Operator Manual

AF COMPRESSORS
Operator Manual
Type: CE 46 B
Serial #: 20FH2203
AF COMPRESSORS
Introduction
Ateliers François low and medium pressure oil free air compressors are designed for PET stretch
blow moulded bottle applications and similar duties.
This manual is designed to assist you in the correct installation of your machine and its
ancillaries in order that the equipment operates satisfactorily for its intended purpose.
Whenever you contact Ateliers François, please indicate the compressor model and
manufacturer’s serial number.
Ateliers François reserves the right to make modifications and apply new developments. For this
reason, it is possible that the drawings shown in this manual do not correspond entirely with the
equipment in your possession. The technical specifications are not restrictive and may not lead
to any claim. Ateliers François reserves all rights over this manual as well as over the drawings
and documents that it contains.
www.afcompressors.com
2-78 MOP 20FH2203

AF COMPRESSORS
Evolutions
Revision
Date Affected § Change designation
Number
2016-02 Source MOP-EN-C-AB-REV00.1

00 2016-12-19 Creation
MOP 20FH2203 3-78

AF COMPRESSORS
List of abbreviations & vocabulary frequently used
AFC Ateliers François Compressors

AFC P Ateliers François Compressors Production
AFS Adjustable Flow System
CE Compresseur Equerre (L-Compressor)
EMC ElectroMagnetic Compatibility
MC MonoCylinder
MIN (Manuel d'INstallation) - Installation Manual
MOP (Manuel OPérateur) - Operator Manual
OPC Oil-free Piston Compressor
PET PolyEthylen Terephthalate

PICKList Installation and control procedure
PLC Programmable Logic Controller
PPM Parts Per Million
PTFE PolyTetraFluoroEthylene
RPM Round Per Minute
SERMI SERvice Maintenance Instruction
UMI User Maintenance Instruction
4-78 MOP 20FH2203

AF COMPRESSORS
DANGER - SAFETY ADVICES - TO BE READ
WARNING:
This chapter must be read and fully understood prior to undertaking any handling,
installation, service, maintenance and repair operation. All advices shall be fully
complied with.
Rules and Regulations

When carrying out work on the equipment, one shall always observe:
 all accident prevention and safety rules and regulations in force,
 recognised good practice and engineering good practice,
 the rules and regulations of the country of use and the appropriate professional bodies and associations
within that country.
Failure to observe the safety rules and regulations

Failure to fully observe all applicable rules and regulations may place staff at risk of injury.
In addition, damage may be caused to the equipment. Some of the hazards involved with installation, handling
and operation of the equipment, but not limited solely to these, are:
 high electric voltage hazard,
 high pressurised air,
 hot surfaces,
 contact with moving equipment,
 hazards involved in the transportation, handling, commissioning, maintenance, repair and disposal of the
equipment or its constituent components,
 hazard through contact with hazardous, chemical or bacteriological substances.
Pictograms and warning signs

Staff shall conform with all the advice and instructions shown on the equipment and in particular:
 shall comply with the arrows indicating the direction of movement of rotating equipment,
 shall comply with all the prohibitive and warning labels,
 shall wear the appropriate personal protection equipment at all times.
All the Pictogram and warning signs shall be kept in a clean and legible state.
An index of the pictograms and warning signs employed in the instructions for handling, installation,
commissioning, operation and disposal is shown at the end of the manual -> 6.2.
These shall be studied and fully understood.
MOP 20FH2203 5-78

AF COMPRESSORS
Electrical installation rules

All country, state and local authority rules regarding electrical installation shall be observed when connecting the
equipment to the electrical supply.
All work on the electrical equipment shall only be carried out by electricians or qualified staff with the appropriate
qualifications and experience. They shall comply with the instructions shown on the electrical components and
in particular the directions of rotation, the warning and hazard labels. These labels shall be maintained in a good
and clean legible condition.
The term qualified staff has the meaning staff who, thanks to their professional training, their experience and the
instructions received have sufficient knowledge of the safety rules and regulations, the accident prevention rules
and the use and method of operation of the equipment on which they are required to work. They must be
capable of assessing the work which is asked of them, of recognising hazards and reducing all possible risks
associated with these hazards to an acceptable level. In addition, they shall have been authorised by a
responsible person, such as the safety officer in charge of their area, to carry out the required work.
The equipment provided is only suitable for use on a low voltage electrical supply in a safe area. The equipment
is not suitable for installation or use in a potentially explosive area as defined by Article 2 of Directive 99/92/EC
(otherwise known as the ATEX directive) and shall not be installed and operated in this manner.
No liability will be accepted by Ateliers François or its subsidiaries in the event of installation and use different to
that for which the equipment was supplied.
Precautions to be taken with machinery and compressed air

Only qualified staff may work on the various components of the installation including in particular, but not only,
the compressor, the dryer, the filters, the cooling system and connecting pipes and the air and water circuits.
With the exception of the surveillance tasks in the checklist that do not require the equipment to be stopped no
work shall be undertaken on the equipment when it is operating or pressurised.
All the safety steps detailed in the MOP and MIN manual shall be performed as indicated before commencing
any work on the equipment.
Contact with various liquids and fluids

Many of the liquids contained in the equipment may be at relatively high temperatures (> 80°C) and some may
contain substances that cause toxic and/or allergic reactions if not handled safely.
Only qualified staff may service or work upon the equipment containing these liquids. They shall take all
necessary precautions.
The compressed air dryer contains a refrigerant gas which may be in a liquid or vapour state. Servicing this type
of equipment requires qualified staff who has received specific training in handling of refrigerants. Refrigerants
are subject to particular regulations concerning their use and disposal that shall be observed by the qualified
staff.
6-78 MOP 20FH2203

AF COMPRESSORS
MOP 20FH2203 7-78

AF COMPRESSORS
LEFT BLANK INTENTIONALLY
8-78 MOP 20FH2203

AF COMPRESSORS
Table of contents
Evolutions .............................................................................................................................................................. 3
List of abbreviations & vocabulary frequently used .......................................................................................... 4
DANGER - SAFETY ADVICES - TO BE READ .................................................................................. 5

