2954 2460 02_OAH 2-OAV 4_EN

OAH 2 OAV 4

Installation Recommendations andInstallation Review for Portable Compressors

Printed matter N°2954 2460 02

01/2010

Original instructions

Installation Recommendations andInstallation Reviewfor Portable Compressors

OAH 2 OAV 4

ATLAS COPCO - PORTABLE AIR DIVISIONwww.atlascopco.com

OAH 2 - OAV 4

major

Warranty and Liability Limitation

Use only authorized parts.Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.The manufacturer does not accept any liability for any damage arising for modifications, additions or conversions made without the manufacturer's approval in writing.While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors.

Copyright 2008, Atlas Copco Airpower n.v., Antwerp, Belgium.

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.

Neglecting maintenance or making changes to the setup of the machine can result in hazards, including fire risk

2

Installation Recommendations and Installation Review

Follow the instructions in this booklet and we guarantee you yearsof troublefree operation. Please read the following instructionscarefully before starting to use your machine.

Always keep the manual available near the machine.

In all correspondence always mention the compressor type andserial number, shown on the data plate.

The company reserves the right to make changes without priornotice.

Always use this manual in conjunction with the operating manual ofthe driving mechanism!

CONTENTS PAGE

1 Safety precautions ...................................................................5

1.1 Introduction .................................................................5

1.2 General safety precautions ..........................................5

1.3 Safety during transport and installation ......................6

1.4 Safety during use and operation ..................................6

1.5 Safety during maintenance and repair.........................7

1.6 Tool applications safety ..............................................7

1.7 Specific safety precautions..........................................7

2 Leading particulars .................................................................9

2.1 Description of safety pictograms used in this manual......................................................9

3 Compressor module ................................................................9

4 Connection pipes between OEM and customer application .............................................................10

4.1 Discharge pipe...........................................................11

4.2 Drain connections......................................................11

5 Remote panel ..........................................................................11

6 Electrical system and shut-down switches .........................12

7 Compressor drive ..................................................................14

8 Dimensional Drawings ..........................................................15

8.1 OAH 2 with Canopy..................................................15

8.2 OAH 2 without Canopy.............................................16

8.3 OAV 4 with Canopy..................................................17

8.4 OAV 4 without Canopy.............................................18

3

OAH 2 - OAV 4

CONTENTS PAGE

9 Installation review................................................................. 19

10 Disposal................................................................................... 25

10.1 General...................................................................... 25

10.2 Disposal of materials ................................................ 25

11 Maintenance Log ................................................................... 26

4


1. SAFETY PRECAUTIONSTo be read attentively and acted accordingly before lifting, operating, performing maintenance or repairing the compressor.

1.1 INTRODUCTION

The policy of Atlas Copco is to provide the users of their equipment withsafe, reliable and efficient products. Factors taken into account are amongothers:- the intended and predictable future use of the products, and the

environments in which they are expected to operate,- applicable rules, codes and regulations,- the expected useful product life, assuming proper service and

maintenance,- providing the manual with up-to-date information.Before handling any product, take time to read the relevant instructionmanual. Besides giving detailed operating instructions, it also gives specificinformation about safety, preventive maintenance, etc.Keep the manual always at the unit location, easy accessible to the operatingpersonnel.See also the safety precautions of the other equipment, which are separatelysent along or are mentioned on the equipment or parts of the unit.These safety precautions are general and some statements will therefore notalways apply to a particular unit.Only people that have the right skills should be allowed to operate, adjust,perform maintenance or repair on Atlas Copco equipment. It is theresponsibility of management to appoint operators with the appropriatetraining and skill for each category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating the unit with the push-buttons, and is trained to know the safety aspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unit the same as theoperator. In addition, the mechanical technician is also trained to performmaintenance and repair, as described in the instruction manual, and is allowedto change settings of the control and safety system. A mechanical techniciandoes not work on live electrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the same qualifications as both theoperator and the mechanical technician. In addition, the electrical technicianmay carry out electrical repairs within the various enclosures of the unit. Thisincludes work on live electrical components.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer or its agent to performcomplex repairs or modifications to the equipment.In general it is recommended that not more than two people operate the unit,more operators could lead to unsafe operating conditions. Take necessarysteps to keep unauthorized persons away from the unit and eliminate allpossible sources of danger at the unit.When handling, operating, overhauling and/or performing maintenance orrepair on Atlas Copco equipment, the mechanics are expected to use safeengineering practices and to observe all relevant local safety requirementsand ordinances. The following list is a reminder of special safety directivesand precautions mainly applicable to Atlas Copco equipment.These safety precautions apply to machinery processing or consuming air.Processing of any other gas requires additional safety precautions typical tothe application and are not included herein.Neglecting the safety precautions may endanger people as well asenvironment and machinery:- endanger people due to electrical, mechanical or chemical influences,- endanger the environment due to leakage of oil, solvents or other

substances,- endanger the machinery due to function failures.All responsibility for any damage or injury resulting from neglecting theseprecautions or by non-observance of ordinary caution and due care requiredin handling, operating, maintenance or repair, also if not expressly mentionedin this instruction manual, is disclaimed by Atlas Copco.

The manufacturer does not accept any liability for any damage arising fromthe use of non-original parts and for modifications, additions or conversionsmade without the manufacturer’s approval in writing.If any statement in this manual does not comply with local legislation, thestricter of the two shall be applied.Statements in these safety precautions should not be interpreted assuggestions, recommendations or inducements that it should be used inviolation of any applicable laws or regulations.

1.2 GENERAL SAFETY PRECAUTIONS

1 The owner is responsible for maintaining the unit in a safe operatingcondition. Unit parts and accessories must be replaced if missing orunsuitable for safe operation.

2 The supervisor, or the responsible person, shall at all times make surethat all instructions regarding machinery and equipment operation andmaintenance are strictly followed and that the machines with allaccessories and safety devices, as well as the consuming devices, are ingood repair, free of abnormal wear or abuse, and are not tampered with.

