Atlas Copco

Industrial aluminium piston compressors

Marine Air Systems

LT 3 KE, LT 5 KE, LT 7 KE, LT 10 KE, LT 15 KE, LT 20 KE

Instruction book
Atlas Copco
Industrial aluminium piston compressors

Marine Air Systems

LT 3 KE, LT 5 KE, LT 7 KE, LT 10 KE, LT 15 KE, LT 20 KE

From following serial No. onwards: API 520 000

Instruction book
Original instructions

Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as identified
in the Declaration of Conformity.

2011 - 02
No. 2920 7092 60

www.atlascopco.com
 Instruction book

Table of contents

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

1.1 SAFETY ICONS...................................................................................................................................4

1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................4

1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................5

1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................6

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................7

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

2.1 GENERAL DESCRIPTION.......................................................................................................................9

2.2 COMPONENTS..................................................................................................................................11

2.3 OPTIONS........................................................................................................................................12

2.4 AIR FLOW.......................................................................................................................................15

2.5 REGULATING SYSTEM........................................................................................................................16

3 Installation.....................................................................................................................18

3.1 DIMENSION DRAWINGS.......................................................................................................................18

3.2 INSTALLATION PROPOSAL...................................................................................................................22

3.3 ELECTRICAL CONNECTIONS.................................................................................................................25

3.4 PICTOGRAPHS.................................................................................................................................28

4 Operating instructions.................................................................................................29

4.1 INITIAL START-UP..............................................................................................................................29

4.2 STARTING.......................................................................................................................................30

4.3 STOPPING.......................................................................................................................................31

4.4 TAKING OUT OF OPERATION ...............................................................................................................31

4.5 STORAGE.......................................................................................................................................31

5 Maintenance..................................................................................................................32

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5.1 PREVENTIVE MAINTENANCE SCHEDULE .................................................................................................32

5.2 LUBRICATION OF COMPRESSORS..........................................................................................................33

5.3 SERVICE KITS..................................................................................................................................33

5.4 DISPOSAL OF USED MATERIAL.............................................................................................................34

6 Servicing and adjustment procedures.......................................................................35

6.1 CHECK VALVE..................................................................................................................................35

6.2 SERVICING VALVES...........................................................................................................................35

6.3 SERVICING AIR INLET FILTER...............................................................................................................36

6.4 ADJUSTMENT PRESSURE SWITCH.........................................................................................................37

6.5 ADJUSTMENT TEMPERATURE SWITCH....................................................................................................38

6.6 SERVICING SAFETY VALVE..................................................................................................................39

6.7 SAFETY VALVE LOW PRESSURE...........................................................................................................39

7 Problem solving............................................................................................................41

8 Technical data...............................................................................................................42

8.1 ELECTRIC CABLE SIZE.......................................................................................................................42

8.2 SETTINGS FOR OVERLOAD RELAY AND FUSES.........................................................................................44

8.3 REFERENCE CONDITIONS...................................................................................................................45

8.4 LIMITATIONS....................................................................................................................................45

8.5 COMPRESSOR DATA..........................................................................................................................45

9 Declaration of conformity............................................................................................47

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 Safety precautions, general

General precautions
1. The operator must employ safe working practices and observe all related work safety requirements and
regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two
shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality,
the compressed air must be adequately purified according to the applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,
press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the
power isolating switch must be opened and locked.
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme
caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall
be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the compressor or its components.
9. Only trained personnel should have access, for short periods only, to the room where the compressor is
installed. If maintenance, repair work or adjustments have to be carried out, the compressor should be
stopped and taken out of operation according to the maintenance procedures. All entrances to the room
where the compressor is installed should have a warning sign "DANGER Trained personnel only” and a
pictograph indicating the mandatory use of ear protection.

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1.3 Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal precautions and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.

Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within
safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction
duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
5. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents, that can lead
to internal fire or explosion.
6. Arrange the air intake so that loose clothing cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that the isolating switch is open and locked
before any maintenance or repair. As a further safeguard, persons switching on remotely controlled
machines shall take adequate precautions to ensure that there is no one checking or working on the
machine. To this end, a suitable notice shall be affixed to the start equipment.
10. The machines must be installed in such a way that an adequate flow of cooling air is available and that
the air from the exhaust does not recirculate to the compressor air inlet or cooling air inlet.
11. The electrical connections must correspond to the applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed
near the compressor.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return
valves (check valves) must not be relied upon for isolating pressure systems.
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be
protected by a pressure-relieving device or devices as required.
15. Pipework or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high-temperature pipework
must be clearly marked.

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Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.

1.4 Safety precautions during operation

All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal precautions and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.

Precautions during operation

1. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure
that a hose is fully depressurized before disconnecting it.
2. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or
particles.
4. Never operate the machine below or in excess of its limit ratings.
5. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
6. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure-relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses etc. are in good repair, free
of wear or abuse
7. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
8. If available, do not remove any of, or tamper with, the sound-damping material.
9. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be
protected by a pressure-relieving device or devices as required.