Rules and Regulations ....................................................................................................................................... 5
Failure to observe the safety rules and regulations ........................................................................................... 5
Pictograms and warning signs ........................................................................................................................... 5
Electrical installation rules .................................................................................................................................. 6
Precautions to be taken with machinery and compressed air ............................................................................ 6
Contact with various liquids and fluids ............................................................................................................... 6
1 Synthesis..................................................................................................................................... 11
1.1 PURPOSE OF THE MANUAL.............................................................................................................................. 11
1.2 USING THE MANUAL ....................................................................................................................................... 11
1.3 APPLICABLE DOCUMENTS ............................................................................................................................... 11
2 Description of the equipment .................................................................................................... 13

2.1 PRESENTATION.............................................................................................................................................. 13
2.2 CE 46 B - CHARACTERISTICS ......................................................................................................................... 14
2.2.1 Compressor dimensions ...................................................................................................................................14
2.2.2 Compressor performance .................................................................................................................................14
2.2.3 Electrical Requirements ....................................................................................................................................14
2.2.4 Water & Air Requirements ...............................................................................................................................14
2.3 DESCRIPTION OF THE COMPRESSOR ............................................................................................................... 15
2.3.1 First stage of compression ................................................................................................................................15
2.3.2 Second stage .....................................................................................................................................................16
2.3.3 Third stage ........................................................................................................................................................17
2.3.4 Final air recovery circuit ...................................................................................................................................18
2.3.5 Other compressor components and ancillary equipments ..............................................................................19
2.3.6 Oil circuit...........................................................................................................................................................20
2.4 ABOUT THE SAFETY DEVICES ......................................................................................................................... 21
2.5 CONNECTIONS............................................................................................................................................... 21
2.5.1 Electrical connections .......................................................................................................................................21
2.5.2 Pneumatic connections ....................................................................................................................................21
3 Principles of operation ............................................................................................................... 23

3.1 OPERATING PRESENTATION............................................................................................................................ 23
3.2 OPERATING CONDITIONS ................................................................................................................................ 24
4 Optional equipment presentation .............................................................................................. 25

4.1 ELECTRICAL CABINET ..................................................................................................................................... 25
4.2 SOFT STARTER.............................................................................................................................................. 25
4.3 AIR DRYER .................................................................................................................................................... 25
4.4 COOLING SYSTEM ......................................................................................................................................... 25
5 Operator Instructions ................................................................................................................. 27

5.1 BEFORE STARTING THE COMPRESSOR ............................................................................................................ 27
MOP 20FH2203 9-78
AF COMPRESSORS
5.2 STARTING THE COMPRESSOR..........................................................................................................................27

5.3 STOPPING THE COMPRESSOR .........................................................................................................................27
6 Maintenance Means and Instruction .......................................................................................... 29

6.1 W HAT ARE UMI AND HOW TO USE THEM ..........................................................................................................29
6.1.1 Guidelines ......................................................................................................................................................... 29
6.1.2 Reports ............................................................................................................................................................. 29
6.1.3 Tasks ................................................................................................................................................................. 29
6.1.4 Basic level UMI presentation ............................................................................................................................ 31
6.1.5 Advanced level UMI presentation .................................................................................................................... 31
6.2 SAFETY PICTOGRAMS LIST ..............................................................................................................................32
6.3 CONSUMABLES ..............................................................................................................................................36
6.3.1 Oil ..................................................................................................................................................................... 36
6.3.2 Antifreeze ......................................................................................................................................................... 36
6.4 SPARE PARTS ................................................................................................................................................36
6.5 UMI FORMS LIST ............................................................................................................................................37
6.5.1 Multiple User Maintenance Instruction ........................................................................................................... 37
6.5.2 Safety Lock & Unlock Procedure Instruction .................................................................................................... 37
6.5.3 Simple User Maintenance Instruction .............................................................................................................. 37
6.6 DETAILED UMI FORMS....................................................................................................................................38
10-78 MOP 20FH2203

AF COMPRESSORS
1 Synthesis
1.1 Purpose of the manual

This manual is designed to assist you in the correct operation of the Ateliers François compressor CE 46 B in
order that the equipment operates satisfactorily for its intended purpose.
In addition, the manual gives information about the ancillary equipment included within the scope of supply.
1.2 Using the manual

The Operator Manual is designed for a quick location of the relevant information. To this end, the manual is
divided into 6 chapters, each of them covering a specific topic.
A potential dangerous hazard, which will put the operator at risk of injury or death, is signalled by the following
pictogram.
WARNING:
An instruction which identifies the possibility that the compressor and its ancillary equipment can be damaged is
signalled by the following pictogram.
CAUTION:
Supplementary information for the appropriate use and operation of the compressor is given using Note.
1.3 Applicable documents
Ref. Document Reference
A1
A2
A3
MOP 20FH2203 11-78

AF COMPRESSORS
12-78 MOP 20FH2203

AF COMPRESSORS
2 Description of the equipment
2.1 Presentation
The compressor CE 46 B is a volumetric machine with 3 compression stages.
The following figure shows the 3 compression stages and their compression cylinder.
1st stage
3rd stage
2nd stage
Each cylinder has an equal number of self-acting suction and outlet valves.
The compressor is equipped with inlet filter-silencer to reduce noise emission and to protect internal parts of the
compressor. The machine is installed on anti-vibration mounts (see the compressor installation drawing layout).
MOP 20FH2203 13-78

AF COMPRESSORS
2.2 CE 46 B - Characteristics
2.2.1 Compressor dimensions
Length 4800 mm
Width 2130 mm
Height 2850 mm
Weight 8550 kg
2.2.2 Compressor performance

Working pressure 40 bar g
Capacity (ISO1217) at 20°C, 0 m asl Humidity 70% RH 1320 m3/h
Compressor Speed 500 rpm
2.2.3 Electrical Requirements

Motor Power 250 kW
Power Supply Voltage See the Electrical diagram
min: - 5 % -- max: + 10 %
Circuit breaker size 630 A
2.2.4 Water & Air Requirements