3 Whenever there is an indication or any suspicion that an internal part ofa machine is overheated, the machine shall be stopped but no inspectioncovers shall be opened before sufficient cooling time has elapsed; this toavoid the risk of spontaneous ignition of oil vapour when air is admitted.

4 Normal ratings (pressures, temperatures, speeds, etc.) shall be durablymarked.

5 Operate the unit only for the intended purpose and within its rated limits(pressure, temperature, speeds, etc.).

6 The machinery and equipment shall be kept clean, i.e. as free as possiblefrom oil, dust or other deposits.

7 To prevent an increase in working temperature, inspect and clean heattransfer surfaces (cooler fins, intercoolers, water jackets, etc.) regularly.

8 All regulating and safety devices shall be maintained with due care toensure that they function properly. They may not be put out of action.

9 Care shall be taken to avoid damage to safety valves and other pressure-relief devices, especially to avoid plugging by paint, oil coke or dirtaccumulation, which could interfere with the functioning of the device.

10 Pressure and temperature gauges shall be checked regularly with regardto their accuracy. They shall be replaced whenever outside acceptabletolerances.

11 Safety devices shall be tested as described in the maintenance scheduleof the instruction manual to determine that they are in good operatingcondition.

12 Mind the markings and information labels on the unit.13 In the event the safety labels are damaged or destroyed, they must be

replaced to ensure operator safety.14 Keep the work area neet. Lack of order will increase the risk of accidents.15 When working on the unit, wear safety clothing. Depending on the kind

of activities these are: safety glasses, ear protection, safety helmet(including visor), safety gloves, protective clothing, safety shoes. Do notwear the hair long and loose (protect long hair with a hairnet), or wearloose clothing or jewelry.

16 Take precautions against fire. Handle oil with care because it is aninflammable substance. Do not smoke or approach with naked flamewhen handling such substances. Keep a fire-extinguisher in the vicinity.

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OAH 2 - OAV 4

1.3 SAFETY DURING TRANSPORT AND INSTALLATION

To lift a unit, all loose or pivoting parts, e.g. doors, shall first be securelyfastened.Use a fork lift truck with forks equal to or longer than the unit.Helicopter lifting is not allowed.It is strictly forbidden to dwell or stay in the risk zone under a lifted load.Never lift the unit over people or residential areas. Lifting acceleration andretardation shall be kept within safe limits.1 To lift heavy parts, a hoist of ample capacity, tested and approved

according to local safety regulations, shall be used.2 Lifting hooks, eyes, shackles, etc., shall never be bent and shall only

have stress in line with their design load axis. The capacity of a liftingdevice diminishes when the lifting force is applied at an angle to its loadaxis.

3 For maximum safety and efficiency of the lifting apparatus all liftingmembers shall be applied as near to perpendicular as possible. Ifrequired, a lifting beam shall be applied between hoist and load.

4 Never leave a load hanging on a hoist.5 A hoist has to be installed in such a way that the object will be lifted

perpendicular. If that is not possible, the necessary precautions must betaken to prevent load-swinging, e.g. by using two hoists, each atapproximately the same angle not exceeding 30° from the vertical.

6 Locate the unit away from walls. Take all precautions to ensure that hotair exhausted from an engine and driven machine cooling systems cannotbe recirculated. If such hot air is taken in, this may cause overheating ofthe unit.

7 Before moving the compressor, switch it off.

1.4 SAFETY DURING USE AND OPERATION

1 When operating in a dust-laden atmosphere, place the unit so that dust isnot carried towards it by the wind. Operation in clean surroundingsconsiderably extends the intervals for cleaning the air intake filters andthe cores of the coolers.

2 Close the compressor air outlet valve before connecting or disconnectinga hose. Ascertain that a hose is fully depressurized before disconnectingit. Before blowing compressed air through a hose or air line, ensure thatthe open end is held securely, so that it cannot whip and cause injury.

3 The air line end connected to the outlet valve must be safeguarded with asafety cable, attached next to the valve.

4 No external force may be exerted on the air outlet valves, e.g. by pullingon hoses or by installing auxiliary equipment directly to a valve, e.g. awater separator, a lubricator, etc. Do not step on the air outlet valves.

5 Never move a unit when external lines or hoses are connected to theoutlet valves, to avoid damage to valves, manifold and hoses.

6 Do not use compressed air from any type of compressor, without takingextra measures, for breathing purposes as this may result in injury ordeath. For breathing air quality, the compressed air must be adequatelypurified according to local legislation and standards. Breathing air mustalways be supplied at stable, suitable pressure.

7 Distribution pipework and air hoses must be of correct diameter andsuitable for the working pressure. Never use frayed, damaged ordeteriorated hoses. Replace hoses and flexibles before the lifetimeexpires. Use only the correct type and size of hose end fittings andconnections.

8 If the compressor is to be used for sand-blasting or will be connected toa common compressed-air system, fit an appropriate non-return valve(check valve) between compressor outlet and the connected sand-blasting or compressed-air system. Observe the right mounting position/direction.

9 Before removing the oil filler plug, ensure that the pressure is released byopening an air outlet valve.

10 Never spill nor leave oil or cleansing agent in or around the unit.

11 All doors shall be shut during operation so as not to disturb the coolingair flow inside the bodywork and/or render the silencing less effective. Adoor should be kept open for a short period only e.g. for inspection oradjustment.

12 Periodically carry out maintenance works according to the maintenanceschedule.

13 Stationary housing guards are provided on all rotating or reciprocatingparts not otherwise protected and which may be hazardous to personnel.Machinery shall never be put into operation, when such guards have beenremoved, before the guards are securely reinstalled.