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Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.

1.5 Safety precautions during maintenance or repair

All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal precautions and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.

Precautions during maintenance or repair

1. Always wear safety glasses.
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign stating "work in progress; do not start" shall be attached to the starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
7. Close the compressor air outlet valve before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify,
pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that
they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been
reinstalled.
17. Protect the motor, air filter, electrical and regulating components etc. to prevent moisture from entering
them, e.g. when steam-cleaning.

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18. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork
and in the air inlet and outlet systems of the compressor, are in good condition. If damaged, replace it by
genuine material from the manufacturer to prevent the sound pressure level from increasing.
19. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
20. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if required, use
breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical
first aid.
21. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.

Also consult the following safety precautions: Safety precautions during installation and
Safety precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.

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2 General description

2.1 General description

Introduction
LT KE are air-cooled, two stage, single acting lubricated piston compressors which deliver air with a minimum
of oil content. They are built for effective working pressure up to 30 bar.

Compressor block

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Base mounted

Reference Description
AF Air filter
CV/WS Check valve / water separator
Dp Oil drain valve
FC Filler cap
FN Fan
Gp Air pressure gauge
M Motor
PS Pressure switch
SG Oil sight glass
SV1 Safety valve (low pressure)
SV2 Safety valve (high pressure)
Y1 Solenoid valve

Reference Description
1 Air inlet silencer
2 Cover
3 Crankcase
4 Cooling pipe
5 Left cylinder (low pressure)
6 Right cylinder (high pressure)

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Compressor variants
The compressor block includes:
• Crankcase (3) and cylinders (5)(6)
• Air inlet filter (AF) and inlet silencer (2)
• Fan (FN)
• Air cooler piping (4)
• Check valve (CV), and waterseparator (WS)
• Safety valve (SV1) on the low pressure side
• Safety valve (SV2) on the high pressure side
The base-mounted unit is a unit with an electric motor and air pressure switch, built on a frame (no air
receiver).
An air temperature switch is delivered loose when booked optionally, unless mandatory by the classification
body.

2.2 Components

Solenoid valve
The solenoid valve allows the compressor to start unloaded. The valve opens for 8 seconds during every start-
up sequence.
At the first start-up, verify the proper working by keeping a piece of paper, cloth in flow-path or by spraying
some leak-finder on the valve outlet.
Electric connection
• NO contact
• 10 W, 220/230 V AC, 50/60 Hz

Air pressure switch

The switch allows the operator to select pressure at which the compressor will start and stop. The stopping
and starting pressures are the opening and closing pressures of the switch.
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).

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Electric connection
Contact load, Alternating current
• Ohmic: 10 A, 440 V, AC-1
• Inductive: 6 A, 440 V, AC-3
• 4 A, 440 V, AC-15
• Starting current max. 50 A (locked rotor)
Contact load, Direct current
• 12 W, 220 V, DC-13

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

Air temperature switch

Air temperature switch monitors outlet air temperature and is activated when certain temperature level is
exceeded.
Moreover, in case a control cubicle is supplied with the compressor, the switch is wired to a potential free
contact (available on terminals) and shall activate an indication lamp. The switch is factory preset.
Note
This feature is installed by default when it is mandatory by the classification body.

Note: The compressor has been tested at manufacturers works. The settings of the
alarm system have the correct values.
It is recommended not to change these settings for proper and secure operation of
your compressor.

Oil level switch

N.C. (normally closed contact) Make contact.

The oil level switch monitors the oil level inside the crankcase and is activated when certain (low) level is
reached. Moreover, in case a control cubicle is supplied with the compressor the switch is wired to a potential
free contact (available on terminals) and shall activate an indication lamp.
To compensate for the impact of ship motion on the level switch, the control circuit includes delay timer set
at 3 seconds. This delay can never be set longer then 10 seconds.

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For units delivered without cubicle, it is advised to execute the control circuit in such a way that the oil level
switch stops the compressor in case of low oil level (as per class requirements). This is a standard practice on
the units delivered with a control cubicle.
There are two different oil level switch versions, depending the size of the unit.
• LT 3, LT 5, LT 7 and LT 10 use an oil level switch mounted on an expansion module at the side of the
piston block. It comes with an extra rubber ring to compensate for rapid changes in oil level due to ship
motion.
• LT 15 and LT 20 use an oil level switch mounted directly in the piston block crankcase.

Motor anti condensation heaters and thermistor protection

Anti condensation heaters are useful in order to prevent failure or corrosion to electric motors by water
condensing inside the enclosure.

The thermistor protection is used for tripping motors, whenever the excessive temperature develops in the
windings.