Cooling water pressure 3 - 4 bar g
Total cooling water flow required 18.1 m3/h
Water volume (compressor) 270 l
Water drain connections 3/4"
Air outlet (40 Bar) 2" - 300 Lbs
Cooling Water in & out 6/4"
Cooling water pipe between Skid & Cooler: for max +/- 25m distance 2"1/2
14-78 MOP 20FH2203

AF COMPRESSORS
2.3 Description of the compressor

2.3.1 First stage of compression
The following figure shows the flow diagram of the first stage of compression main components.
1 Inlet air filter casing and filter cartridge

2 Suction Valve, valve cover, unloading system
3 Discharge Valve and valve cover
4 1st stage air cooler & tube bundle
5 1st stage safety valve
6 1st stage separator
7 1st stage air discharge flange
8 1st stage cylinder and piston (double action)
MOP 20FH2203 15-78

AF COMPRESSORS
2.3.2 Second stage

The following figure shows the flow diagram of the second stage of compression main components.
9 2nd stage cylinder and piston (simple action)

11 2nd stage air inlet flange
12 2nd stage separator
13 2nd stage safety valve
14 2nd stage air discharge flange
15 2nd stage air cooler & tube bundle
16-78 MOP 20FH2203

AF COMPRESSORS
2.3.3 Third stage

The following figure shows the flow diagram of the third stage of compression main components.
17 3rd stage cylinder and piston (simple action)

18 3rd stage air inlet flange
19 Safety valve
20 3rd stage final air cooler & tube bundle
21 Water safety valve
22 Pulsation dampener
MOP 20FH2203 17-78

AF COMPRESSORS
2.3.4 Final air recovery circuit

The following figure shows the flow diagram of the air recovering main equipment for the final user.
25 40 bar Air receiver and safety valve

26 40 bar flexible
27 Air outlet for the final user
28 Dryer and filters
18-78 MOP 20FH2203

AF COMPRESSORS
2.3.5 Other compressor components and ancillary equipments

The following figure shows the flow diagram of the main other components of the compressor and ancillary
equipments.
Other compressor components
30 Motor and pulley

31 Grooved flywheel
32 Distance pieces Horizontal & Vertical
33 Anti-vibration pads
34 Oil pump
Ancillary equipments
28 Dryer and filters

29 Electrical cabinet
MOP 20FH2203 19-78

AF COMPRESSORS
2.3.6 Oil circuit

The following figures show flow diagrams for the oil circuitry main components.
Outside the crankcase
34 Oil pump
35 Oil thermostatic valve
36 Oil level box
37 Oil radiator
38 Oil pressure sensor
39 Oil filter
Inside the crankcase
40 Oil deflector
41 Piston rod
42 Crosshead
43 Crosshead guide
44 Connecting rods
45 Oil pump
46 Crankcase
47 Crankshaft
48 Grooved flywheel
49 Oil scraper
20-78 MOP 20FH2203

AF COMPRESSORS
2.4 About the Safety Devices

All the operational safety devices are set in the factory. During the commissioning, the alarms settings are
adjusted to local conditions by the authorised persons.
The safety valves are calibrated in the factory by their manufacturer.
WARNING:
Any ill-advised modification of the instructions regarding the safety devices or
interference with the safety valves may lead to injury to the staff, and/or to damage
the installation.
On no account shall security devices be bypassed or neutralised.
2.5 Connections
2.5.1 Electrical connections
The electrical connections shall comply with the wiring diagram of the control console.
Electromagnetic compatibility is provided for an industrial environment. For a residential environment, it may be
necessary to take measures to prevent interference; appropriate protection equipment must then be installed in
order to comply with local regulations.
2.5.2 Pneumatic connections

The cross-section of the compressed air distribution pipes is suited to the flow rate of the compressor.
The outlet flexible hose must be attached in accordance with the installation drawing. The flexible hose shall not
be misaligned to create either tension or compression loads. Mechanical protection to limit the risk due to
accidental hose rupture is provided around the flexible hose connection. This protection shall not be removed.
For all standard installations, this protection is supplied with the machine.
MOP 20FH2203 21-78

AF COMPRESSORS
22-78 MOP 20FH2203

AF COMPRESSORS
3 Principles of operation
3.1 Operating presentation

Oil-free compression in several stages ensures to obtain different levels of pressure whilst keeping the air at a
satisfactory temperature. Each stage increases the pressure and the temperature of the air. After each stage, a
shell-tube heat exchanger cools the air. This cooling effect produces condensation of water which is extracted
from the main flow into water-air separators throughout drain system.
The entire machine - including cylinders and intercoolers - is cooled by an independent water circuit.
A regulation system maintains the compressor delivery pressure between two adjustable values. The system is
based on pneumatic unloaders which give the possibility to maintain suction valves open. By acting on these
unloaders, compression process could be hold on, and the delivered flow could be adjusted to the requested
one. Variable speed is also available on some models as an option.
Generally, a compressed air dryer is positioned at the outlet of the compressor. The principle of the dryer
consists of lowering the temperature to a defined level by refrigeration, removing the condensed water and then
reheating the air at the exit of the dryer.
Some installations have equipment for cooling the compressor cooling water. In these cases, this manual
provides the information required for the proper installation and operation of this equipment.
The quality of the inspired air shall comply with the conditions required for blowing into the food or beverage
containers.
Atmospheric pressure
Air flow
m3/h
3
stages
MOP 20FH2203 23-78

AF COMPRESSORS
3.2 Operating conditions

The following instructions must be observed.
 Efficient ventilation, either natural or forced.
 The air inspired by the machine should be as cool as possible.
But if the temperature of the machinery space is below 10°C (50°F), heating of the area shall be provided. In
no event may the temperature of the location be below 5°C (41°F).
 The compressor cooling water shall never fall below 2°C (36°F).
If temperatures lower than 2°C are expected to arise, then a bypass system shall be installed to maintain the
cooling water temperature supplied to the compressor and dryer above 2°C.
WARNING:
Do not store hazardous, flammable or volatile products in the machine room. Do not
store other objects in the machinery space that reduce or impede access to the
installed equipment.
24-78 MOP 20FH2203

