Adjustment of pilot valve 6 On CR 15 compr...

Page 38: ...ease or decrease the pressure at the outlet of the pressure regulator Regularly drain condensate CR Contractor with gas engine 1 On CR check the oil level which must be near the top of the red circle of the sight glass The minimum level is the lower part of the red circle 2 Check the engine oil level as follows Remove the oil filler cap and wipe the dipstick clean Insert the dipstick into the fill...

Page 39: ...e 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 ...

Page 40: ...rds Check for unusual noise or vibration Check for lubricant leaks Check pressurized components for rust cracks or leaks Weekly 40 Hours Manually operate the pressure relief valves Clean cooling surfaces of the intercooler aftercooler and compressor Check for air leaks in the compressor and air distribution system Clean or replace the air intake filter Use a shorter interval in humid dirty conditi...

Page 41: ...22101700 2022101800 Overhaul Kit 2022100300 2022100500 2022100700 2022155201 w head unloaders Gasket Set 2022106702 2022106800 2022106900 2022104800 Intercooler Repair Kit 2023501682 Head Kit 2022154601 2022154801 w head unloaders 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 ...

Page 42: ... silencer 3 Using a damp cloth clean the filter chamber and cover Discard damaged elements 4 Install the new element cover and cap 6 2 Adjustment of MDR4 pressure switch Views of air pressure switch MDR4 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 stoppin...

Page 43: ...opping and starting pressures i e to increase the starting pressure turn the screw counter clockwise To increase the pressure difference turn the screw clockwise 6 3 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 stopp...

Page 44: ... 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 6 4 Adjustment of pilot valve The adjustment of the maximum or unloading pressure of the compressor is effected by means of pilot valve The valve also controls the difference ...

Page 45: ...il 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 Gra...

Page 46: ...e too large for application Incorrect or inferior grade of lubricant System pressure leaking back through discharge valve Rusty valves and or cylinders Compressor operated too infrequently Compressor does not run long enough to get hot and vaporize the liquids squeezed out of the air during compression compressor may be too large for application Compressor not properly prepared for storage Dischar...

Page 47: ...g system Defective compressor head unloader Pilot valve or pressure switch set incorrectly or defective Pressure switch wired incorrectly Tube to compressor head unloader plugged Excessive intercooler pressure Intercooler restricted or plugged Compressor valves in second stage broken or not functioning properly Pilot valve or pressure switch set incorrectly or defective Intercooler pressure Compre...

Page 48: ...king oil seal Piston rings not seated allow 100 hours for seating Wrong oil may be a detergent oil with a tendency to foam Inferior grade of oil Excessive current draw To determine maximum amperage allowed multiply the FLA on the motor nameplate by the service factor CAUTION Motor surface temperature normally exceeds 170 F Low voltage must be within 10 of nameplate voltage Loose electrical connect...

Page 49: ...ith refrigerant dryer Minimum ambient air temperature F 41 8 3 Compressor data Compressor Data CRC10 CRC15 CRC20 CRP20 CRI5 CRI7 5 CRI10 CRI15 Compressor shaft speed RPM 1425 1117 941 1028 942 1026 968 923 Motor HP HP 2 3 5 5 5 7 5 10 15 Motor shaft speed RPM 3450 3450 3450 3450 1750 1750 1750 1750 Max working pressure Psig 145 145 145 175 175 175 175 175 FAD MWP CFM 4 1 7 6 9 5 14 5 17 2 22 6 35 ...

Page 50: ...g 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 r...

Page 51: ...er receipt of notification of readiness for shipment Claims for shortages will be deemed to have been waived if not made in writing with ten 10 days after the receipt of the material in respect of which any such shortage is claimed Seller is not responsible for loss or damage in transit after having received In Good Order receipt from the carrier All claims for loss or damage in transit should be ...

Page 52: ...50 2022 2096 26 Instruction book ...

Page 53: ... 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 www atlascopco com ...

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