Atlas Copco Oil-injected rotary screw compressors GA 7 VSD+, GA 11 VSD+, GA 15 VSD+ Instruction book
Atlas Copco Oil-injected rotary screw compressors GA 7 VSD+, GA 11 VSD+, GA 15 VSD+ From following serial No. onwards: API 250 000 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.
Instruction book Table of contents 1 Safety precautions..........................................................................................................5 1.1 SAFETY ICONS...................................................................................................................................5 1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................5 1.3 SAFETY PRECAUTIONS DURING INSTALLATION..........
Instruction book 3.13 MODIFYING GENERAL SETTINGS...........................................................................................................49 3.14 INFO MENU......................................................................................................................................51 3.15 WEEK TIMER MENU...........................................................................................................................52 3.16 TEST MENU...................................
Instruction book 8 Technical data.............................................................................................................105 8.1 READINGS ON DISPLAY....................................................................................................................105 8.2 ELECTRIC CABLE SIZE AND FUSES......................................................................................................106 8.3 REFERENCE CONDITIONS AND LIMITATIONS....................................
Instruction book 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.
Instruction book 1.3 Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution 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.
Instruction book 16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touched by personnel in normal operation must be guarded or insulated. Other high temperature piping must be clearly marked. 17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure. 18.
Instruction book • Air cooling filters of the electrical cabinet are not clogged 9. 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. 10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria. 11.
Instruction book 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 vapour 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.
Instruction book 2 General description 2.1 Introduction Introduction GA 7 VSD+ up to GA 15 VSD+ are single-stage, oil-injected screw compressors driven by an interior permanent magnet motor (IPM). The compressors are controlled by the Atlas Copco Elektronikon® Graphic regulator (ER). The regulator is fitted to the front panel. An electric cabinet (1) comprising fuses, transformers, relays, etc. is located behind this panel. The compressors use (Variable Speed Drive) technology.
Instruction book Open side view, GA VSD+ Workplace GA Workplace Full-Feature The Workplace Full Feature compressors have an air dryer which is integrated in the sound-insulated bodywork. The dryer removes condensate from the compressed air by cooling the air to near freezing point.
Instruction book Front view, GA VSD+ Workplace Full-Feature Open side view, GA VSD+ Workplace Full-Feature 12 Reference Name AF Air filter AR Air receiver 2920 7109 21
Instruction book Reference Name AV Air outlet Ca Air cooler Co Oil cooler Da Automatic condensate outlet Dm Manual condensate outlet DR Refrigerant dryer E Compressor element ED Electronic water drain ER Elektronikon® Graphic controller FN Cooling fan IPM Drive motor OF Oil filter OS Oil separator S3 Emergency stop button 1 Electric cabinet 2920 7109 21 13
Instruction book 2.
Instruction book GA 7 VSD+ and GA 15 VSD+ Workplace Full-Feature Reference Description A Air inlet B Air/oil mixture C Oil D Wet compressed air E Condensate 2920 7109 21 15
Instruction book Reference Description F Dry compressed air (Full-Feature) Air flow Air comes in through filter (AF) and inlet valve (IV) and is compressed in the compressor element (E). A mixture of compressed air and oil flows into the air receiver/oil separator (AR). The air flows through the minimum pressure valve (Vp), the air cooler (Ca) and the condensate trap (MT) to the outlet valve (AV).
Instruction book Location of electronic water drain (Workplace) Location of electronic water drain (Workplace Full-Feature) The water in the air condenses in the collector of the air cooler. When the condensate comes to a certain level, it drains through the automatic drain outlet (Da). The water in the air condenses in the separator of the heat exchanger/evaporator. When the condensate comes to a certain level, it drains through the automatic drain outlet (Da).
Instruction book Electronic water drain (ED), typical example Test the electronic water drain. Press the test button (2) on top of the device. 2.4 Regulating system Description If the air consumption is less than the air output of the compressor, the net pressure increases. When the net pressure is higher than the set-point (desired net pressure), the regulator decreases the motor speed. If the net pressure increases and the motor operates at minimum speed, the regulator stops the motor.