14 Noise, even at reasonable levels, can cause irritation and disturbancewhich, over a long period of time, may cause severe injuries to thenervous system of human beings. When the sound pressure level, at anypoint where personnel normally has to attend, is:below 70 dB(A): no action needs to be taken,above 70 dB(A): noise-protective devices should be provided for

people continuously being present in the room,below 85 dB(A): no action needs to be taken for occasional visitors

staying a limited time only,above 85 dB(A): room to be classified as a noise-hazardous area and

an obvious warning shall be placed permanently ateach entrance to alert people entering the room, foreven relatively short times, about the need to wearear protectors,

above 95 dB(A): the warning(s) at the entrance(s) shall be completedwith the recommendation that also occasionalvisitors shall wear ear protectors,

above 105 dB(A): special ear protectors that are adequate for this noiselevel and the spectral composition of the noise shallbe provided and a special warning to that effect shallbe placed at each entrance.

15 The unit has parts, which may be accidentally touched by personnel, ofwhich the temperature can be in exess of 80 °C (176 °F). The insulationor safety guard, protecting these parts shall not be removed before theparts have cooled down to room temperature.

16 Never operate the unit in surroundings where there is a possibility oftaking in flammable or toxic fumes.

17 If the working process produces fumes, dust or vibration hazards, etc.,take the necessary steps to eliminate the risk of personnel injury.

18 When using compressed air or inert gas to clean down equipment, do sowith caution and use the appropriate protection, at least safety glasses,for the operator as well as for any bystander. Do not apply compressedair or inert gas to your skin or direct an air or gas stream at people. Neveruse it to clean dirt from your clothes.

19 When washing parts in or with a cleaning solvent, provide the requiredventilation and use appropriate protection such as a breathing filter,safety glasses, rubber apron and gloves, etc.

20 Safety shoes should be compulsory in any workshop and if there is a risk,however small, of falling objects, wearing of a safety helmet should beincluded.

21 If there is a risk of inhaling hazardous gases, fumes or dust, therespiratory organs must be protected and depending on the nature of thehazard, so must the eyes and skin.

22 Remember that where there is visible dust, the finer, invisible particleswill almost certainly be present too; but the fact that no dust can be seenis not a reliable indication that dangerous, invisible dust is not present inthe air.

23 Never operate the unit at pressures or speeds below or in excess of itslimits as indicated in the technical specifications.

6


1.5 SAFETY DURING MAINTENANCE AND REPAIR

Maintenance, overhaul and repair work shall only be carried out byadequately trained personnel; if required, under supervision of someonequalified for the job.1 Use only the correct tools for maintenance and repair work, and only

tools which are in good condition.2 Parts shall only be replaced by genuine Atlas Copco replacement parts.3 All maintenance work, other than routine attention, shall only be

undertaken when the unit is stopped. Steps shall be taken to preventinadvertent starting. In addition, a warning sign bearing a legend such as”work in progress; do not start” shall be attached to the startingequipment. On engine-driven units the battery shall be disconnected andremoved or the terminals covered by insulating caps. On electricallydriven units the main switch shall be locked in open position and thefuses shall be taken out. A warning sign bearing a legend such as ”workin progress; do not supply voltage” shall be attached to the fuse box ormain switch.

4 Before dismantling any pressurized component, the compressor orequipment shall be effectively isolated from all sources of pressure andthe entire system shall be relieved of pressure. Do not rely on non-returnvalves (check valves) to isolate pressure systems. In addition, a warningsign bearing a legend such as ”work in progress; do not open” shall beattached to each of the outlet valves.

5 Prior to stripping an engine or other machine or undertaking majoroverhaul on it, prevent all movable parts from rolling over or moving.

6 Make sure that no tools, loose parts or rags are left in or on the machine.Never leave rags or loose clothing near the compressor air intake.

7 Never use flammable solvents for cleaning (fire-risk).8 Take safety precautions against toxic vapours of cleaning liquids.9 Never use machine parts as a climbing aid.10 Observe scrupulous cleanliness during maintenance and repair. Keep

away dirt, cover the parts and exposed openings with a clean cloth, paperor tape.

11 Never weld on or perform any operation involving heat near the oilsystem. Oil tanks must be completely purged, e.g. by steam-cleaning,before carrying out such operations. Never weld on, or in any waymodify, pressure vessels. Disconnect the alternator cables during arcwelding on the unit.

12 Use only lubricating oils and greases recommended or approved by AtlasCopco or the machine manufacturer. Ascertain that the selectedlubricants comply with all applicable safety regulations, especially withregard to explosion or fire-risk and the possibility of decomposition orgeneration of hazardous gases. Never mix synthetic with mineral oil.

13 Protect the air intake filter, electrical and regulating components, etc., toprevent moisture ingress, e.g. when steam-cleaning.

14 When performing any operation involving heat, flames or sparks on amachine, the surrounding components shall first be screened with non-flammable material.

15 Never use a light source with open flame for inspecting the interior of amachine.

16 Disconnect –battery-clamp before starting electrical servicing or welding(evt. turn battery-switch in “off” position).

17 When repair has been completed, the machine shall be barred over atleast one revolution for reciprocating machines, several revolutions forrotary ones to ensure that there is no mechanical interference within themachine or driver. Check the direction of rotation of electric motorswhen starting up the machine initially and after any alteration to theelectrical connection(s) or switch gear, to check that the oil pump and thefan function properly.

18 Maintenance and repair work should be recorded in an operator’slogbook for all machinery. Frequency and nature of repairs can revealunsafe conditions.

19 When hot parts have to be handled, e.g. shrink fitting, special heat-resistant gloves shall be used and, if required, other body protection shallbe applied.

20 When using cartridge type breathing filter equipment, ascertain that thecorrect type of cartridge is used and that its useful service life is notsurpassed.

21 Make sure that oil, solvents and other substances likely to pollute theenvironment are properly disposed of.

22 Before clearing the unit for use after maintenance or overhaul, check thatoperating pressures, temperatures and speeds are correct and that thecontrol and shutdown devices function correctly.

