Atlas Copco LE 3 Instruction Book
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Atlas Copco LE 3 Instruction Book

Industrial aluminium piston compressors
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Industrial aluminium piston compressors
LE 2, LE 3, LE 5, LE 7, LE 10, LE 15, LE 20
Instruction book

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  • Page 1 Atlas Copco Industrial aluminium piston compressors LE 2, LE 3, LE 5, LE 7, LE 10, LE 15, LE 20 Instruction book...
  • Page 3 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.

  • Page 4: Table Of Contents

    Instruction book Table of contents Table of contents ..........................2     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 ...
  • Page 5 Instruction book 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  Servicing and adjustment procedures ................. 59     6.1 ...

  • Page 6: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note 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.
  • Page 7 Instruction book Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits.

  • Page 8: Safety Precautions During Operation

    Instruction book 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.

  • Page 9: Safety Precautions During Maintenance Or Repair

    Instruction book 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.
  • Page 10 Instruction book Also consult the following safety precautions: Safety precautions during installation and Safety precautions during operation. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein.

  • Page 11: General Description

    Instruction book General description 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 2920 7089 80...
  • Page 12 Instruction book Power pack with unloading valve Base mounted 2920 7089 80...
  • Page 13 Instruction book Tank-mounted, LE 2 up to LE 3, horizontal receiver Tank-mounted, horizontal receiver 2920 7089 80...
  • Page 14 Instruction book Tank-mounted, Full-Feature unit, 475 l receiver LE Trolley Petrol/Electric Reference Description Air filter Air receiver Air outlet valve Check valve Condensate drain valve Oil drain plug Filler cap 2920 7089 80...
  • Page 15 Instruction book Reference Description Air pressure gauge Motor Air pressure switch Electric motor Petrol engine Hourmeter, running time Pulsation damper Pilot valve On/off switch On/off switch dryer Oil sight glass Safety valve Unloader Blow-off silencer Loading solenoid valve Reference Description Cover Air inlet silencer Crankcase...

  • Page 16: Options

    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).

  • Page 17: Air Flow

    Instruction book Motor anti-condensation Used with LE 2-20 with 400V/50Hz and heaters and thermistor 460V/60Hz protection CD adsorption dryer LE 2-3 on 90 and 250 receiver Heavy duty air inlet filter For PP-BM-TM-FF versions make contact (NO) Oil level switch break contact (NC) Receiver wheel set Wheelset for 90/250 receiver...
  • Page 18 Instruction book Air flow and regulating system with DOL starter 2920 7089 80...
  • Page 19 Instruction book Air flow and regulating system with Y/D starter 2920 7089 80...
  • Page 20 Instruction book Air flow and regulating system of trolley 2920 7089 80...
  • Page 21 Instruction book Full-Feature Air flow and regulating system, Full- Feature References on flow diagrams Reference Description Air filter Air receiver Air outlet valve AV1/AV2 Air outlet valves Check valve Condensate drain valve Oil filler cap Air pressure gauge Motor Air pressure switch Pulsation damper On/off switch 2920 7089 80...

  • Page 22: Regulating System

    Instruction book Reference Description Pilot valve Safety valve Unloader Unloading valve Blow-off silencer Loading solenoid valve Oil drain plug Oil level sight-glass Reference Description Air inlet silencer Left cylinder Right cylinder Cooler Cooling pipe Pressure release valve Electrical cubicle Plunger Spring Pressure regulator Refrigerant dryer...
  • Page 23 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).