AF COMPRESSORS
4 Optional equipment presentation
4.1 Electrical cabinet

The electrical cabinet provides power supply, control and regulation for the compressor and its ancillaries.
4.2 Soft Starter

The soft-starter equipment ensures a progressive start of the compressor motor in order to prevent the plant
from suffering from energy consumption peaks.
4.3 Air Dryer

This ancillary equipment filters and dries up the compressed air.
WARNING:
The Air Dryer equipment shall always remain in vertical position.
4.4 Cooling System

This ancillary equipment allows maintaining the compressor cooling water at normal operating temperatures.
MOP 20FH2203 25-78

AF COMPRESSORS
26-78 MOP 20FH2203

AF COMPRESSORS
5 Operator Instructions
The compressor may be started and operated only by an operator or personnel who have received the required
training.
All the results from inspection, checking or corrective action shall be recorded on the specific sheets provided by
Ateliers François. These forms are presented -> 6.
5.1 Before starting the compressor

The operator shall carry out the following operations.
 Check that the Control panel isolation switch is switched on.
 Check that there are no alarms.
 Do a general inspection of the machine to check that there are no obstructions, no water and/or oil leaks and
check the condition of the air outlet hoses.
 Check the water pump rotation and the delivery water pressure.
 Check the oil level.
 Check the presence of a minimum 5 bar in the air regulation tank. If needed, re-pressurise the air regulation
tank.
 Check that all the auxiliaries are working including the water pump (if not on the compressor skid), the dryer
and the cooling system (if applicable).
5.2 Starting the compressor

Proceed as follows.
 Press the Start button on the PLC.
 Listen for any unusual noises when the compressor is started.
Stop the compressor immediately if any unusual noises or vibrations are evident and investigate the cause
(see UMI -> 6).
 Check the proper operation of the drainage/venting systems.
5.3 Stopping the compressor

Proceed as follows.
 Press the Stop button on the PLC.
CAUTION:
On no account must the emergency stop button be used to stop the machine in
normal mode. Systematic use of the emergency stop button may have adverse effects
on the machine and lead to a loss of the guarantee.
 Before performing any maintenance, keep the main breaker switched on for at least 10 minutes after
pressing the PLC Stop button. If the control panel feeds heating elements, it must remain permanently
switched on except for maintenance of equipment.
 In the event of a stop for a long period, also stop all the ancillary equipment.
MOP 20FH2203 27-78

AF COMPRESSORS
CAUTION:
Always leave the dryer switched on: keep the compressor cabinet main breaker
switched on, unless stopping for a long period. If the dryer is switched off, then
ensure to switch it back on 24 hours in advance of any further use.
28-78 MOP 20FH2203

AF COMPRESSORS
6 Maintenance Means and Instruction
In order to simplify the control/maintenance work and the exchanges with Ateliers François, all the tasks are
listed in forms classified according to the level and the period of intervention. These forms are called UMI (see
below).
Therefore, depending on the compressor type and operating hours, maintenance shall be scheduled to allow
the intervention of an Ateliers François Service Engineer for the required maintenance tasks.
6.1 What are UMI and how to use them

UMI are User Maintenance Instruction forms. They are numbered and divided into three types as shown in the
following table.
UMI 001 to 199 Basic instructions for the end-users operating and maintenance staff
UMI 200 and above Advance level instructions for end-users staff who have received specific training
UMI 1000 and above List of instructions for different periods of time
Those UMI list the operations described in UMI 001 to UMI 999, that have to be performed
Note:
Some UMI are titled "SERMI" (SERvice Maintenance Instruction); they list tasks reserved for Ateliers
François Service Engineers only.
6.1.1 Guidelines
All the maintenance and control operations that are to be performed at any specific period are resumed in a
synthesis form, the UMI 2009.
This form shall be used by the customer’s qualified staff in charge of the control and maintenance operations.
6.1.2 Reports
For each specific period from the UMI 2009, a UMI shall be used as the maintenance & control operations
report.
6.1.3 Tasks
For each operation, all the tasks are listed in the corresponding UMI.
Refer to the figure on next page.
MOP 20FH2203 29-78

AF COMPRESSORS
Guidelines
Reports
Tasks
30-78 MOP 20FH2203

AF COMPRESSORS
6.1.4 Basic level UMI presentation

Every UMI from basic level (1 to 199) is language free. All maintenance tasks are clearly explained step by step.
Every UMI from basic level starts and ends with safety instructions. Operators shall follow these instructions
before working on the compressor. Example is shown below with the UMI 102.
6.1.5 Advanced level UMI presentation

Every UMI numbered from 200 to 999 are dedicated to the advanced and high maintenance level.
MOP 20FH2203 31-78

AF COMPRESSORS
6.2 Safety pictograms list

The safety pictograms and signs which can be found in a UMI and on the equipment are listed below.
Informative signs
Read the compressor manual Disconnect power
Lock compressor electrical cabinet Perform maintenance
Unlock compressor electrical cabinet Pulley and belt protection
Lock compressor + ancillaries Direction of movement
Unlock compressor + ancillaries Crane anchor point
Informative personal protective equipment signs
High noise area Safety vest
Safety shoes Safety gloves
Safety glasses Mask needed
Safety helmet Wash hands
32-78 MOP 20FH2203

AF COMPRESSORS
Prohibited, not allowed
No battery or battery charger No forklift / Don't use a forklift
No chemicals Don’t switch on
No poison No explosive materials
No car or truck exhaust-gas No maintenance allowed
No hot work allowed No voltage allowed
No magnetic field No pressure allowed
Danger or Warning
Electrically Live Under maintenance
Hot surface Magnetic field
Air under pressure Under pressure
Moving Parts Keep hands clear
Danger
MOP 20FH2203 33-78

AF COMPRESSORS
Combination of Pictogram signs
Maintenance NOT allowed
Maintenance allowed
Read the manual before action
Action pictograms
Take photo(s) showing precisely the problem
Send a mail to AF Aftersales Department
Check visually
Move in this direction
Control the surface area
34-78 MOP 20FH2203