1.6 TOOL APPLICATIONS SAFETY

Apply the proper tool for each job. With the knowledge of correct tool useand knowing the limitations of tools, along with some common sense, manyaccidents can be prevented.Special service tools are available for specific jobs and should be used whenrecommended. The use of these tools will save time and prevent damage toparts.

1.7 SPECIFIC SAFETY PRECAUTIONS

BatteriesWhen servicing batteries, always wear protecting clothing and glasses.1 The electrolyte in batteries is a sulphuric acid solution which is fatal if it

hits your eyes, and which can cause burns if it contacts your skin.Therefore, be careful when handling batteries, e.g. when checking thecharge condition.

2 Install a sign prohibiting fire, open flame and smoking at the post wherebatteries are being charged.

3 When batteries are being charged, an explosive gas mixture forms in thecells and might escape through the vent holes in the plugs. Thus anexplosive atmosphere may form around the battery if ventilation is poor,and can remain in and around the battery for several hours after it hasbeen charged. Therefore:- never smoke near batteries being, or having recently been, charged,- never break live circuits at battery terminals, because a spark usually

occurs.4 When connecting an auxiliary battery (AB) in parallel to the unit battery

(CB) with booster cables: connect the + pole of AB to the + pole of CB,then connect the - pole of CB to the mass of the unit. Disconnect in thereverse order.

7

OAH 2 - OAV 4

Pressure vesselsMaintenance/installation requirements:1 The vessel can be used as pressure vessel or as separator and is designed

to hold compressed air for the following application:- pressure vessel for compressor,- medium AIR/OIL,

and operates as detailed on the data plate of the vessel:- the maximum working pressure ps in bar (psi),- the maximum working temperature Tmax in °C (°F),- the minimum working temperature Tmin in °C (°F),- the capacity of the vessel V in l (US gal, Imp gal, cu.ft).

2 The pressure vessel is only to be used for the applications as specifiedabove and in accordance with the technical specifications. Safety reasonsprohibit any other applications.

3 National legislation requirements with respect to re-inspection must becomplied with.

4 No welding or heat treatment of any kind is permitted to those vesselwalls which are exposed to pressure.

5 The vessel is provided and may only be used with the required safetyequipment such as manometer, overpressure control devices, safetyvalve, etc.

6 Draining of condensate shall be performed daily when vessel is in use.7 Installation, design and connections should not be changed.8 Bolts of cover and flanges may not be used for extra fixation.Safety valvesPotential hazards exist with the operation and maintenance of safety valves.Hazards can include catastrophic failure of the protected pressurised systemresulting in death or serious injury or the emission of pressure medium, whichmay be noisy, hot, poisonous or aggressive. Inappropriate handling maypresent a risk of injury due to weight or sharp edges. Your attention is drawnto our joint responsibility to ensure that all statuory National regulationsconcerning Health and Safety including the Pressure Equipment Directive97/23/EC are not contravened by incorrect installation, commissioning orservicing. Refer also to ISO 4126 or contact Seetru if you require furtherinformation regarding the use of safety valves.Operating & MaintenanceOnly trained and technically competent personnel should consider overhaul,re-set or performance testing of safety valves.The safety valve is supplied with either a lead security seal or crimped coverto deter unauthorised access to the pressure regulation device.

Under no circumstances should the set pressure of the safety valve be alteredto a different pressure than that stamped on the valve without the permissionof the installation designer.If the set pressure must be altered then use only correct parts supplied bySeetru and in accordance with the instructions available for the valve type.Safety valves must be frequently tested and regularly maintained.The set pressure should be periodically checked for accuracy.When fitted, the lifting device should be operated at pressures not less than75% of the set pressure to ensure free and easy movement of internal parts.The frequency of tests is influenced by factors such as the severity of theoperating environment and aggressiveness of the pressurised medium.Soft seals and springs should be replaced as part of the maintenanceprocedure.Do not paint or coat the installed safety valve.

Valve OutletThe outlet of the discharge holes or pipe-work must not terminate in aposition where discharged gas will cause a hazard.Outlet pipe-work should be as short and straight as possible and not allow anaccumulated back pressure to build up from a discharging safety valve ofgreater than 10% of the set pressure.Superimposed back pressure must not be allowed.Outlet pipe-work should be supported to prevent mechanical loading of thesafety valve. A drain should be fitted to the lowest point of the outlet pipe-work, which must be kept dry and clean to prevent blockage.

Control of Substances Hazardous to Health (COSHH) DataA small quantity of synthetic rubber components may be present in the safetyvalve. Synthetic rubber represents a hazard to health when subject to elevatedtemperature (315°C) such as fire. It will show physical signs such as charringor black sticky deposits, toxic and or corrosive fumes will also be given off.Treat with extreme caution if it has been subject to fire. Allow to cool beforeinspection. Avoid contact. Inform fire fighters of the presence offluoroelastomer material. Compliance with Environmental Protection Act isessential when disposing of residue.Air supply respirators and acid resistant gloves must be worn if the above conditions apply.

Synthetic Component Material

Hyd

roge

nC

yani

de [

HC

N]

Cya

noge

n[C

2N

2]

Hyd

roch

loric

Aci

d [H

CL

Gas

]

Hyd

roch

loric

Aci

d [H

F]

Car

bon

Mon

oxid

e [C

O]

Div

ided

Sili

ca [

SiO

2]

Mon

omer

icA

cryl

lic

Residual Ash

Cor

rosi

ve

Non

Cor

rosi

ve

Nitrile X X X

Neoprene X X

Viton X X

Butyl X X

Silicon X X

Fluoro Silicon X X X

Other X X X X

8


2. LEADING PARTICULARS

2.1 DESCRIPTION OF SAFETY PICTOGRAMS USED IN THIS MANUAL

3. COMPRESSOR MODULEThe OEM is designed for direct installation on a floor or on a frame of sufficient strength.

If the underlying structure is not completely vibration free, mounting of rubber buffers underneath the OEM is recommended to prevent transmissions of vibrations to the compressor.