  • Page 24: Installation

    Instruction book Installation Dimension drawings Dimension drawings LE/LF/LT 2-3:WITHOUT VIBRATION DAMPER LE/LF/LT 5 :WITH VIBRATION DAMPER Compressor Air Inlet VIEW F For Dismantling Air filter M8(4x) 8 p9 Cooling Air Inlet VIEW F Ø Compressed Air outlet G1/2" For dismantling Air filter Compressed Air outlet G1/2"...
  • Page 25 Instruction book LE/LT/LF 7-10 For Dismantling Air inlet Compressor Air Inlet VIEW E 10 p9 M8(4x) VIEW E Cooling Air Inlet Ø 49,5 Compressor Air Outlet G1/2" VIEW H Cooling Air inlet VIEW H Compressor Air Outlet G 1/2" Net Mass Net Mass Power Type Block (Kg)
  • Page 26 Instruction book AIR INLET FOR DISMANTLING AIR FILTER Z ( 1:2 ) 14pg 45 k5 COOLING AIR INLET VIEW Y VIEW Y 14(4x) COMPRESSED AIR OUTLET G1/2" COOLING AIR VIEW X VIEW X COMPRESSED AIR OUTLET G1/2" TYPE FRAME SIZE NET MASS BLOCK NET MASS POWERPACK 9820 2239 07/02...
  • Page 27 Instruction book BM LE/LT/LF 2-3-5 DOL Compressor air Inlet For dismantling Air filter Cooling Air outlet Compressor Motor Cooling Air inlet Cooling Air inlet Compressed Air oulet G 1/2" Type Net Mass (Kg) LE/LF 2 LE/LF 3 LE/LF 5 LT 2 9820 2239 42/06 LT 3 81452D...
  • Page 28 Instruction book For dismantling BM LE/LT/LF 7-10 YD Air filter Compressor Air inlet Cooling Air outlet Motor cooling Compressor cooling Air inlet Air inlet Compressed Air outlet G1/2" Type Net mass (Kg) 9820 2239 43/05 LE/LT/LF 7 81453D LE/LT/LF 10 LE 10 (60 Hz) LE 7 up to LE 10, Base-mounted 2920 7089 80...
  • Page 29 Instruction book MIN. 280 COOLING AIR COOLING AIR OUTLET OUTLET COMPRESSOR AIR+ MOTOR COOLING COOLING AIR INLET AIR INLET TYPE SIZE NET MASS 10 (50 Hz) 1180 1395 42.5 191.5 296.5 123.5 10 (50 Hz) 1180 1395 42.5 191.5 296.5 123.5 10 (50 Hz) 1180...
  • Page 30 Cooling air inlet Compressed air outlet G 1/2" Slot Hole 15x25 (4x) Manual drain G 1/4" Type Receiver (L) Netmass (Kg) A LE/LF 9820 2239 21/07 81455D 533 279 LE 2 up to LE 3, Tank-mounted, receiver 90 l 2920 7089 80...
  • Page 31 Instruction book For Dismantling Air filter Compressor Air inlet Cooling Air outlet Cooling Air inlet Compressed Air Outlet G1/2" Manual drain G 1/4" Ø Type Receiver (L) Net Mas s(kg) 9820 2239 23/05 LE/LF 504 252 687 343 81456D 533 279 687 343 LE 2 up to LE 5, Tank-mounted, receiver 250 l 2920 7089 80...
  • Page 32 Instruction book LE/LT/LF 5 OPTIONAL LARGER VESSEL ON LE/LT/LF 2-3-5 For dismantling air filter Compressor air inlet Cooling air Outlet Cooling air Inlet Ø J Compressed Air outlet G 1/2" Manual drain G 1/4" Dmax T y p e R e c e i v e r ( L ) N e t M a s s ( K g ) 1 4 7 5 0 4...
  • Page 33 Instruction book LE/LT/LF 7-10 FOR DISMANTLING AIR FILTER COMPRESSOR AIR INLET COMPRESSOR AIR INLET COOLING AIR OUTLET COMPRESSOR MOTOR COOLING COOLING AIR INLET AIR INLET Ø L COMPRESSED AIR OUTLET G 1/2" SLOT HOLE MANUAL DRAIN 15x25 (4x) OUTLET G 1/4" F max.
  • Page 34 Instruction book LE/LT 15-20 For Dismantling Air Filter Air Inlet Cooling air Electrical cable entry Inlet (pg 21on rear side) Compressed Air Outlet G1/2" ØM SLOT HOLE 15x25(4x) Manual drain Gmax G 1/4" Type Receiver(L) Net Mass(Kg) 1793 310 336 382 554 450 1250 1062.5 1867 395 476 530 729 600 1425 1793 310 336 382 554 450 1250...
  • Page 35 Instruction book 1390 For dismantling air filter Compressor Air inlet Cooling air outlet Dryed compressed air outlet G 1/2" Cooling air inlet 352 5 Compressed air outlet G 1/2" 402 5 1782 Manual drain outlet G 1/4" Dryer cooling air outlet Dryer cooling air inlet Type Net Mass...
  • Page 36 Instruction book 1398 For dismantling air filter Compressor Air inlet Cooling air outlet Cooling air inlet Dryed compressed air outlet G 1/2" Compressed air outlet G 1/2" 476 5 Manual drain outlet G 1/4" 1888 Dryer cooling air outlet Dryer cooling air inlet Type Net Mass 225 kg...
  • Page 37 Instruction book 191,5 COOLING COOLING AIR OUTLET AIR OUTLET COOLING AIR INLET COMPRESSED AIR OUTLET G1/2" ØK SLOT HOLE 15x25 (4x) Manual drain outlet G1/4" Emax Net Mass Type Receiver (Kg) LF/LE 1161 1694 1852 LF/LE 1340 1872 1926 1025 1161 1694 1852...
  • Page 38 Instruction book 9820 2239 26/09 81461D LE 7 up to LE 10, Tank-mounted with silencing hood 2920 7089 80...
  • Page 39 Instruction book 40 (For dismantling air filter) Inlet 311,5 1131 Compressed 1569 air outlet RECEIVER NET MASS TYPE (lit.) (Kg) LE/LT/LF 2 x 10 ltr. LE/LT/LF 2 x 10 ltr. LE/LT 2 x 10 ltr. 1024 9820 2239 71/07 81462D LE Trolley with electrical motor 2920 7089 80...
  • Page 40 Instruction book 9820 2239 91/05 81463D LE Trolley with petrol engine References of figures on dimension drawings. Reference Description Air inlet Hole, 15 x 25 (4X) Cooling air inlet Net mass Compressed air outlet, G1/2 2920 7089 80...