AF COMPRESSORS
Status pictograms
Correct
Incorrect or prohibited
Don't move
Locked Unlocked
Tools to use
Brush Vacuum cleaner
Sponge Marker
Paper for cleaning Plastic gloves
MOP 20FH2203 35-78

AF COMPRESSORS
Clear water Oil recycling disposal container
Food industry compatible grease

AF recommended oil only
or AF recommended grease
AF original genuine kit or Spare Parts only
6.3 Consumables
All consumables (used rings, gaskets, spares, …) and waste (cotton rag, used oil, antifreeze + water,…) from
the compressor should be taken care of by the customer. Ateliers François is not liable for the disposal, or
recycling thereof.
6.3.1 Oil
The types of approved oil and quantities are shown in the following table.
Qty Qty Qty
Manufacturer Brand CE 2 -> CE 24 CE 46 CE 6 -> CE 680

Q8 Q8 SCHUBERT 150
Mobil Rarus 429 17lt 35lt 45lt
Shell Corena OIL P 150
6.3.2 Antifreeze
The glycol antifreeze added to the cooling circuit can be classical antifreeze involved in the food industries
6.4 Spare parts

The spare parts which might be delivered with the compressor must stay in their original packing for being
stocked in a location dry and clean, free from light and with normal moisture content.
36-78 MOP 20FH2203

AF COMPRESSORS
6.5 UMI forms list

The UMI forms are listed below in alphanumeric order.
Remark
Please note that the extension following the UMI’s number (-two letters) specifies the
language that is used for the UMI. All UMIs that are followed by the code (-un) are without
language and are considered as universal.
6.5.1 Multiple User Maintenance Instruction
Reference Procedure designation
UMI 1001-en Yearly Maintenance and Inspection job

UMI 1023-en Maintenance and Inspection at 2nd & 3rd stage cylinders
UMI 1052-en Weekly Maintenance and Inspection job
UMI 1100-en Maintenance and Inspection depending on local situation (year running hrs)
UMI 1112-en Daily Performance Record
UMI 1123-en Maintenance and Inspection at 1st, 2nd & 3rd stage cylinders
UMI 2009-en Maintenance and inspection job summary for Permanent "Life cycle"
UMI 2400-en 20-24000 hrs control & maintenance operation
6.5.2 Safety Lock & Unlock Procedure Instruction
UMI 008-un Safety locks & unlocks procedure for AF compressor

UMI 009-un Safety locks & unlocks procedure for AF Electrical cabinet
6.5.3 Simple User Maintenance Instruction
UMI 012-en Weekly compressor performance record > 220 kW

UMI 050-un PLC control and settings
UMI 100-un Controlling and/or replacing suction valves
UMI 101-un Controlling and/or replacing discharge valve
UMI 102-un Cleaning the oil filter
UMI 106-un Control of screws, nuts draw and bolts torque of valve covers
UMI 109-un Pressure & temperature sensor control or replacement
UMI 110-un Oil changing and mechanism control
UMI 111-un Control and/or maintenance of Bekomats
UMI 112-un Cleaning or changing the inlet air filter
UMI 113-un Changing the dryer air filter
UMI 114-un Motor bearing greasing
UMI 115-un Controlling and/or changing the water and antifreeze from circuit
MOP 20FH2203 37-78

AF COMPRESSORS
UMI 116-un Control and/or replacement of the 1st & 2nd stage separator demister pad
UMI 117-un Control and maintenance of the diaphragm/unloader system
UMI 119-un Control of the electrical cabinet and its filter
UMI 120-un Control and/or cleaning of the dryer cooler system
UMI 121-un Checking the emergency stop
UMI 122-un Control of the water cooling system
UMI 123-un Cleaning and controlling the main motor
6.6 Detailed UMI forms

See next pages.
38-78 MOP 20FH2203

AF COMPRESSORS
UMI 2009-EN / MAINTENANCE AND INSPECTION JOB SUMMARY
Customer:
Compressor Maintenance
Serial number:
operation reference
Compressor type:
Depending on local situation
On maintenance complete
On maintenance 2nd - 3rd
Control Period
and working conditions
After 20-24000 hours

Once a year at least
At commissioning
Every week
Maintenance and inspection job summary for
Permanent "Life cycle"
Daily
Description of maintenance or inspection job
UMI 011-012 Filling out the "Weekly performance record" X X X X

UMI 1112 Sending the "Weekly performance record" to AF X X X
UMI 110 Oil changing X X X X
UMI 050 Programming UMI 1100 X X X X X
UMI 102 Cleaning the oil filter X X X X X
UMI 050 Programming UMI1023 X X X X X
UMI 205 Control of driving belts alignment and tension (when necessary) X X X X X
UMI 103  108 Control of screws, nuts draw and bolts torque of valve covers X X X X X
UMI 110 Control of piston rod 1st, 2nd & 3rd stage X X X X X
UMI 110 Control of crankshaft, crankcase & connecting rod/bolts X X X X
UMI 110 Control of horizontal and vertical crosshead X X X X
UMI 110 Control of horizontal and vertical packing-ring X X X X
UMI 110 Control of horizontal and vertical oil scraper ring X X X X
UMI 121 Checking the emergency stop X X X X X
UMI 122 Control of the water cooling system X X X X X
UMI 112 Cleaning or changing the inlet air filter X X X X
UMI 050 Programming UMI 1001 X X X X X
UMI 120 Control and/or cleaning of the dryer cooler system X X X X X
UMI 119 Control of the electrical cabinet and its filter X X X
SERMI 105 Control of the tightening of screws and nuts in electrical cabinet X X X
UMI 207 Control of piston rings 2nd & 3rd stage X
UMI 206 Control of piston rings 1st stage X X
UMI 050 Programming UMI 1123 X X X X
UMI 116 Control of the 1st and 2nd stage separator demister pad (if any) X X X
UMI 111 Control and/or maintenance of Bekomats X X X X
UMI 100-101 Controlling and/or replacing valves X X
UMI 117 Control and maintenance of the diaphragm/unloader system X X
UMI 113 Changing the dryer air filter X X
UMI 113 Changing the active carbon filter element (if any) X X
SERMI 101 Changing the piston rings 2nd & 3rd stage X X
SERMI 102 Changing the piston rings 1st stage X
UMI 115 Controlling and/or changing the water and antifreeze from circuit X X X X
UMI 114 Motor bearing greasing X
UMI 123 Cleaning and controlling the main motor X X
SERMI 801 Control and/or replacement of connecting rod bolts X
UMI 050 Programming UMI 2400 X X
UMI 205 Control and/or replacement of driving belts X
UMI 116 Changing the 1st & 2nd stage separator demister pad (if any) X
MOP 20FH2203 39-78