To ensure optimal conditions for heat dissipation and to provide sufficient accessibility for service purpose, a free area of 500 mm at both left and right sides of the module must be observed.

This symbol draws your attention to dangerous situations. The operation concerned may endanger persons and cause injuries.

This symbol is followed by supplementary information.

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OAH 2 - OAV 4

4. CONNECTION PIPES BETWEEN OEM AND CUSTOMER APPLICATION

All piping specified below must be provided by the installer. If flexible pipes are mounted, it is recommended to specify a bursting pressure not lower than 4 times the operating pressure of the OEM. Furthermore all materials used must comply with the expected extreme operating conditions and be suitable for the air/oil mixture circulating in the compressor system.

The required temperature range extends from the lowest expected ambient temperature to 120°C.

All connections should be as short as possible.

Fig. 1 OAH 2

a Air discharge flangeb Pressure gauge connectionc Drain elementd Drain vessele Drain oilcooler

OAV 4

a b c dc e d b a c e

10


4.1 DISCHARGE PIPE

The inside diameter must be at least equal to the OEM discharge connection. It is recommended to install a flexible element in the pipe e.g., a stainless steel bellow, to prevent static and/or dynamic loading resulting from operation and/or installation conditions. In order to prevent leakages, flange connections as shown in Fig. 1 are proposed. The groove dimensions are shown for a fluor rubber O-ring of inner diameter 57.2 x 3 mm. The dimensions of the groove may be adapted depending on the dimensions of the available O-rings and the dimensions of the air outlet flange of the OEM unit.

4.2 DRAIN CONNECTIONS

There are three drain plugs, all located at the left side of the unit (see Fig. 1):a. air receiver / oil separatorb. oil coolerc. oil stop valve.

5. REMOTE PANELThe remote panel must be provided by the installer.

The remote panel must incorporate following items:

- End pressure gauge with maximum pressure indication,- Main on-off switch,- Starter button to load the compressor,- Alarm lamp (or other warning device) to indicate a too high

underpressure in the compressor inlet system.The pressure gauge has to be connected to the connection panel by means of flexible pipe with a minimum inside diameter of 6 mm. The strength of the flexible pipe should be sufficient to withstand the operating conditions specified under 4.

The temperature-switch mounted on the OEM has to be incorporated in a safety shutdown system to stop the prime mover or to disengage the compressor drive whenever the compressor outlet temperature exceeds the allowed maximum.

11

OAH 2 - OAV 4

6. ELECTRICAL SYSTEM AND SHUT-DOWN SWITCHES (FIG. 2)The compressor module is as standard equipped with a 24 V negative earthed system, which comprises:

1. A temperature shut-down switch (TS1),

2. A loading solenoid valve (Y1),

3. A vacuum indicator switch ( PS3),

5. A fuse 10A (F1).

All connections are grouped on a connection plug (type DIN 43652), situated at the left side of the units.

The vacuum indicator switch (PS3) will be connected to an alarm lamp (horn) indicating when the air filter elements need servicing.

Fig. 2.a Typical customer installation for mechanically controlled diesel engine

The vessel, element and canopy are to be connected to GND.

Apart from the typical customer installation documented in the circuit diagram it is also possible to connect other compressor drive arrangements, like an electric motor, to the OEM.

12/24VDC

K10

S30

S20

D+

B-

B+

G30

W+

K10

S60

S50

Y10

H10

H20

S10

10

9

8

5

4

3

2

1

X1

7

6

K20

S70 K20

87

30

87a

H50

PS10P

TS10

LS10

H40

Engin

e Safe

ty Sw

itche

s

B4/C4B4/C4K20

-A2K10

Compressor Drive GNDConnect to

H30

S40

+

-G10

+

-G20

K0

M

M10

K0

12


Fig. 2.b Typical customer installation for mechanically controlled diesel engine

10

9

8

5

4

3

2

1

X1

7

6

PS3P

PS2P

Y1 A1

A2

K1

8730

87a

K3 86

85

K387

30

F1

10A

K1 86

85

TS1

+12/24 VDC

GND

24

2428

28 28

2828

28

33

33

34

34

35

19

19 19

193232

37

3737

36

29

3031

37

B8B8K1

-D10K3

GNDEGNDC

36

GNDV

X1:

PIN 1: POWER SUPPLYConnect 12 or 24 Vdc, as shown on the dataplate of the OEM.It must be possible to interrupt this power with a main power switch and an emergency stop.A 10A fuse protects the complete OEM installation.

PIN 2: POWER AFTER CONTACTThis pin can be used for customer purposes.When the main power switch is switched ON this pin is also powered.

PIN 3: AIRFILTER WARNINGWhen the airfilter needs servicing PS3 closes to put power on this pin.

PIN 4: ELEMENT TEMPERATURE SHUTDOWNWhen the compressor elements get too hot this pin is powered, the compressor drive must shut down (pin 5 is not powered when K1 deactivates).The element temperature is protected by TS1 and K1.

PIN 5: COMPESSOR DRIVE ENABLEWhen the compressor can start and run this pin is powered.It is not allowed to run the compressor when this pin is not powered!

PIN 6: NOLOAD SIGNALWhen the compressor needs to go to noload (keeps running without load) a pulse signal needs to be applied to this pin.This should be done with a normally closed (NC) pulse contact between pin 5 and pin 6.The power supply of K3 and Y1 is interrupted.

PIN 7: LOAD SIGNALWhen the compressor needs to load a pulse signal needs to be applied to this pin.This should be done with a normally open (NO) pulse contact between pin 5 and pin 7.

PIN 8: NOT CONNECTED

PIN 9: NOT CONNECTED

PIN 10: GNDThis pin needs to be connected to the compressor drive GND.