  • Page 41: Installation Instruction

    Instruction book Reference Description Manual condensate drain Hole, 15 x 25 (3X) Receiver Cooling air inlet Motor cooling air inlet Compressed air outlet Compressor cooling air and air inlet For dismantling air filter Compressor air outlet with flexible (2 meters) Electric cable entry (on rear side) Air outlet Installation instruction...
  • Page 42 Instruction book Installation proposal for tank-mounted unit (250/475 l receiver) 2920 7089 80...
  • Page 43 Instruction book Installation proposal for tank-mounted unit (vertical 250 l receiver) 2920 7089 80...
  • Page 44 Instruction book Installation proposal for base-mounted unit with optional silencing hood 2920 7089 80...
  • Page 45 Instruction book Installation proposal for tank mounted compressors with silencing hood References of figures on installation drawings. Reference Description Cooling air outlet Compressor air and cooling air inlet Install the compressor horizontally, in a cool but frost-free and well-ventilated room. Place the compressor as level as possible;...

  • Page 46: Electrical Connections

    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. Electrical connections Warning The electrical connection must be carried out by an electrician and corresponds to the local...
  • Page 47 Instruction book Electric cabinet Example of an electrical cubicle Reference Description Fuse 2920 7089 80...

  • Page 48: Settings Of Overload Relay And Fuses

    Instruction book Reference Description Overload relay Line contactor with integrated Y-D timer Star contactor Delta contactor Hourmeter, running hours Terminal board On/off switch Electrical diagram with direct-on-line starter Settings of overload relay and fuses Settings of overload relay - fuses of compressors with DOL starter 50 Hz Type Voltage...
  • Page 49 Instruction book Type Voltage Overload relay Fuses LE 3 230 MONO LE 3 LE 3 LE 3 LE 3 LE 3 LE 3 LE 3 1000 LE 5 LE 5 LE 5 LE 5 1000 LE 7 LE 7 LE 7...
  • Page 50 Instruction book Type voltage overload relay fuses 230 MONO LE10 LE10 LE10 LE10 LE15 LE15 LE15 LE20 LE20 LE20 Settings of overload relay and fuses of compressors with Y-D starter 50 Hz Type voltage overload relay fuses 10.5 2920 7089 80...
  • Page 51 Instruction book Type voltage overload relay fuses 1000 LE10 LE10 10.5 LE10 LE10 LE10 LE10 LE10 LE10 1000 LE15 LE15 LE15 LE15 LE20 LE20 LE20 LE20 60 Hz Type voltage overload relay fuses 10.5 LE10 LE10 10.5 LE10 LE10 2920 7089 80...
  • Page 52 Instruction book Type voltage overload relay fuses LE15 LE15 LE15 LE20 LE20 LE20 2920 7089 80...