AF COMPRESSORS
UMI 1112-EN / DAILY PERFORMANCE RECORD

Numbering
Daily Performance Record UMI 1112
Customer:
Compressor type:
Serial number: E-mail:
D01 Date dd/mm/yy

D02 Time hh:mn
D05 Total service hours Hrs
D06 On load hours Hrs
D17 Atmospheric pressure Bar
D18 Ambient temperature °C
D19 Relative humidity %
D24 Cooling water inlet pressure bef. pump Bar 1
D25 Cooling water inlet pressure aft. pump Bar
D09 Oil pressure Bar 2
D28 Air regulator pressure Bar 3
D20 First stage discharge Bar 4
D22 Second stage discharge Bar 4
D03 Third stage discharge Bar 5
D16 Oil temperature °C 6
D10 First stage discharge temperature °C 7
D21 Second stage inlet temperature °C 8
D11 Second stage discharge temperature °C 7
D23 Third stage inlet temperature °C 8
D12 Third stage discharge temperature °C 7
D04 After-cooler outlet temperature °C 8
D14 Vertical crosshead temperature °C 9
D15 Horizontal crosshead temperature °C 9
D26 Compressor water inlet temperature °C 10
D27 Compressor water outlet temperature °C 10
D13 H.P. stage cylinder water temperature °C 11
D29 Air dryer inlet temperature °C 8
D30 Air dryer dew point OK Y or N 12
Supply voltage OK Y or N 13
D44
Motor line Amps OK Y or N 13
D31 Safety valve OK Y or N 14
D32 Oil level OK Y or N 15
D33-D36 Purging drains: compressor / dryer OK Y or N 16
D37 Oil filter to be turned OK Y or N 17
D42 Noise OK Y or N 18
D43 Vibration OK Y or N 19
D45 40/15 bar flexible hose OK Y or N 20
Remarks
Dx0
D46 Alarm:
D47
D48
D49
D50
D51
D52
40-78 MOP 20FH2203

AF COMPRESSORS
UMI 1052-EN / WEEKLY MAINTENANCE AND INSPECTION JOB
Customer:
Serial number:
Compressor type:
operation reference
Week 01
Week 02
Week 03
Week 04
Week 05
Week 06
Week 07
Week 08
Week 09
Week 10
Week 11
Week 12
Week 13
Weekly Maintenance and Inspection job
UMI 1052
UMI 1112 Sending the "Weekly performance record" to AF
UMI 122 Control of the water cooling system
UMI 120 Control and/or cleaning of the dryer cooler system
Week 14
Week 15
Week 16
Week 17
Week 18
Week 19
Week 20
Week 21
Week 22
Week 23
Week 24
Week 25
Week 26
UMI 1052


Week 27
Week 28
Week 29
Week 30
Week 31
Week 32
Week 33
Week 34
Week 35
Week 36
Week 37
Week 38
Week 39
UMI 1052


Week 40
Week 41
Week 42
Week 43
Week 44
Week 45
Week 46
Week 47
Week 48
Week 49
Week 50
Week 51
Week 52
UMI 1052

Inspection job realised by:
Name
Position
Signature
Signature by end user

Remarks
MOP 20FH2203 41-78

AF COMPRESSORS
UMI 1001-EN / YEARLY MAINTENANCE AND INSPECTION JOB
Customer:
Serial number:
Compressor type:
operation reference
Total running hours
Achievement date
Loading hours
Yearly Maintenance and Inspection job
UMI 1001
UMI 110 Oil changing
UMI 050 Programming UMI 1100
UMI 102 Cleaning the oil filter
UMI 205 Control of driving belts alignment and tension (when necessary)
UMI 103  108 Control of screws, nuts draw and bolts torque of valve covers
UMI 110 Control of piston rod 1st, 2nd & 3rd stage
UMI 110 Control of crankshaft, crankcase & connecting rod/bolts
UMI 110 Control of horizontal and vertical crosshead
UMI 110 Control of horizontal and vertical packing-ring
UMI 110 Control of horizontal and vertical oil scraper ring
UMI 121 Checking the emergency stop
UMI 112 Cleaning or changing the inlet air filter
UMI 119 Control of the electrical cabinet and its filter
UMI 116 Control of the 1st and 2nd stage separator demister pad (if any)
UMI 111 Control and/or maintenance of Bekomats
UMI 113 Changing the dryer air filter
UMI 113 Changing the active carbon filter element (if any)
UMI 115 Controlling and/or changing the water and antifreeze from circuit
UMI 123 Cleaning and controlling the main motor
Name
Position
Signature

Remarks
42-78 MOP 20FH2203

AF COMPRESSORS
UMI 2400-EN / 20-24000 HRS CONTROL & MAINTENANCE OPERATION
Customer:
Serial number:
Compressor type:
operation reference
Total running hours
Achievement date
Loading hours
20-24000 hrs control & maintenance operation
UMI 2400
UMI 050 Programming
SERMI 801 Control and/or replacement of connecting rod bolts
UMI 205 Control and/or replacement of driving belts
Name
Position
Signature

Remarks
MOP 20FH2203 43-78

AF COMPRESSORS
UMI 1100-EN / MAINTENANCE AND INSPECTION DEPENDING ON LOCAL SITUATION
Customer:
Serial number:
Compressor type:
operation reference
Total running hours
Achievement date
Loading hours
Maintenance and Inspection depending on local situation
UMI 1100
UMI 050 Programming UMI1023
UMI 207 Control of piston rings 2nd & 3rd stage
UMI 206 Control of piston rings 1st stage
UMI 113 Changing the dryer air filter
UMI 113 Changing the active carbon filter element (if any)
UMI 114 Motor bearing greasing
UMI 100-101 Controlling and/or replacing valves
UMI 123 Cleaning and controlling the main motor
SERMI 205 Control and/or replacement of driving belts
Name
Position
Signature