13

OAH 2 - OAV 4

7. COMPRESSOR DRIVEThe prime mover is normally directly flanged to the OEM. The prime mover power has to be transmitted to the OEM through a high-elastic coupling. The prime mover has to be supported in such a way that the bending moment at the compressor coupling housing does not exceed 1300 Nm. Power take-off drives are allowed to be installed, if the installation complies with the recommendations of the suppliers of the prime mover.

If a vehicle is used to drive the compressor, a safety interlock must be provided in the transmission to prevent compressor engagement when the vehicle is in motion.

E.g. when a V-belt drive is used, V-pulleys may not be mounted on the compressor drive shaft but must be properly supported by a bearing construction.

For any kind of drive no axial nor radial forces may be transmitted to the compressor drive shaft.

14


8. DIMENSIONAL DRAWINGS

8.1 OAH 2 WITH CANOPY

EdPo

si-

tion

Gew

ijzig

d va

nM

odifi

ed fr

omD

ate

Dat

umIn

gev.

/Goe

dg.

Intr.

/App

d.

12

34

56

78

9

A

10

B C D E F G

Pare

nt 3

D m

odel

Ed .

Vers

ion

3D

Dit document is onze eigendom en zal niet zonder toestemming worden gewijzigd,gekopieerd, gebruikt voor fabricatie of mededeling aan enig ander persoon of firma.This document is our property and shall not without our pur permission be altered,copied, used for manufacturing or communicated to any other person or company

03.0

0D

ecal

s ad

ded

+ N

ame

chan

ged

2007

-09-

1998

2210

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g ge

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g./Ap

pd.

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ndel

ing

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min

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eria

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k w

t .R

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k nr

.R

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icat

ie/D

esig

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n

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imh.k

lasse

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elijk

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pare

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ate

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indi

en n

iet a

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ijn v

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f not

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ASS

(Kg)

CEN

TER

OF

GR

AVIT

YXz

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258

746

844

550

0

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NT

VIEW

LEFT

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IEW

RIG

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R V

IEW

400

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UC

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SLO

TSFO

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NG

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050

416

0

Driv

e Sh

aft

228

403

AIR

DIS

CH

ARG

E

320

PRES

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AUG

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0

43

525

575

TEM

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212,5

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ON

DIT

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S&

SER

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SIBI

LITY

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AIR

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AIR

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LET

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HO

LES

130

664

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5 )

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15

OAH 2 - OAV 4

8.2 OAH 2 WITHOUT CANOPY

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Gew

ijzig

d va

nM

odifi

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omD

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umIn

gev.

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12

34

56

78

9

A

10

B C D E F G

Pare

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Vers

ion

3D


03.0

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k nr

.R

uw n

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ate

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TC

OO

LIN

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R IN

LET

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.

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E AC

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500

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H

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DIS

SIPA

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N.

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NN

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4" D

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4" D

RAI

N

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CO

OLE

R

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4" D

RAI

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ELEM

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8" P

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S.G

AUG

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NEC

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320

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0

Xz(C

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403

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CH

ARG

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6,5

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821

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155,5

212,5

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UN

TIN

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DIS

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ARG

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ANG

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R40

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41,2

5 82,5

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B

54,8-0,30+

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OU

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TR

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160

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1x)

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ww

w.a

tlasc

opco

.com

16


8.3 OAV 4 WITH CANOPY

UN

ITM

AS

S (k

g)Xz

(mm

)Y

z (m

m)

Zz (m

m)

OA

V 4

OE

M52

976

255

084

0

CE

NTE

R O

F G

RA

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EdPo

si-

tion

Gew

ijzig

d va

nM

odifi

ed fr

omD

ate

Dat

umIn

gev.

/Goe

dg.

Intr.

/App

d.

12

34

56

78

9

A

10

B C D E F G

Pare

nt 3

D m

odel

Ed .

Vers

ion

3D


02.0

0D

ecal

s ad

ded

+ N

ame

chan

ged

2007

-09-

1998

2210

5446

02.0

0Fi

ni w

t.Af

g ge

w.

Goed

g./Ap

pd.

Beha

ndel

ing

Bena

min

g

Trea

tmen

t

Mat

eria

lM

ater

iaal

Nam

e

Dra

wn

byG

etek

end

Des g

ez./c

hd.

Versi

on D

rwg

Scha

alSc

ale

Blan

k w

t.R

uw g

ew.

Prod

gez/c

hd.

Fam

ilieFa

mily

Blan

k nr

.R

uw n

r. KgId

entif

icat

ie/D

esig

natio

n

Bla

d/Sh

eet

1102

K /

Gehe

imh.k

lasse

INV

Verv

angt

Rep

lace

s

Verg

elijk

Com

pare

Dat

um/D

ate

Kg

Dra

win

g ow

ner

Eige

naar

/

Secre

cy C

lass

STAT

US

Tole

rant

ies,

indi

en n

iet a

ange

geve

n, z

ijn v

olge

ns:

Tole

ranc

es, i

f not

indi

cate

d, a

ccor

ding

to:

ATLA

S C

OPC

O S

TAN

DAR

D /K

lass

e/C

LASS

A1

NO

T AP

PLIC

ABLE

0101

2005

-06-

2398

2210

5446

1:10

00

2

DIM

ENS.

DR

WG

02.0

0

Prel

imin

ary

sdee

pak

AIP

OAV

4 O

EM

Lass

enW

eldi

ng

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B

Snijb

rand

enFl

ame

cutti

ng

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C

Plaa

twer

kSh

eet m

etal

1350

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. opp

./Gat

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ach.

surf.

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es

1350

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m

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NT

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HAN

D V

IEW

RIG

HT

HAN

D V

IEW

REA

R V

IEW

FREE

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PTIM

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N

CO

OLI

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AI

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UTL

ET

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1400


Xz (C

ENTE

R O

F G

RAV

ITY)

500

min

338,

546

1,5

385

122

82

324

350

Yz (C

ENTE

R O

F G

RAV

ITY)

610

450

1430

1364

MO

UN

TIN

G H

OLE

S

500

min

.50

0 m

in.

