Manual OSC Manual
Manual OSC Manual
OSC 145
AIF999999
Instruction book
Atlas Copco
            OSC 145
            AIF999999
            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.
2012 - 11
www.atlascopco.com
                                                                                                                                 Instruction book
Table of contents
1 Safety precautions..........................................................................................................3
2 General description........................................................................................................6
2.1 INTRODUCTION...................................................................................................................................6
2.2 OPERATION.......................................................................................................................................6
3 Installation.....................................................................................................................11
4 Operating instructions.................................................................................................14
5 Maintenance..................................................................................................................15
5.1 MAINTENANCE.................................................................................................................................15
5.5 OPTIONS........................................................................................................................................21
6 Problem solving............................................................................................................22
7 Technical data...............................................................................................................23
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1 Safety precautions
Explanation
Warning
Important note
                            Also consult following safety precautions: Safety precautions during operation and Safety
                            precautions during maintenance or repair.
                            These precautions apply to electrical devices.
                            For precautions applying to the connected equipment consult the relevant instruction book.
                            Some precautions are general and cover several machine types and equipment; hence
                            some statements may not apply to your device.
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      1. 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.
      2. Never operate the device in the presence of flammable or toxic fumes, vapours or particles.
      3. Never operate the device below or in excess of its limit ratings.
      4. Do not operate the device when there are flammable or toxic fumes, vapors or particles.
      5. Keep all bodywork doors and panels closed during operation. The doors may be opened for short periods
         only, e.g. to carry out routine checks.
      6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
         shall wear ear protectors.
      7. Periodically check that:
         • All guards and fasteners are in place and tight
         • All hoses and/or pipes are in good condition, secure and not rubbing
         • There are no leaks
         • All electrical leads are secure and in good order
      8. Never remove or tamper with the safety devices.
                          Also consult following safety precautions: Safety precautions during installation and
                          Safety precautions during maintenance or repair.
                          These precautions apply to electrical devices.
                          For precautions applying to the connected equipment consult the relevant instruction book.
                          Some precautions are general and cover several machine types and equipment; hence
                          some statements may not apply to your machine.
      1. Use only the correct tools for maintenance and repair work.
      2. Use only genuine spare parts.
      3. A warning sign bearing a legend such as "Work in progress - do not start" shall be attached to the starting
         equipment, including all remote start equipment.
      4. 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.
      5. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
         toxic vapours of cleaning liquids.
      6. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
         and exposed openings with a clean cloth, paper or tape.
      7. Never use a light source with open flame for inspecting the interior of the device.
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        8. 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.
        9. Before clearing the device for use after maintenance or repair, 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.
       10. Make sure that no tools, loose parts or rags are left in or on the device.
       11. Never use caustic solvents which can damage materials of the device.
                            Also consult following safety precautions: Safety precautions during installation and Safety
                            precautions during operation.
                            These precautions apply to electrical devices.
                            For precautions applying to the connected equipment consult the relevant instruction book.
                            Some precautions are general and cover several machine types and equipment; hence
                            some statements may not apply to your machine.
                            Units and/or used parts should be disposed of in an environmentally friendly and safe
                            manner and in line with the local recommendations and legislation.
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2 General description
2.1 Introduction
      Compressed air produced by oil-injected compressors contains a small quantity of oil. During the cooling of
      the air in the aftercooler and in the refrigeration dryer (on compressors with built-in refrigeration dryer), oil-
      containing condensate is formed.
      OSC are condensate treatment devices, designed to separate the major part of this oil from the condensate
      and absorb it in filters.
      They are insensitive to shocks and vibration because of the use of filters and can be used with all types of
      drains. The condensate meets the requirements of the environmental codes.
      The number in the model designation is the air capacity of the compressor in litres per second (see section
      Technical data).
      OSC 35 up to OSC 145 have two towers and are called two-step units.
      OSC 355 up to OSC 1200 have three towers and are called three-step units.
      OSC 2400 have six towers. They consist of two three-step units.
2.2    Operation
      OSC 35 up to OSC 145:
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OSC 145
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    1                    Condensate inlet
    2                    Service indicator (oleophilic filter)
    3                    Mufflers
    4                    Oleophilic filter
    5                    First tower
    6                    Condensate outlet
    7                    Activated carbon filter
    8                    Second tower
    9                    Protector
    The condensate, containing fine oil droplets, enters the unit via mufflers (3) and is depressurised. The
    condensate flows to the first tower and seeps through an oleophilic filter (4), which absorbs most of the oil.
    The water from the first tower, still containing a small quantity of oil, gradually flows to a second tower (8),
    where an activated carbon filter (7) is fitted. This filter absorbs almost all of the remaining oil.
    The clean condensate is drained to the condensate outlet (.
    The oleophilic filter floats on the water. The more oil the filter absorbs, the deeper it will sink, and service
    indicator (2) will move downwards with the filter. The filter must be replaced when the service indicator is
    down.