Instruction book Electric cabinet, typical example Reference Designation T1 Transformer Q15 Circuit breaker Q1 Circuit breaker K15 Contactor Z1 EMC filter U1 Frequency converter Electrical diagrams You find the complete electrical diagram inside the electric cabinet.
Instruction book 2.
Instruction book This causes the air to cool further close to the evaporating temperature of the refrigerant. More water in the air condenses. The cold air flows through the separator (3) where all the condensate gets out of the air. The condensate is automatically drained through the outlet (4). The outgoing, cold, dried air flows through the heat exchanger (1) where it is warmed up by the incoming compressed air.
Instruction book 3 Elektronikon® Graphic controller 3.
Instruction book Protecting the compressor Shut-down Several sensors are provided on the compressor. If one of the measured signals exceeds the programmed shutdown level, the compressor will be stopped. This will be indicated on display (1) and general alarm LED (2) will blink. Remedy the trouble and reset the message. See also the Inputs menu. Before remedying, consult the applicable safety precautions. Shut-down warning A shut-down warning level is a programmable level below the shut-down level.
Instruction book 3.2 Control panel Elektronikon regulator Control panel Parts and functions 24 Reference Designation Function 1 Display Shows the compressor operating condition and a number of icons to navigate through the menu. 2 Pictograph Automatic operation 3 Pictograph General alarm 4 Alarm LED Flashes in case of a shut-down, is lit in case of a warning condition.
Instruction book 3.3 Icons used Status icons Name Icon Description Stopped / Running When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating.
Instruction book Name Icon Active protection functions Description Emergency stop Shutdown Warning Service Service required Main screen display Value lines display icon Chart display icon General icons No communication / network problem Not valid Input icons Icon Description Pressure Temperature Digital input Special protection 26 2920 7109 21
Instruction book System icons Icon Description Compressor element (LP, HP, ...
Instruction book Icon Description Settings Service Event history (saved data) Access key / User password Network Setpoint Info Navigation arrows Icon Description Up Down 28 2920 7109 21
Instruction book 3.4 Main screen Control panel (1) Scroll keys (2) Enter key (3) Escape key Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed. Typically, 5 different main screen views can be chosen: 1. 2. 3. 4. 5.
Instruction book Text on figures (1) Compressor Outlet (2) Flow (3) Load, shutdown, ... (text varies upon the compressors actual condition) (4) Menu (5) Unload, ES,...(text varies upon the compressors actual condition) Typical Main screen (4 value lines) Text on figures (1) Compressor Outlet (2) Flow (3) Off, Shutdown,... (text varies upon the compressors actual condition) (4) Menu (5) Running hours (6) Element outlet (7) Load, Unload, ...
Instruction book • Section D shows the Action buttons. These buttons are used: • To call up or program settings • To reset a motor overload, service message or emergency stop • To have access to all data collected by the regulator The function of the buttons depends on the displayed menu.
Instruction book When the Chart (Low Resolution) is selected, the chart shows the variation of the selected input per day. The screen shows the evolution over the last 10 days. Selection of a main screen view To change between the different screen layouts, select the far right icon in the control icons line (see value lines display icon or chart display icon in section Icons used) and press the Enter key. A screen similar to the one below opens: Select the layout required and press the Enter key.
Instruction book 3.5 Calling up menus Control panel Control panel (1) Scroll keys (2) Enter key (3) Escape key Description When the voltage is switched on, the main screen is shown automatically (see section Main screen): Typical Main screen (2 value lines) • To go to the Menu screen, select
Instruction book • The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings (Regulation) icon is selected. The status bar shows the name of the menu that corresponds with the selected icon. • Use the Scroll keys to select an icon. • Press the Escape key to return to the Main screen. 3.
Instruction book Procedure Starting from the main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on image (1) Menu (2) Regulation • Using the Scroll keys, move the cursor to the Inputs icon (see above, section Menu icon). • Press the Enter key.