Master slave switch

The option master slave switch is installed in the control circuit between 2 compressors and allows the user
to choose which of both compressors is the primary unit, and which is used as a backup or topping up unit.
In this setup, each unit has its own control cubicle and pressure switch. Both units are connected to the same
air discharge pipe. The compressor control cubicles are connected to each other.
The pressure switches are adjusted as follow:
• Pressure switch at compressor 1 as master-pressure switch
• cut in setting point : 24 bar
• cut out setting point: 30 bar
• Pressure switch at compressor 2 as slave-pressure switch
• cut in setting point : 22 bar
• cut out setting point: 28 bar
As it is not known what the intended setup is on board of the ship, both pressure switches are factory
set at 24/30 bar cut in/out. The user is required to adjust the switch on compressor 2 to 22/28 bar cut
in/out. Setting of switch can be found in section : Adjustment of pressure switch.
By setting the selection switch towards compressor 1, compressor 1 will be controlled by the master pressure
switch and compressor 2 by the slave pressure switch. .
Switching the selection switch towards compressor 2, will allow compressor 2 to be controlled by the master
pressure switch and compressor 1 by the slave pressure switch.

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Purpose of master-slave configuration is to equalize the running hours between both compressors and avoid
long stop or stand still of one compressor.
Please note that no stop valves are allowed to be closed between two pressure switches when running in
master-slave configuration. Both compressors should be switched to “auto” position if controlled by the
master/slave configuration.

Caution: If the switch position is set to “Manual”, the pressure switches are bypassed
and the compressor will not stop and has an overpressure protection only by the safety
valve.

Units delivered with control cubicle (Y-D or DOL)

Connect all wiring according service diagram supplied with the unit. Use the appropriate cable sections, as
indicated in section Electric cable size.

Control cubicle is standard equipped with following switches and signal lights:
1. Main switch (MS): disconnects compressor from power supply network
2. Hour counter (h): indicates compressor running hours
3. Green light (H1): indicates if compressor is running
4. Red light (H2): indicates motor overload warning
5. Selector switch with following positions (S1)
• Auto: Compressor is on and working is controlled by pressure switch (see Adjustment of pressure
switch)
• 0: Compressor is switched off
• Manual: Compressor is always on. Regulation by pressure switch is by-passed. Safety valve will blow
off if pressure exceeds maximum allowable working pressure.
Optionally, control cubicle is foreseen with following:

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1. Red light (H3): Air temperature warning light. If air temperature exceeds setting of air temperature switch,
a red indication light will switch on.
2. Red light (H4): Oil level switch indicator. If oil level in the crankcase drops below minimum level, the
red warning light will switch on.
3. Push button (S2): Resets all warnings.

Units delivered without control cubicle

If no cubicle is delivered with the unit, care should be taken that all safety and regulating devices
present on the unit are connected to a control circuit in such a way that their intended working
principle by the manufacturer is respected.

- Solenoid valve , see Components

- Air pressure switch, see Adjustment of pressure switch
- Air temperature switch (optional equipment), see Adjustment of temperature switch
- Oil level switch (optional equipment)

2.4 Air flow

LT units
Air drawn through air filter (AF) and inlet silencer (1) into LP (low-pressure) cylinder (5) is compressed, then
discharged to HP (high-pressure) cylinder (6) via intercooler (Ci).
The air is compressed further and discharged through cooler piping (4) and combined water separator / check
valve (WS/CV) towards to air receiver.

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Air flow and regulating system

References on flow diagrams

Reference Description Reference Description

AF Air filter 1 Air inlet silencer
Ci Intercooler 4 Cooling pipe
CV Check valve 5 Left cylinder (LP)
DP Oil drain plug 6 Right cylinder (HP)
FC Oil filler cap 7 Control cabinet
FN Fan
PS Air pressure switch
SG Oil level sight-glass
SV1/SV2 Safety valve
WS Water separator
Y1 Solenoid valve

2.5 Regulating system

Electric motor driven unit type KE
The regulating system includes:
• Control cabinet (7)
• Solenoid valve (Y1)
• Air pressure switch (PS)

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Automatic Operation
The control cabinet controls the unit.
The air pressure switch (PS) on the unit opens and closes its contacts at preset air pressures. At preset minimum
air pressure the electric motor will start. A timer in the control cabinet keeps solenoid valve (Y1) for
approximately 12 seconds de-energised, the electric motor starts. With this, the compressor unit keeps in
unload operation. After approxately 12 seconds the solenoid valve (Y1) is energised. The electric motor driven
unit comes in loaded operation.
When the pressure in the air receiver reaches the preset maximum pressure, the contacts of the pressure switch
(PS) are opened. This results that the motor will stop and the solenoid valve (Y1) is de-energized and will
open, so the air and moist is can escape to the atmosphere.

Important note:
Loaded starting and stopping is not allowed. This can cause damage to the unit.

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3 Installation

3.1 Dimension drawings

LT 3 KE up to LT 5 KE

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LT 7 KE up to LT 10 KE

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LT 15 KE up to LT 20 KE

Note :Vibration damper and welding plate will be delivered as loose parts.
References of figures on dimension drawings.