  • Page 53: Cable Sizes

    Instruction book Cable sizes Starter Cable size mm² LE 2 and LE 3 LE 5 and LE 7 LE 10 LE 5 LE 7 LE 10 and LE 15 LE 20 Pictographs Reference Description Temperature Pressure Warning: voltage Switch off voltage and depressurize before maintenance or repair...

  • Page 54: Operating Instructions

    Instruction book Operating instructions 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.
  • Page 55 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.

  • Page 56: Stopping

    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.

  • Page 57: Storage After Installation

     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. 2920 7089 80...

  • Page 58: Maintenance

    Instruction book Maintenance Petrol engine maintenance Consult the engine "Owner's manual". 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.

  • Page 59: Lubrication Of Compressors

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

  • Page 60: Disposal Of Used Material

    Instruction book Reference Description Valve kit Filter kit Check valve Unloader 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.

  • Page 61: Servicing And Adjustment Procedures

    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).
  • Page 62 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 9 13 1 Reference Description Suction disc Seat O-ring Delivery disc Valve guard Spring Head Bolt Washer Stud...

  • Page 63: Air Filter

    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.
  • Page 64 Instruction book Name Air pressure switch Solenoid valve Pressure release valve Adjusting screw, stopping pressure 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).

  • Page 65: Adjustment Of Mdr3 Pressure Switch

    Instruction book Example:  Stopping pressure: 7 bar(e)  Starting pressure: adjustable between 3 and 5.7 bar(e) 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 Dial, overload relay...

  • Page 66: Adjustment Of Pilot Valve On Trolley

    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) Name Starting pressure - bar(e) Stopping pressure - bar(e) 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.

  • Page 67: Safety Valve

    Instruction book Reference Description Control air to unloader Vent hole Unloading handle Pressure adjusting screw Nuts 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.
  • Page 68 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.

  • Page 69: Problem Solving

    Instruction book Problem solving Condition Fault Remedy Insufficient air pressure Air leak Check and correct as necessary Air filter choked Replace filter Air pressure switch incorrectly Adjust switch Air consumption exceeds Check equipment connected maximum output of compressor Damaged valve Inspect valves and replace parts where necessary Unloader malfunctioning...
  • Page 70 Blow-off silencer choked Replace Ambient temperature too high Improve ventilation of room Motor stops and starts too See "Too frequent starting/too frequently short operating periods" Overcurrent due to motor or Consult Atlas Copco compressor failure 2920 7089 80...

  • Page 71: Technical Data

    See below Only applicable for Full Feature variants. (with refrigerant dryer) Minimum ambient air temperature °C Compressor data 50 Hz (10 bar) Compressor type LE 2 LE 3 LE 5 LE 7 LE 10 LE 15 LE 20 Maximum working bar(e)
  • Page 72 Instruction book Compressor type LE 2 LE 3 LE 5 LE 7 LE 10 LE 15 LE 20 - Tank-mounted dB(A) - Tank-mounted with dB(A) hood - Base-mounted with dB(A) hood 60 Hz (10 bar) Compressor type LE 2 LE 3...

  • Page 73: Instructions For Use

    Instruction book Instructions for use Air receiver (tank-mounted units) 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.

  • Page 74: Pressure Equipment Directive (Ped)

    Instruction book 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.

  • Page 75: Declaration Of Conformity

    Instruction book Declaration of conformity EC DECLARATION OF CONFORMITY We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product Machine name Machine type 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.
  • Page 76 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.
  • Page 77 Instruction book EC DECLARATION OF CONFORMITY We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product Machine name Machine type 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.
  • Page 78 Instruction book 2920 7089 80...
  • Page 80 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.

This manual is also suitable for:

Le 2Le 5Le 7Le 10Le 15Le 20

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