R40

4

160

660

160

1250

135

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ING

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IFT

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90

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VIEW

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NT

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A-A

2

2

2

2

2

22

2

33

2

2

ww

w.a

tlasc

opco

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17

OAH 2 - OAV 4

8.4 OAV 4 WITHOUT CANOPY

)gk( S

SA

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NU

Xz (m

m)

Yz

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(mm

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AV

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umIn

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dg.

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d.

13

24

56

79

8

A

10

B C D E F G

Pare

nt 3

D m

odel

Ed .

Vers

ion

3D


02.0

0D

ecal

add

ed +

Nam

e ch

ange

d09

/19/

2007

9822

1054

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.00

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gew

.

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ndel

ing

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min

g

Trea

tmen

t

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eria

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e

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on D

rwg

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alSc

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k w

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.R

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angt

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elijk

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pare

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lass

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iet a

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ranc

es, i

f not

indi

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ding

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ATLA

S C

OPC

O S

TAN

DAR

D /K

lass

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5447

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00

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DIM

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Prel

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ary

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ENS.

DR

WG

OAV

4 O

EM W

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ANO

PY

Lass

enW

eldi

ng

1356

K /

B

Snijb

rand

enFl

ame

cutti

ng

1355

K /

C

Plaa

twer

kSh

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etal

1350

:01K

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. opp

./Gat

enM

ach.

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es

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m

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NT

VIEW

RIG

HT

HAN

D V

IEW

LE

FT H

AND

VIE

W

REA

R V

IEW

CO

OLI

NG

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UTL

ET

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ALH

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N

CO

OLI

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LET

CO

OLI

NG

AI

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AR

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NS

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LET

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500

500

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82

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18


9. INSTALLATION REVIEWIn order to be in line with the Atlas Copco Airpower warranty procedures it is recommended to answer the attached Installation Review and mail it to the local AC organisation.

In all cases the installation needs to be approved of by the local sales company before first start up.

Especially if electrical prime movers are going to be installed, sufficient information about the type of prime mover, voltage and starting method need to be advised to the local sales company for every single installation during design phase, but at the latest before first start up.

Not following these instructions will result in loosing warranty.

Purpose of the document :

OEM-compressor is a part of the installation of the customer.For avoiding malfunctioning of the compressor, a correct installation is required.This document is required for having warranty on the compressor-part.

** : obligatory information

1. Identification

1.1. Atlas Copco Customer Center :

Name: **...............................................................

Contact person: ** ................................................ function: **...................................................

Tel: ................................................ Fax: .............................................

1.2. Customer :

Name: **...............................................................

Address: ** ...................................................................................................................................

...........................................................................................................................................

Contact person: ** ................................................ function: **...................................................

λ Δ⁄( )

INSTALLATION REVIEWOEM-compressor

To be filled-in by customer center, before ordering !!!

Customer: **………..

Model: **………..

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OAH 2 - OAV 4

2. OEM-compressor-version

2.1. OEM-Calculator

Model: ** .....................................................................................................................................

Engine drive speed : **................................................................................................

Required flow : ** .......................................................................................................

Required pressure : ** .................................................................................................

Please, add resulting file of OEM-calculator !!!!

Remark : on value of required power, resulting from OEM-calculator, add a tolerance of 4% for production

tolerances and fouling of the oil separator. Customer has to foresee sufficient power coming from drive

arrangement in all conditions.

2.2. Info on Prime mover

Driver type: Diesel engine / electric motor / other** ......................

Manufacturer: ** .................................................. Model: ** ......................................................

Rating: ** .......................... kW @ ** ................. rpm (full load rpm)

Rating type: Continuous / Intermittent / other

2.3. OEM-compressor version

Standard version (yes/no) : **..............................

Special version (description ) : ....................................................................................................

......................................................................................................................................................

......................................................................................................................................................

Approval received from Airpower ?? : ..........................................................................

20


3. Compressor installation - review

3.1. Vessel

- On ORH2 and ORV4, airreceiver is integrated.

- On ORV 10-12 and ORX 10-12, the airreceiver is not integrated (delivered separately).

Recommended is to mount the airreceiver on flexible pads (not included in scope) for limiting noise emission.

Due to different possible locations of the airreceiver, customer has to foresee piping. (design is customer responsibility !!!)

Piping in combination with vitaulic couplings, for flexibility, is strongly preferred. (hoses on 25 and 30 bar have a risk of rupture!!)

Installation proposals with pipes + vitaulic couplings are existing.

Installation of vessel :

Vibration pads under receiver (yes/no): ** ..................................................................

Flexible connections & piping (yes/no): ** .................................................................

Is vessel installed according above instructions (yes/ no) : ** ................................

3.2. External communication

Customer to design and install own external control panel.

Detailed Electrical diagrams are available.

On the cubicle of the OEM-compressor a 16 pin-connector is foreseen.

1. delivered signals (for warning lamps) : airfilter warning/element temperature shutdown

2. external input signal to cubicle for compressor control : load/no load

Is external control panel foreseen according above instructions (yes/ no) : ** .....................

Remark : because customer can choose different engine types, no possibility is foreseen for speed regulation of the engine.

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OAH 2 - OAV 4

3.3. V-belt / Coupling

A V-belt or a coupling is required to dampen the torsional vibrations of the engine.

Power transmission type: V-belt / coupling : ** .........................................................................

V-belt :

Our gearbox is designed to be directly flanged on a suitable diesel engine.

A V-belt drive is possible, when following requirements are met :

- drive pulley to be mounted on a separate shaft with bearings

- a cardan between driven pulley-haft and gearbox-shaft, limiting radial forces on gearbox-shaft

- no elastic coupling is required.