Reference Description
1 Compressor air inlet
2 Compressor cooling air inlet
3 Service space for air filter
4 Motor electrical connection

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Reference Description
5 Cable entry
6 Electric connection solenoid valve
7 Pressure gauge
8 Safety valve
9 Non return valve
10 Motor cooling air inlet
11 Compressed air outlet (M30x2)
12 Condensate drain outlet G 1/2"
13 Flexible hose
14 Oil level sight glass
15 Motor lifting eye
16 Welding plate
17 Oil drain outlet G 1/4"
Oil plug
18 Unit Type
19 Mass (kg)
20 Details vibration damper

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3.2 Installation proposal

Installation proposal

Typical example of compressor room.

1 Compressor frame on buffers

2 Ball valve on outlet
3 Compressed air network
4 Ventilation fan
5 Main drain pipe
6 Compressor drain connection
7 Air vessel
8 Compressor air outlet pipe

Note
Always install an air vessel between the compressor and the air network.

Location
The compressor should be installed in a well ventilated room. The inlet grid and ventilation fan (4) should be
installed in such a way that any re-circulation of cooling air to the compressor is avoided. The direction of

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the airflow (indicated by arrows) needs to be respected in all conditions. The air velocity to the grid(s) has to
be limited to 5 m/s. The maximum air temperature at the compressor intake opening is 50°, minimum 0° C.
The required ventilation to limit the compressor room temperature can be calculated from:
Qv = 0.92 N / ΔT
• Qv is the required ventilation capacity (m3/s)
• N is the nominal motor power of the compressor (kW)
• ΔT is the compressor room temperature over the outdoor temperature (°C)
The pressure drop over the air delivery pipe can be calculated from:
Δp = (L x 450 x Qc1.85) / (d5 x P)
or,
the maximum total pipe length of the pipe can be calculated from:
L = (Δp x d5 x P) / (450 x Qc1.85)
• d = Inner diameter of the pipe in mm
• Δp = Pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi))
• L = Length of the pipe in m
• P = Absolute pressure at the compressor outlet in bar
• Qc = Free air delivery of the compressor in l/s

Mounting
The compressor unit should be installed on a solid, level floor suitable for taking the weight of the compressor.
The compressor should be installed on supplied buffers, and on level surface as not to introduce extra stress
in the mounting frame and components. The supplied plates can be bolted or directly welded on deck.

Service space

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Service space must be according figure above.

Recommended minimum distance between top of unit and ceiling is 1100 mm. If multiple compressors are
installed, minimum service space between two units is 400 mm.

Connections to air network

All pipes should be installed stress free to the compressor unit.

Air outlet
• Always install an air vessel (7) between compressor and compressed air network.
• Air outlet pipe (8) has a cutting ring pipe fitting suitable for pipes of outer diameter 22 mm. Alternatively,
a pipe coupling with O-ring and 24° sealing cone according DIN 2353 or equivalent can be used. Optionally
flanged fittings are available.
• Install a shut-off valve between the compressor and the compressed air network for maintenance purposes.
(2)
• The LT KE range compressors are fitted with a dedicated water/oil separator.
• LT KE compressors are fitted with a integrated non-return valve. No additional non return valve needs to
be installed.
Drain outlet (6)
• The drain outlet has a G 1/2” connection. It is recommended to connect this to a drain hole or drain pipe.
• The main drain pipe must be dimensioned that the pressure increase during draining will not cause overflow
of condensate through open end to atmosphere.

Following figure shows recommended ways of connecting the compressor to the air network.

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3.3 Electrical connections

Warning

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

Electric cabinet

Example of an electrical cubicle (DOL)

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Electrical diagrams

Electrical diagram with DOL starter

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Electrical diagram with star-delta starter

Reference Description
Q1 Main switch
Q2 Timer
K1 Main contactor
K1M Line contactor
K2M Delta contactor
K3M Star contactor
F1 Motor Overload relay
T1 Transformer
H1 Signal light, green
H2/3/4 Signal light, red
F2/3/4/5 Fuses
S1 Control switch
S2 Reset button
K2/3/4 Control relays
K5 Timer
h Hour-meter, running hours

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Reference Description
R1 Heat resistor
Y1 Solenoid valve
T Temperature switch
P Pressure switch
L Oil level switch

3.4 Pictographs

Pictographs

References on figure

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

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4 Operating instructions

4.1 Initial start-up

Following checks and actions should be taken at first start-up or after long period of standstill.

After long standstill

If the compressor has not run between 6 months and 1 year:
Check the lubrication of the compressor element:
• drain the compressor oil.
• refill the compressor with compressor lubrication RXD oil (ROTO XTEND DUTY) while turning the
crankshaft by hand.
If the compressor has not run for longer than 1 year:
Check the lubrication:
• drain the compressor oil, remove cylinder heads, lubricate cylinder liners with compressor lubrication oil.
• refit the cylinder heads, refill the compressor with new compressor lubrication oil (RXD) while turning
the crankshaft by hand.