    OSC 355 up to OSC 2400:
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OSC 355
        The condensate, containing fine oil droplets, enters the unit via mufflers (5) and is depressurised. The
        condensate flows to the first tower and seeps through an oleophilic filter, which absorbs most of the oil.
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     The water from the first tower, still containing a small quantity of oil, gradually flows to a second tower (9),
     where two filters are fitted: a small oleophilic filter, which absorbs some more oil from the condensate, and
     an activated carbon filter (7). The activated carbon filter starts to absorb the remaining oil in the condensate.
     The condensate gradually flows to a third tower (10), where another activated carbon filter is fitted, which
     absorbs almost all of the remaining oil.
     The clean condensate is drained to the condensate outlet (1).
     The oleophilic filter floats on the water. The more oil the filter absorbs, the deeper it will sink, and service
     indicator (2) will move downwards with the filter. The filter must be replaced when the service indicator is
     down.
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3 Installation
                       OSC 35    OSC 95     OSC 145 OSC 355 OSC 600 OSC 825 OSC 1200   OSC 2400
         A (mm)        470       680        680     750     750         945    945     945
         B (mm)        165       255        255     546     546         650    695     1185
         C (mm)        745       940        940     1100    1330        1450   1450    1450
         Shipping      4         13         15      25      26          28     30      60
         weight (kg)
         Operating     16        51         53      80      103         151    164     324
         weight (kg)
         Model                                             Connections
                                Inlet                              Outlet
                                BSP/NPT                            BSP/NPT
                                1 x 1/2 "                          1 x 1/2 "
                                2 x 1/2 "                          1 x 1/2 "
         OSC 145                2 x 1/2 "                          1 x 1/2 "
                                2 x 3/4 "                          1 x 3/4 "
                                2 x 3/4 "                          1 x 3/4 "
                                2 x 3/4 "                          1 x 3/4 "
                                2 x 3/4 "                          1 x 3/4 "
                                2 x 3/4 "                          1x1"
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      Reference             Description
      1                     Service indicator (unit clogged)
      2                     Condensate inlet
      3                     Service indicator (oleophilic filter)
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         Reference                      Description
         4                              Condensate outlet
         5                              Tower 1
         6                              Tower 3
         7                              Tower 2
         8                              Diffuser
         9                              Condensate outlet (test)
         10                             Protector
         A                              Housing part 1
         B                              Housing part 2
Procedure
       1. Install the OSC on a level floor, suitable for taking its weight.
          Keep in mind to reserve sufficient free space for replacement of the filters (see section Maintenance).
       2. On OSC 355 and OSC 600:
          If the three towers stand in one line, rotate the third tower to the front.
                        It is possible to operate the unit with the three towers in line. However, it is recommended to
                        rotate the third tower as described above for easy change of the activated carbon filter in the
                        third tower. When the unit is operated with the towers in line, they have to be rotated in order
                        to change the filter. Keep in mind that the unit in operation can be heavy. (See the operating
                        weight in section Dimension drawing).
       3. Stop the compressor and close the air outlet valve. Switch off the voltage. Depressurise the outlet piping
          by opening the manual condensate drain.
       4. Connect the automatic drain of the compressor condensate trap to the condensate inlet of the OSC.
          The connection can be made using one or both condensate inlets. The piping diameter must be at least 6
          mm . The flexible must be laid out in such a way that no pockets are formed where condensate can collect.
       5. Connect the condensate outlet of the OSC to the sewer.
          The outlet piping should have a section, sufficient to allow the condensate to flow without building up
          pressure. An inner diameter of 19 mm (3/4 ") or larger is recommended. See section Dimension
          drawing for the connection dimensions.
                        The OSC must be positioned higher than the sewer and the OSC outlet piping must be
                        installed with a slight downward slope to the sewer.
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4 Operating instructions
Procedure
      OSC 35 up to OSC 145:
      1. Remove the lid of the first tower. Take out the oleophilic filter.
      2. Remove the lid of the second tower and take out the activated carbon filter. Remove the plastic bag and
         put the filter back. Check that the top of the filter is just below the condensate outlet. If not, check that the
         filter is resting on the flow plate.
      3. Pour clean water into the unit until the water comes out of the condensate outlet.
      4. Put the oleophilic filter on the water surface in the first tower. Do not push the filter down.
      5. Put back the lids.
      OSC 355 up to OSC 1200:
      1. Remove the lids. Take the oleophilic filter out of the first tower.
      2. Remove the plastic bag from the activated carbon filter in the third tower. Put the filter back and check
         that the top of the filter is just below the condensate outlet. If not, check that the filter rests on the bottom
         of the vessel.
      3. Take the small oleophilic filter and the activated carbon filter out of the second tower. Remove their bags.
         First put back the activated carbon filter, then the small oleophilic filter. Fit the lid and check that the
         service indicator is free to move.
      4. Pour clean water into the unit until the water comes out of the condensate outlet.
      5. Put the oleophilic filter back on the water surface of the first tower. Do not push the filter down.
      6. Refit the lids.
      OSC 2400:
      The steps in section OSC 355 up to OSC 1200 must be done for the left side and for the right side.