Instruction book The first item in the list is highlighted. In this example, the Net Pressure is selected (chart icon). To change, press the Enter button again: a pop-up window opens: Press Enter again to remove this input from the chart. Another confirmation pop-up opens: Select Yes to remove or No to quit the current action.
Instruction book (1): Set as main chart signal 3.7 Outputs menu Control panel (1) Scroll keys (2) Enter key (3) Escape key Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact (on air cooled compressors), the Emergency stop contact, etc. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key.
Instruction book (1) Menu (2) Regulation • Move the cursor to the Outputs icon (see above, section Menu icon, using the Scroll keys. • Press the Enter key. A screen similar to the one below appears: Outputs screen (typical) Text on image (1) Outputs (2) Fan motor contact (3) Blow-off contact (4) General shutdown (5) Automatic operation • The screen shows a list of all outputs with their corresponding icons and readings.
Instruction book (1) Scroll keys (2) Enter key (3) Escape key Menu icon, Counters Function To call up: • • • • • The running hours The loaded hours The number of motor starts The number of hours that the regulator has been powered The number of load cycles Procedure Starting from the Main screen (see Main screen), • Move the cursor to the action button Menu and press the Enter key.
Instruction book (1) Counters (2) Running hours (3) Motor starts (4) Load relay (5) VSD 1-20 % rpm in % (the percentage of the time during which the motor speed was between 1 and 20 %) (compressors with frequency converter) The screen shows a list of all counters with their actual readings. 3.9 Control mode selection Control panel (1) Scroll keys (2) Enter key (3) Escape key Function To select the control mode, i.e.
Instruction book Next, use the scroll buttons to go to the regulation icon (2) and press the enter button: There are 3 possibilities: • Local control • Remote control • LAN (network) control After selecting the required regulation mode, press the enter button on the controller to confirm your selection. The new setting is now visible on the main screen. See section Icons used for the meaning of the icons.
Instruction book 3.10 Service menu Control panel (1) Scroll keys (2) Enter key (3) Escape key Menu icon, Service Function • • • • To reset the service plans which are carried out. To check when the next service plans are to be carried out. To find out which service plans were carried out in the past. To modify the programmed service intervals. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key.
Instruction book • Press the Enter key. Following screen appears: Text on image (1) Service (2) Overview (3) Service plan (4) Next service (5) History • Scroll through the items to select the desired item and press the Enter key to see the details as explained below. Overview Text on image (1) Overview (2) Running Hours (3) Real Time hours (4) Reset Example for service level (A): The figures at the left are the programmed service intervals.
Instruction book The figures within the bars are the number of hours to go till the next service intervention. In the example above, the compressor was just started up, which means it still has 4000 running hours or 8280 hours to go before the next Service intervention. Service plans A number of service operations are grouped (called Level A, Level B, etc...). Each level stands for a number of service actions to be carried out at the time intervals programmed in the Elektronikon® controller.
Instruction book Modify the value as required using the ↑ or ↓ scroll key and press the Enter key to confirm. Note: Running hours can be modified in steps of 100 hours, real time hours can be modified in steps of 1 hour. Next Service Text on image (1) Next service (2) Level (3) Running hours (4) Actual In the example above, the A Service level is programmed at 4000 running hours, of which 0 hours have passed.
Instruction book 3.11 Modifying the setpoint Control panel (1) Scroll keys (2) Enter key (3) Escape key Menu icon, Setpoint Function On compressors with a frequency converter driven main motor, it is possible to program two different setpoints. This menu is also used to select the active setpoint. Procedure Starting from the Main screen, • Highlight the action key Menu using the Scroll keys and press the Enter key.
Instruction book (1) Menu (2) Regulation • Activate the menu by pressing the enter key. A screen similar to the one below appears: Text on image (1) Regulation (2) Setpoint 1 (3) Indirect stop level 1 (4) Direct stop level 1 (5) Setpoint 2 (6) Modify • The screen shows the actual settings. To modify the settings, move the cursor to the action button Modify and press the Enter key. Following screen appears: • The first line of the screen is highlighted.