Use only authorized oil. Any damage or malfunction caused by the use of unauthorized oil is not
covered by Warranty or Product Liability.

Check functioning of compressor safety valves.

Oil level check

LT compressors are filled with RXD compressor oil. Check that the oil level is still at the top of the red circle
of sight-glass.

Direction of rotation
For the LT 15 KE and LT 20 KE, it is mandatory to check direction of rotation.
Start compressor, and immediately stop it again. Check if rotation of motor (by checking fan rotation) is
corresponding to direction indicated by arrow on piston block

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or by the arrow on the fan housing.

If the rotation direction is wrong, switch off the voltage and reverse two of the input line connections.

Caution:
Running the compressor in the wrong direction of rotation can lead to possibly dangerous
situations. Always check the direction of rotation after maintenance work performed on the
unit.

Electrical check
1. Check the electrical installation, which must be in accordance with the instructions given in section
Electrical connections
2. Switch on the voltage. Start the motor.
3. Check the operation of the air pressure switch. See section Adjustment of pressure switch
4. Verify working of the solenoid valve by keeping piece of paper, cloth in flow path, or by spraying some
leak-finder on valve outlet before start-up.

4.2 Starting
1. On LT type KE, check the oil level, which must be at the top of the red circle of sight-glass (SG) in the
compressor block. The minimum level is the lower part of the red circle.
2. Move the switch (S1) on the control cabinet from "0" to position "manual" or "automatic".

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3. Open the air outlet valve (AV).

Regularly drain condensate

Important note:
When the compressor is operated on "manual", it is not controlled by the pressure
switch. Only use "manual" operation when operation personnel is present.

4.3 Stopping
LT electric motor driven unit Type KE
1. Turn the switch (S1) to position 0 (Off).
2. Close air outlet valve (AV)
3. Switch off the voltage.

4.4 Taking out of operation

At the end of the service life of the compressor, proceed as follows:
1. Switch off the voltage and disconnect the compressor from the mains.
2. Depressurize the compressor.
3. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the
compressor from the air net.

4.5 Storage

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5 Maintenance

5.1 Preventive maintenance schedule

The schedule contains a summary of the maintenance instructions. Read the respective section
before taking maintenance measures.
When servicing, replace all disengaged packing components, e.g. gaskets, O-rings, washers.
The "longer interval" checks must also include the "shorter interval" checks.

Period Running hours Operation Consult section See notes Preventive

below table maintenance
kit
Weekly Check oil level. Starting 1 -
Weekly Drain - -
condensate from
air receiver.
6-monthly Test safety valve Safety valve 2 -
and relief valve. Safety valve low
pressure
6-monthly Inspect air filter. Air filter 3/4 -
Yearly 500 Replace air filter. Air filter 3/4 2
Yearly 2000 Change oil. Lubrication of - 4
compressor
2000 Replace the Service kit - 5
mechanical
coupling and the
(drain-) solenoid
valve.
3000 to 4000 Replace check Check valve - 3
valve.
4000 On LT 3, LT 5, LT Valves - 1
15 and LT 20,
replace valve
discs.
5000 On LT 7 and LT Valves - 1
10, replace valve
discs.
Replace
mechanical
coupling.
Replace
solenoid valve.

Notes:
1. Maintain the level in the red circle of the sight-glass.
2. Wear gloves and safety glasses.

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3. For normal operation in clean surroundings. More frequently when operating in a dusty environment.

5.2 Lubrication of compressors

It is strongly recommended to use the RXD (ROTO XTEND DUTY) compressor oil to keep the compressor
in excellent operating condition.
Traditional lubricants cannot cope with the extreme conditions of piston compressors, resulting in a fast oil
degradation, overheating and potentially irreversible damage and high repair costs. Therefore, high
performing lubricants increase the equipment lifetime.
Considering the low oil content in piston compressors, often less than 2 liters, the economy of lesser quality
oils simply is not worth the risk.

5.3 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.

Example of typical service kits

References on figure

Reference Description
1 Valve kit
2 Filter kit
3 Check valve
4 Roto-Xtend Duty Fluid
5 Mechanical coupling kit

Other kits, not shown in figure.

Solenoid kit

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1. Use only authorized parts. Any damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty or Product Liability.
2. Whichever interval comes first. The local Sales Company may overrule the
maintenance schedule, especially the service intervals, depending upon the
environmental and working conditions of the compressor.
3. For the contents of all kits, consult the Parts list.

5.4 Disposal of used material

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

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6 Servicing and adjustment procedures

6.1 Check valve

Warning

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

It is recommended to replace the check valve as indicated in section Preventive maintenance schedule.
Dirt, condensate, coke formation and oxidation influence the proper operation of the valve. Depending on the
environmental and working conditions, the local Atlas Copco customer centre or authorized distributor may
overrule the maintenance schedule (consult Atlas Copco).