- a belt-tensioner is recommended

V-belt installed according above instructions (yes/ no) : ** ...................................................

- Flexible coupling:

Because of pulsations, coming from diesel engine, electrical motor, hydraulic motor, a high elastic coupling is required. A high elastic coupling, (with dedicated rubber parts), dampens the pulsations

A compressor + coupling + engine is a 2 mass-system with a critical frequency.

Customer has to contact coupling-supplier. Based on :

- moments of inertia of compressor (coming from OEM-calculator)

- moments of inertia of engine (mainly flywheel !!), coming from engine-supplier

- dynamic stiffness of the coupling (coupling supplier)

Sometimes the coupling-supplier makes a finer calculation, taking more detailed masses and stiffnesses into account.

Coupling-supplier has to approve the coupling for each installation. (oversized engine, etc.)

- Rule of thumb for a diesel-engine :

firing frequencies of driving engine > 1.4x torsional resonance frequency of kinematic system

- Rule of thumb for an electrical motor (50 Hz or 60 Hz) :

50 Hz or 60 Hz > 1.4x torsional resonance frequency of kinematic system

Coupling calculated according above instructions (yes/ no) : ** ...........................................

Please, add coupling calculation of supplier

22


3.4. Alignment

Following types for having a good alignment are common practice

- bolted connection with SAE-flanges

- a cardan-shaft

- a wavespring-based connection

Type of connection : **.................................................................................................................

Remark : none of these alignment-types eliminate the need of a V-belt/elastic coupling (see previous paragraph)

3.5. Cooling air flowBased on free cooling airflow, OEM-compressors are designed to work at an ambient of 50°C.

But, the maximum ambient can be reduced drastically, by :

- Heat coming from external heat sources

- Recirculation of the hot cooling air to the inlet of the compressor

- Restrictions in the cooling air flow

Customer has to foresee sufficient ducting for avoiding the above.

Sufficient ducting foreseen (yes/no) : ** ...................................................................................

If required, send a drawing of the build-up for comments.

Include :

- external heat sources (extra coolers, engines, etc) + direction of airflow (pushing/pulling fans)

- foreseen ducting

- restriction of cooling air (distance of panels to cooler air out)

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OAH 2 - OAV 4

Notes: ...................................................................................................................................................

...................................................................................................................................................

...................................................................................................................................................

...................................................................................................................................................

Approved by: .............................. Date: ........................... Signature: .........................................................

Requested extra documents :

1. calculation OEM-calculator

2. coupling calculation

3. cooling air flow

24


10. DISPOSAL

10.1 GENERAL

When developing products and services, Atlas Copco tries to understand, address, and minimize the negative environmental effects that the products and services may have, when being manufactured, distributed, and used, as well as at their disposal.

Recycling and disposal policy are part of the development of all Atlas Copco products. Atlas Copco company standards determine strict requirements.

Selecting materials the substantial recyclability, the disassembly possibilities and the separability of materials and assemblies are considered as well as the environmental perils and dangers to health during the recycling and disposal of the unavoidable rates of not recyclable materials.

Your Atlas Copco compressor consists for the most part of metallic materials, that can be remelted in steelworks and smelting works and that is therefore almost infinite recyclable. The plastic used is labelled; sorting and fractioning of the materials for recycling in the future is forseen.

Note:

10.2 DISPOSAL OF MATERIALS

Dispose contaminated substances and material separately, according to local applicable environmental legislations.

Before dismantling a machine at the end of its operating lifetime drain all fluids and dispose of according the applicable local disposal regulations.

Remove the batteries. Do not throw batteries into the fire (explosion risk) or into the residual waste. Separate the machine into metal, electronics, wiring, hoses, insulation and plastic parts.

Dispose all components according to the applicable disposal regulations.

Remove spilled fluid mechanically; pick up the rest with absorbing agent (for example sand, sawdust) and dispose it according the applicable local disposal regulations. Do not drain into the sewage system or surface water.

This concept can only succeed with your help. Support us by disposing professionally. By assuring a correct disposal of the product you help to prevent possible negative consequences for environment and health, that can occur with an inappropriate waste handling.

Recycling and re-usage of material helps to preserve natural resources.

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OAH 2 - OAV 4

11. MAINTENANCE LOG

Compressor.........................................................................................

Customer ............................................................................................

Serial number .....................................................................................

Service hours Maintenance action Date By initials

26


Notes:

27

OAH 2 - OAV 4

Notes:

28

3

Following documents are provided with this unit:

– Test Certificate– EC Declaration of Conformity:

Atlas Copco Airpower n.v. puorG ocpoC saltA eht nihtiw ynapmoc A

Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651 P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231 B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp

evitatneserper ocpoC saltA lacol ruoy tcatnoc esaelp ,ofni roF muigleB muigleBwww.atlascopco.com

p.1(3)

Form

5009

060

0 02

ed

. 05,

201

0-01

-01

1 DECLARATION OF INCORPORATION2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product 3 Machine name air compressor4 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

8 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

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. Pressure equipment 97/23/EC x

b. CE24/6002 ytefas yrenihcaM

EN ISO 12100-1 EN ISO 12100-2

EN 1012-1 EN 294 EN 349 EN 418 EN 563 EN 842 EN 953

EN 1037 EN 1050 EN 13478

c. Simple pressure vessel 87/404/EEC x

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

9

10

Atlas Copco Airpower n.v. is authorized to compile the technical file 11 The harmonized and the technical standards used are identified in the attachments hereafter

12 Conformity of the specification to the directives

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

directives13 gnirutcafunaM gnireenigne tcudorP yb deussI14 Name15 Signature

16 Date

0

Pri

nte

d in

Bel

giu

m 0

1/2

01

0 - 2

95

4 2

46

0 0

2

www.atlascopco.com

2954 2460 02_OAH 2-OAV 4_EN

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