Remarks
44-78 MOP 20FH2203

AF COMPRESSORS
UMI 1023-EN / MAINTENANCE AND INSPECTION AT 2ND & 3RD STAGE CYLINDERS
Customer:
Serial number:
Compressor type:
operation reference
Total running hours
Achievement date
Loading hours
Maintenance and Inspection at 2nd & 3rd stage cylinders
UMI 1023
UMI 011-012 Filling out the "Weekly performance record"
UMI 117 Control and maintenance of the diaphragm/unloader system
SERMI 101 Changing the piston rings 2nd & 3rd stage
Name
Position
Signature

Remarks
MOP 20FH2203 45-78

AF COMPRESSORS
UMI 1123-EN / MAINTENANCE AND INSPECTION AT 1ST , 2ND & 3RD STAGE CYLINDERS
Customer:
Serial number:
Compressor type:
operation reference
Total running hours
Achievement date
Loading hours
Maintenance and Inspection at 1st, 2nd & 3rd stage cylinders
UMI 1123
UMI 011-012 Filling out the "Weekly performance record"
UMI 206 Control of piston rings 1st stage
UMI 117 Control and maintenance of the diaphragm/unloader system
SERMI 101 Changing the piston rings 2nd & 3rd stage
SERMI 102 Changing the piston rings 1st stage
Name
Position
Signature

Remarks
46-78 MOP 20FH2203

AF COMPRESSORS
UMI 008-UN / SAFETY LOCKS & UNLOCKS PROCEDURE FOR AF COMPRESSOR 1/2
MOP 20FH2203 47-78

AF COMPRESSORS
UMI 008 UN / SAFETY LOCKS & UNLOCKS PROCEDURE FOR AF COMPRESSOR 2/2
48-78 MOP 20FH2203

AF COMPRESSORS
UMI 009-UN / SAFETY LOCKS & UNLOCKS PROCEDURE FOR AF ELECTRICAL CABINET
MOP 20FH2203 49-78

50-78
Daily Performance Record UMI 012
AF COMPRESSORS
Customer:
Compressor type:
Serial number: E-mail:
Numbering
D01 Date dd/mm/yy 01/
D02 Time hh:mn
D05 Total service hours Hrs
D06 On load hours Hrs
D17 Atmospheric pressure Bar

D18 Ambient temperature °C
D19 Relative humidity %
D09 Oil pressure Bar

D24 Cooling water inlet pressure bef. pump Bar
D28 Air regulator pressure Bar
UMI 012-EN / WEEKLY COMPRESSOR PERFORMANCE RECORD > 220 KW
D20 First stage discharge Bar

D22 Second stage discharge Bar
1/3
D25 Cooling water inlet pressure aft. pump Bar D03 Third stage discharge Bar
MOP 20FH2203
MOP 20FH2203
D16 Oil temperature °C D23 Third stage inlet temperature °C
D10 First stage discharge temperature °C
D21 Second stage inlet temperature °C D12 Third stage discharge temperature °C
D11 Second stage discharge temperature °C D04 After-cooler outlet temperature °C
D14 Vertical crosshead temperature °C
D13 H.P. stage cylinder water temperature °C
D15 Horizontal crosshead temperature °C

D26 Compressor water inlet temperature °C

D27 Compressor water outlet temperature °C D29 Air dryer inlet temperature °C
2/3
D30 Air dryer dew point OK Y or N

AF COMPRESSORS
51-78
52-78
Supply voltage OK Y or N D32 Oil level OK Y or N
D44
AF COMPRESSORS
Motor line Amps OK Y or N
D31 Safety valve OK Y or N D33-36 Purging drains: compressor / dryer OK Y or N
D37 Oil filter to be turned OK Y or N
D42 Noise OK Y or N Fault Date - Hrs

D43 Vibration OK Y or N D46
D47
D48
D49
D50
D51
D52
3/3
D45 40/15 bar flexible hose OK Y or N
MOP 20FH2203
AF COMPRESSORS
UMI 050-UN / PLC CONTROL AND SETTINGS
MOP 20FH2203 53-78