6.2 Servicing valves

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

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

Different parts of the cylinder heads

Reference Description
1 Air inlet silencer
2 Gasket
3 Spring
4 Outlet valve guard
5 Outlet valve disc
6 Valve seat
7 Inlet valve disc
8 Guide pin
9 O-ring
10 O-ring
11 O-ring
12 Cylinder head cover
13 Cylinder cap
14 O-ring

Replacing valve discs

1. Depressurize and disconnect from piping.

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2. Remove the fan guard, unscrew the cap and remove the cover, air inlet filter and cover of the air inlet
silencer (1).
3. Disconnect cylinder cap (13) from the inlet and outlet pipe flanges. Remove cylinder head cover (12).
Remove cylinder cap (13).
4. Remove spring (3), outlet valve guard (4) and outlet valve disc (5).
5. Lift off valve seat (6) and remove inlet valve disc (7). Do not remove guide pins (8).
6. Remove and discard all O-rings.
7. If necessary, remove the carbon deposits from the inlet valve guard at the cylinder top. Take care that no
dirt drops into the cylinder.
8. Clean and inspect all parts.
9. Fit a new O-ring (11). Do not stretch the cord while inserting it in its groove; the ends should meet.
10. Put a new inlet valve disc (7) into place and install valve seat (6).
11. Fit new O-rings (9 and 10).
12. Install a new outlet valve disc (5), guard (4) and spring (3).
13. Reinstall cylinder cap (13). Fit a new joint (14). Install cylinder head cover (12). Fit new O-rings/gaskets
(2) for the pipe flanges. Fit the flange and cylinder head bolts and tighten them alternately.
14. Reinstall the fan guard, cover of the air inlet silencer, air filter, cover (1) and cap.
Tightening torque values

Thread size Tightening torque (Nm) Allowed deviation (Nm)

Strength class 8.8
M6 10.1 ±1
M8 24.3 ±2.4
M10 48.2 ±5
Strength class 10.9
M6 14.2 ±1.4
M8 34.2 ±3.4
M10 67.8 ±7

6.3 Servicing air inlet filter

To replace the air filter, follow these steps:

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Reference Description
1 Cap
2 Cover
3 Air inlet silencer
AF Air inlet filter

1. Stop the compressor.

2. Unscrew the cap (1) on top of the cover (2). Lift off the filter cover and remove the air inlet filter (AF).
Take care that no dirt drops inside the air inlet silencer (3).
3. Using a damp cloth, clean the filter chamber and cover. Discard damaged elements.
4. Install the new element, cover and cap.

6.4 Adjustment pressure switch

Function
Note: The compressor has been tested at manufacturer's works. The settings of the control
system are set at the correct values.
The adjustment of the maximum or stopping pressure of the compressor is effected by means of the air pressure
switch. The switch also controls the pressure difference between the maximum pressure (stopping pressure)
and the pressure at which compression is resumed (starting pressure).
.

Adjustment

• Adjust the air pressure switch while it is pressurized.

• Switch off the voltage before removing the cover of the switch; reinstall it after an
adjustment has been made and before the voltage is switched on again.
• Maximum allowable unit working pressure is 30 bar.

Remove the cover. Loosen the locking screw (5).

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The maximum or stopping pressure is controlled by adjusting spindle (1). Turn

the screw clockwise to raise the maximum or stopping pressure, counter-clockwise
to lower it. The pressure can be read on scale (2).

The pressure difference is adjusted by means of spindle (3). To reduce the

difference between the stopping and starting pressures, i.e. to increase the starting
pressure, turn the screw clockwise. To increase the pressure difference, turn the
screw counter-clockwise. The pressure difference can be read on scale (4).

After adjustment, fasten and seal the locking screw (5) and re-install the cover.

Note: It is recommended to set the differential in such way that the minimum pressure does
not drop below 2 bar.
Note: starting pressure = stopping pressure - pressure difference.

6.5 Adjustment temperature switch

Function
Note: The compressor has been tested at manufacturer's works. The settings of the control
system are set at the correct values.
The adjustment of the alarm-setting is effected by means of changing the air temperature switch setting.

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Adjustment

Adjustment shall only be carried out by authorised, competent, trained personnel.

Switch off the voltage before removing the cover of the switch; reinstall it after an adjustment
has been made and before the voltage is switched on again.

Remove the cover. Unscrew locking screw (5).

Adjust the switch setting with screw (1). Turn the screw clockwise to raise the switch setting, counter-
clockwise to lower it. The temperature can be read on scale (2).
The temperature difference (switch-off setting) is adjusted by means of screw (3). To reduce the difference,
i.e. increase the temperature alarm switch off value, turn the screw clockwise. To increase the difference, turn
the screw counter-clockwise. The temperature difference can be read on scale 4.
After adjustment, fasten and seal the locking screw (5) with threadlocker and re-install the cover.

Note: temperature alarm switch setting-off value = (temperature switch setting –

temperature difference)

6.6 Servicing safety valve

Always wear safety glasses and ear protection.