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5 Maintenance
5.1      Maintenance
                         Check the filters regularly as explained below in order to prevent untreated condensate from
                         entering the sewer.
                         Sample the condensate weekly.
                          • If the filters are not installed properly, oil-containing condensate can leave the OSC.
                          • When new activated carbon filters are placed, the outgoing water may initially look black
                              (caused by carbon dust). This is not harmful.
                          • Each new filter is provided with a label. The correct position is marked on the label.
                          • Used filters can be heavy.
                          • See to it that no condensate comes into contact with eyes, mouth, …
Oleophilic filter
                         If the activated carbon filter has to be replaced, do this first (see section Activated carbon
                         filters).
        Initially, the oleophilic filter will float almost completely on the condensate and only the bottom part will act
        as filtration medium. By sorbing more and more oil, the filter will sink and new filter material will be exposed
        to the condensate.
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       The filter must be replaced when the service indicator (see section Introduction) approaches the lid of the
       tower.
       The lifetime of the filter depends on the amount of oil in the condensate.
       Replacement instructions
      1. Stop the compressor and close the air outlet valve. Switch off the voltage. Depressurise the outlet piping
         by opening the manual condensate drain.
      2. Remove the lid of the first tower and take out the oleophilic filter (4 - Flow diagram of OSC 35 up to OSC
         145). On OSC 355 up to OSC 1200, remove also the lid of the second tower and remove also the small
         oleophilic filter (6 - View of OSC 355).
      3. Only if necessary (see Problem solving, item 1), clean the inside of the OSC with water and tissue.
         Do not use any form of soap or detergents as they could contain dispersants which deteriorate the ability
         to break oil/water emulsions.
      4. Fit the new filter (white label), observing the position. Do not push the filter below the water surface.
      5. Fit the lid(s).
      6. Remove the diffuser and pull out the mufflers. See section Introduction.
      7. Fit the new mufflers and diffuser.
       On OSC 2400: Repeat the instructions for OSC 355 up to OSC 1200 once for the left side of the unit and
       once for the right side of the unit.
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        Atlas Copco has a complete range of service kits available. Service kits comprise all parts needed for servicing
        components and offer the benefits of using genuine Atlas Copco parts while keeping the maintenance budget
        low.
Service kits
                                           Part Number
         Service kit A                     2901 1400 00
         Service kit B                     2901 1400 01
         Service kit D                     2901 1575 00
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                                  Part Number
     Service kit A                2901 1401 00
     Service kit B                2901 1401 01
     Service kit D                2901 1576 00
                                  Part Number
     Service kit A                2901 1403 00
     Service kit B                2901 1403 01
     Service kit D                2901 1578 00
                                  Part Number
     Service kit A                2901 1404 00
     Service kit B                2901 1404 01
     Service kit D                2901 1579 00
                                  Part Number
     Service kit A                2901 1408 00
     Service kit B                2901 1408 01
     Service kit D                2901 1581 00
                                  Part Number
     Service kit A                2901 1409 00
     Service kit B                2901 1409 01
     Service kit D                2901 1582 00
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                                          Part Number
         Service kit A                    2901 1410 00
         Service kit B                    2901 1410 01
         Service kit D                    2901 1583 00
        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.
Spare parts
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5.5      Options
        Alarm
        Optional electronic alarm sensors are available warning the operator for condensate overflow and filter
        replacement.
        Manifold
        An optional manifold is available for easy connection of several condensate lines into the unit.
        Anti-bacteria kit
        An optional anti-bacteria kit is available to prevent the growth of bacteria in the unit.
        Anti-freezing kit
        An optional heater kit is available to prevent the condensate from freezing.
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6    Problem solving
     Condition               Fault                  Remedy
     A lot of oil entered the Compressor            Replace all filters. Clean the vessels. Check the compressor.
     OSC.                     malfunctioning
     The service indicator   Too much condensate Check the compressor FAD (see section Technical data).
     (3 - View of OSC 52)    flows into the OSC.
     rises
                             The unit is clogged.   Replace the activated carbon filters. Check the flexible
                                                    between the first and the second tower.
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7 Technical data
Reference conditions
Compressor FAD
         Models                                               OSC
                                                              145
         Cold climate       l/s          65         180       270    665       1150     1550       2220     4440
         Mild climate       l/s          35         95        145    355       605      825        1180     2360
         Hot climate        l/s          17         45        70     170       290      400        570      1145
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       Models                                               OSC
                                                            145
       Cold climate        l/s          105       280       415      1035      1800      2410      3450         6895
       Mild climate        l/s          45        118       175      435       760       1020      1455         2910
       Hot climate         l/s          20        50        75       190       330       440       630          1260
Correction factors
      For operation in other than reference conditions, multiply the compressor capacity (FAD) with the appropriate
      correction factors.
Separation performance
      For an outlet oil carry-over of 10 mg/l instead of 15 mg/l, multiply the unit capacity by 2/3.
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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
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committed to providing you the customized quality air solution that
is the driving force behind your business.
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