AF COMPRESSORS
UMI 100-UN / CONTROLLING AND/OR REPLACING SUCTION VALVES 1/2
54-78 MOP 20FH2203

AF COMPRESSORS
UMI 100-UN / CONTROLLING AND/OR REPLACING SUCTION VALVES 2/2
MOP 20FH2203 55-78

AF COMPRESSORS
UMI 101-UN / CONTROLLING AND/OR REPLACING DISCHARGE VALVE 1/2
56-78 MOP 20FH2203

AF COMPRESSORS
UMI 101-UN / CONTROLLING AND/OR REPLACING DISCHARGE VALVE 2/2
MOP 20FH2203 57-78

AF COMPRESSORS
UMI 102-UN / CLEANING THE OIL FILTER
58-78 MOP 20FH2203

AF COMPRESSORS
UMI 106-UN / CONTROL OF SCREWS, NUTS DRAW AND BOLTS TORQUE OF VALVE COVERS
MOP 20FH2203 59-78

AF COMPRESSORS
UMI 109-UN / PRESSURE & TEMPERATURE SENSOR CONTROL OR REPLACEMENT 1/2
60-78 MOP 20FH2203

AF COMPRESSORS
UMI 109-UN / PRESSURE & TEMPERATURE SENSOR CONTROL OR REPLACEMENT 2/2
MOP 20FH2203 61-78

AF COMPRESSORS
UMI 110-UN / OIL CHANGING AND MECHANISM CONTROL 1/2
62-78 MOP 20FH2203

AF COMPRESSORS
UMI 110-UN / OIL CHANGING AND MECHANISM CONTROL 2/2
MOP 20FH2203 63-78

AF COMPRESSORS
UMI 111-UN / CONTROL AND/OR MAINTENANCE OF BEKOMATS
64-78 MOP 20FH2203

AF COMPRESSORS
UMI 112-UN / CLEANING OR CHANGING THE INLET AIR FILTER
MOP 20FH2203 65-78

AF COMPRESSORS
UMI 113-UN / CHANGING THE DRYER AIR FILTER
66-78 MOP 20FH2203

AF COMPRESSORS
UMI 114-UN / MOTOR BEARING GREASING
MOP 20FH2203 67-78

AF COMPRESSORS
UMI 115-UN / CONTROLLING AND/OR CHANGING THE WATER AND ANTIFREEZE FROM CIRCUIT
68-78 MOP 20FH2203

AF COMPRESSORS
UMI 116-UN / CONTROL AND/OR REPLACEMENT OF THE 1ST & 2ND STAGE SEPARATOR DEMISTER PAD
MOP 20FH2203 69-78

AF COMPRESSORS
UMI 117-UN / CONTROL AND MAINTENANCE OF THE DIAPHRAGM /UNLOADER SYSTEM 1/2
70-78 MOP 20FH2203

AF COMPRESSORS
UMI 117-UN / CONTROL AND MAINTENANCE OF THE DIAPHRAGM /UNLOADER SYSTEM 2/2
MOP 20FH2203 71-78

AF COMPRESSORS
UMI 119-UN / CONTROL OF THE ELECTRICAL CABINET AND ITS FILTER
72-78 MOP 20FH2203

AF COMPRESSORS
UMI 120-UN / CONTROL AND/OR CLEANING OF THE DRYER COOLER SYSTEM
MOP 20FH2203 73-78

AF COMPRESSORS
UMI 121-UN / CHECKING THE EMERGENCY STOP
74-78 MOP 20FH2203

AF COMPRESSORS
UMI 122-UN / CONTROL OF THE WATER COOLING SYSTEM
MOP 20FH2203 75-78

AF COMPRESSORS
UMI 123-UN / CLEANING AND CONTROLLING THE MAIN MOTOR
76-78 MOP 20FH2203

AF COMPRESSORS
Comments
(For personal use)
MOP 20FH2203 77-78

AF COMPRESSORS
Whenever you contact Ateliers François, please indicate the

compressor model and serial number.
Liability
Ateliers François does not accept any liability for loss or damage that results as a consequence of:
 negligence in the maintenance and daily monitoring of the equipment, in particular failure to maintain the daily
record file and any failure to communicate this to Ateliers François or its local representative responsible for
monitoring machines under guarantee,
 any error in handling, installation, electrical connection and in particular faulty electricity supply or cabling
unsuitable for the local conditions,
 any error of handling, installation, pneumatic connection and in particular customer pipes unsuited either by their
size or by their arrangement or by a lack of suitable attachments,
 unauthorised modifications made to the equipment by the customer or the failure to observe Ateliers François’
recommendations and instructions,
 any failure to ensure that cooling water of the correct quality suitably inhibited, or protected in some manner, to
prevent freezing during operation or whilst stopped,
 the use of oils and greases that are not approved by Ateliers François.
Ateliers François withholds the right to void all warranty claims and guarantees when the customer uses counterfeit
replacement parts or accessories not supplied by Ateliers François.
No liability will be accepted by Ateliers François or its affiliates in the event of installation and use different to that for which
the equipment was supplied.
To retain Ateliers François’s warranty, the customer shall follow the maintenance program and undertake all required
inspections.
The content of this manual is the property of Ateliers François and is protected by copyright. Any full or partial
reproduction is strictly prohibited.
End of Manual
78-78 MOP 20FH2203

Operator Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operator Manual

Uploaded by

Copyright:

Available Formats

AF COMPRESSORS

2-78 MOP 20FH2203

2016-02 Source MOP-EN-C-AB-REV00.1

MOP 20FH2203 3-78

List of abbreviations & vocabulary frequently used

AFC Ateliers François Compressors

CE Compresseur Equerre (L-Compressor)

EMC ElectroMagnetic Compatibility

OPC Oil-free Piston Compressor

PET PolyEthylen Terephthalate

RPM Round Per Minute

SERMI SERvice Maintenance Instruction

UMI User Maintenance Instruction

4-78 MOP 20FH2203

DANGER - SAFETY ADVICES - TO BE READ

Rules and Regulations

Failure to observe the safety rules and regulations

Pictograms and warning signs

MOP 20FH2203 5-78

Electrical installation rules

Precautions to be taken with machinery and compressed air

Contact with various liquids and fluids

6-78 MOP 20FH2203

MOP 20FH2203 7-78

LEFT BLANK INTENTIONALLY

8-78 MOP 20FH2203

DANGER - SAFETY ADVICES - TO BE READ .................................................................................. 5

2 Description of the equipment .................................................................................................... 13

3 Principles of operation ............................................................................................................... 23

4 Optional equipment presentation .............................................................................................. 25

5 Operator Instructions ................................................................................................................. 27

5.2 STARTING THE COMPRESSOR..........................................................................................................................27

6 Maintenance Means and Instruction .......................................................................................... 29

10-78 MOP 20FH2203

1.1 Purpose of the manual

1.2 Using the manual

1.3 Applicable documents

Ref. Document Reference

MOP 20FH2203 11-78

LEFT BLANK INTENTIONALLY

12-78 MOP 20FH2203

2 Description of the equipment

MOP 20FH2203 13-78

2.2.2 Compressor performance

2.2.3 Electrical Requirements

2.2.4 Water & Air Requirements

14-78 MOP 20FH2203

2.3 Description of the compressor

1 Inlet air filter casing and filter cartridge

MOP 20FH2203 15-78

2.3.2 Second stage

9 2nd stage cylinder and piston (simple action)

16-78 MOP 20FH2203

2.3.3 Third stage

17 3rd stage cylinder and piston (simple action)

MOP 20FH2203 17-78

2.3.4 Final air recovery circuit

25 40 bar Air receiver and safety valve

18-78 MOP 20FH2203

2.3.5 Other compressor components and ancillary equipments

Other compressor components

30 Motor and pulley

28 Dryer and filters

MOP 20FH2203 19-78