6.7 Safety valve low pressure

The safety valve (SV1) protects the LP side of the compressor. No adjustment is allowed.
Testing: Testing as described below shall only be carried out by competent personnel.
Wear safety glasses and ear protection.

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Position of safety valves.

Remove the safety valve (SV1) and fit a G 1/4" plug instead. Remove the safety valve from the air receiver
and replace it by the valve from the compressor. The latter can then be tested at increasing air receiver pressure
after the compressor has been started with the open air outlet valve. If the valve has not opened at the pressure
specified in section Compressor data, it must be replaced by a new one. Lock the safety valve with small
quantities of pipe sealant to prevent blocking the orifice. Reinstall the valves in their respective places after
testing.

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7 Problem solving
Problem
Insufficient air pressure
Unit does not speed up
Relief valve blows
Too frequent starting/too short
operating periods
High oil consumption on compressors
Unit does not start
Overload relay cuts out
2920 7092 60
Fault
Air leak
Air consumption exceeds Check equipment connected.
maximum output of compressor
Damaged valve
Voltage drop at motor terminals Check the power supply. Use
correct size of cable.
Defective inlet valve in HP
cylinder head
Relief valve not airtight
Check valve leaks
Oil level too high
Piston ring(s) worn or broken
Electrical failure
Overload relay cuts out
Overload relay incorrectly set
Ambient temperature too high
Over-current due to motor or
compressor failure
Remedy
Check and correct as
necessary.
Inspect valves and replace
parts where necessary.
Inspect and replace part(s) as
necessary.
Replace valve.
Check for broken valve and
springs.
Do not overfill crankcase. Keep
level in red circle of sight-glass.
Have condition of piston rings
checked.
Have electrical system
checked. Check fuses and line
terminals for tightness.
Reset overload relay. If the
relay cuts out again after
starting, see "Overload relay
cuts out".
Check and adjust. Reset relay.
Consult Atlas Copco.
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 Instruction book

8 Technical data

8.1 Electric cable size

Important warning

To preserve the protection degree of the electric cubicle and to protect its components
from dust from the environment, it is mandatory to use a proper cable gland when
connecting the supply cable to the compressor.

• The voltage on the compressor terminals must not deviate more than 10% of the
nominal voltage.
It is however highly recommended to keep the voltage drop over the supply cables at
nominal current below 5% of the nominal voltage (IEC 60204-1).
• Use the original cable entry. See section Dimension drawings.
• Local regulations remain applicable if they are stricter than the values proposed below.

Supply Cables calculation IEC

For IEC designed control panels, the below suggested cable sections are calculated according to 60092,
electrical installations in ships.
For these electrical installations in ships, the following reference methods of IEC 60364-5-52 (electrical
installations in buildings) are considered applicable.

Table A.52-4 (52-C3) - Current-carrying capacities in amperes for methods of installation in table A.
52-1 (52-B1) -
PVC insulation / three loaded conductors / copper.
Conductor temperature: 70° C / Ambient temperature: 30° C in air, 20° C in ground.
Temp conversion for 45° C, 50° C and 55° C.

Installation methods of table A.52-1

B2
Multi-core cable in conduit on a wooden wall.

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Method B2
Ambient temp. 30° C Ambient temp. 45° C Ambient temp. 50° C Ambient temp. 55° C
Amps Cable size Amps Cable size Amps Cable size Amps Cable size
mm² mm² mm² mm²
<15 1,5 <12 1,5 <11 1,5 <9 1,5
<20 2,5 <16 2,5 <14 2,5 <12 2,5
<27 4 <21 4 <19 4 <16 4
<34 6 <27 6 <24 6 <21 6
<46 10 <36 10 <33 10 <28 10

Installation methods of table A.52-1

C
Single-core or multi-core cable on a wooden wall.

Method C
Ambient temp. 30° C Ambient temp. 45° C Ambient temp. 50° C Ambient temp. 55° C
Amps Cable size Amps Cable size Amps Cable size Amps Cable size
mm² mm² mm² mm²
<17 1,5 <14 1,5 <12 1,5 <11 1,5
<24 2,5 <19 2,5 <17 2,5 <15 2,5
<32 4 <25 4 <23 4 <20 4
<41 6 <32 6 <29 6 <25 6
<57 10 <45 10 <40 10 <35 10

Table A.52-10 (52-C9) - Current-carrying capacities in amperes for installation methods F of table A.
52-1 (52-B1) -
PVC insulation / copper conductors
Conductor temperature: 70° C / Ambient temperature: 30° C
Temp conversion for 45° C, 50° C and 55° C.

Installation methods of table A.52-1

F
Single-core cables, Three loaded conductors trefoil.

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Method F
Ambient temp. 30° C Ambient temp. 45° C Ambient temp. 50° C Ambient temp. 55° C
Amps Cable size Amps Cable size Amp Cable size Amps Cable size
mm² mm² s mm² mm²
<110 25 <87 25 <78 25 <67 25
<137 35 <108 35 <97 35 <84 35
<167 50 <132 50 <119 50 <102 50

Fuse calculationsIEC are done according to 60092, electrical installations in ships, where the following
reference methods of IEC 60364 (electrical installations in buildings) are considered applicable.
Fuse calculations for IEC are done according to 60364-4-43 electrical installations of buildings, part 4:
protection for safety- section 43: protection against overcurrent. Fuse sizes are calculated in order to protect
the cable against short circuit. Fuse type aM is recommended but gG/gL is also allowed.

8.2 Settings for overload relay and fuses

Overload relay and fuses

Voltage Freq. Starting Max fuse Overload Supply

method setting ** setting cable Imax
(V) (Hz) (A) (A) (A)
LT 3 400 50 DOL 16 7,2 9,2
440-460 60 DOL 16 7 9
690 60 DOL 10 4,7 6,7
LT 5 400 50 DOL 16 9 11,0
440-460 60 DOL 16 9 11,0
690 60 DOL 10 5,7 7,7
LT 7 400 50 DOL 20 12,5 14,5
440-460 60 DOL 20 12,3 14,3
690 60 DOL 16 8,3 10,3
LT 10 400 50 DOL 25 17,3 19,3
LT 15 400 50 DOL 32 24,2 26,2
440-460 60 DOL 32 23,7 25,7
690 60 DOL 20 15,7 17,7
400 50 Y/D 32 14 26,2
440-460 60 Y/D 32 13,7 25,7
LT 20 400 50 DOL 40 32,8 34,8
440-460 60 DOL 40 31,4 33,4
690 60 DOL 25 19 21,0
400 50 Y/D 40 18,9 34,8
440-460 60 Y/D 40 18,1 33,4

** Fuse type gL/gG (slow blow)

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Other connections
For connection of:
• Air pressure switch
• Solenoid valve
• Air temperature switch
• Oil level switch
use at least 0,75 mm2 wire section.

8.3 Reference conditions

8.4 Limitations
Limitation Unit Value
Maximum effective working bar(e) 30
pressure
Maximum effective working bar(g) 1
pressure for unloading valve
Maximum inlet temperature ºC 50
Minimum inlet temperature °C 0

8.5 Compressor data

50 Hz

Compressor data Unit LT 3 KE LT 5 KE LT 7 KE LT 10 LT 15 LT 20

KE KE KE
Free air delivery (note 1) l/s 2.5 4.4 6.4 8.5 9.3 17.0
Specific main shaft requirement J/l 840 841 806 794 733 794
Mean sound pressure level (note 2) dB(A) 79 79 80 81 85 86
Air temperature, leaving low pressure °C 86 130 117 149 165 180
cylinder head, approximately
Air temperature, leaving high pressure °C 91 148 148 168 145 160
cylinder head, approximately
Maximum compressed air temperature at °C 49 60 42 58 52 98
outlet pipe
Shaft power input (note 1) kW 2.83 4.73 6.11 7.89 8.5 15.7
Oil capacity l 0.8 0.8 1.4 1.4 5.4 5.4
Opening pressure of safety valve high bar(e) 31 31 31 31 31 31
pressure
Opening pressure of safety valve low bar(e) 6.5 6.5 6.5 6.5 6.5 6.5
pressure

60 Hz

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Compressor data Unit LT 3 KE LT 5 KE LT 7 KE LT 15 KE LT 20 KE

Free air delivery (note 1) l/s 3.1 5.5 8 11.1 19.7
Specific main shaft requirement J/l 840 841 806 759 832
Mean sound pressure level (note 2) dB(A) 81 81 82 89 88
Air temperature, leaving low pressure °C 92 140 126 110 171
cylinder head, approximately
Air temperature, leaving high pressure °C 98 158 163 110 171
cylinder head, approximately
Maximum compressed air temperature at °C 53 65 49 55 105
outlet pipe
Shaft power input (note 1) kW 3.44 5.77 7.63 9.57 18.53
Oil capacity l 0.8 0.8 1.4 5.4 5.4

Opening pressure of safety valve high bar(e) 31 31 31 31 31

pressure
Opening pressure of safety valve low bar(e) 6.5 6.5 6.5 6.5 6.5
pressure

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9 Declaration of conformity

Typical example of a Declaration of Conformity document

(1): Contact address:

Atlas Copco Airpower n.v.
P.O. Box 100
B-2610 Wilrijk (Antwerp)
Belgium

2920 7092 60 47
In order to be First in Mind—First in Choice® for all your quality
compressed air needs, Atlas Copco delivers the products and
services that help to increase your business’ efficiency and
profitability.
Atlas Copco's pursuit of innovation never ceases, driven by our
need for reliability and efficiency. Always working with you, we are
committed to providing you the customized quality air solution that
is the driving force behind your business.

No. 2920 7092 60 / 2011 - 02 - Printed in Belgium

www.atlascopco.com