Instruction book If necessary, change the other settings as required in the same way as described above. Indirect stop: occurs when the pressure rises to the pre-set Indirect stop setpoint (= setpoint plus Indirect stop level). The motor will decelerate to minimum speed and the compressor will switch to unloaded condition. Direct stop: occurs when the compressor runs at a speed between minimum and maximum and the net pressure rises above the direct stop setpoint (= setpoint plus Direct stop level).
Instruction book • Using the Scroll keys, move the cursor to the Event History icon (see above, section Menu icon) • The list of last shut-down and emergency stop cases is shown. Example of Event History screen • Scroll through the items to select the desired shut-down or emergency stop event. • Press the Enter key to find the date, time and other data reflecting the status of the compressor when that shut-down or emergency stop occurred. 3.
Instruction book Menu icon, Settings Function To display and modify a number of settings. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Next, move the cursor to the Settings icon (see above, section menu icon).using the Scroll keys. • Press the Enter key. Following screen appears: This screen shows again a number of icons. By default, the User Password icon is selected.
Instruction book Text on image (1) General (2) Language used (3) Time (4) Date (5) Date format (6) Modify • To modify, select the Modify button using the Scroll keys and press the Enter key. • A screen similar to the one above is shown, the first item (Language) is highlighted. Use the ↓ key of the Scroll keys to select the setting to be modified and press the Enter key. • A pop-up screen appears. Use the ↑ or ↓ key to select the required value and press the Enter key to confirm. 3.
Instruction book Menu icon, Info Function To show the Atlas Copco internet address. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon). • Press the Enter key. The Atlas Copco internet address appears on the screen. 3.
Instruction book Menu icon, Week timer Function • • • • To program time-based start/stop commands for the compressor To program time-based change-over commands for the net pressure band Four different week schemes can be programmed. A week cycle can be programmed, a week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week schemes can be chosen. Important remark: In the Elektronikon you can select different timers on one day.(up to 8 actions).
Instruction book (1) Week Timer (2) Week Action Schemes (3) Week Cycle (4) Status (5) Week Timer Inactive (6) Remaining Running Time The first item in this list is highlighted in red. Select the item requested and press the Enter key on the controller to modify. Programming week schemes • Select Week action schemes and press Enter. A new window opens. The first item in the list is highlighted in red. Press the Enter key on the controller to modify Week Action Scheme 1.
Instruction book (6) Friday (7) Saturday (8) Sunday • A new window opens. The Modify action button is selected. Press the enter button on the controller to create an action. (1) Monday (2) Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller. When ready press the Enter key to confirm. (1) Monday (2) Actions (3) Remove (4) Start (5) Stop (6) Pressure Setpoint 1 (7) Modify • A new window opens.
Instruction book (1) Monday (2) Start (3) Save (4) Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. (1) Monday (2) Start (3) Save (4) Modify • 56 A pop-up window opens. Use the ↑ or ↓ key of Scroll keys to modify the values of the hours. Use the ← or → Scroll keys to go to the minutes.
Instruction book • Press the Escape key on the controller. The action button Modify is selected. Use the Scroll keys to select the action Save. (1) Monday (2) Start (3) Save (4) Modify • A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions. Press the Enter key to confirm. (1) Monday (3) Are you sure? (4) No (5) Yes (6) Save (7) Modify Press the Escape key to leave this window. • The action is shown below the day the action is planned.
Instruction book (1) Week Action Scheme 1 (2) Monday - Start (3) Tuesday (4) Wednesday (5) Thursday (6) Friday (7) Saturday (8) Sunday Press the Escape key on the controller to leave this screen. Programming the week cycle A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week schemes can be chosen. • Select Week Cycle from the main Week Timer menu list.
Instruction book (3) Week 2 (4) Week 3 (5) Week 4 (6) Modify Press twice the Enter key on the controller to modify the first week. • A new window opens. Select the action, example: Week Action Scheme 1 (1) Week Cycle (2) Week 1 (3) Week Action Scheme 1 (4) Week Action Scheme 2 (5) Week Action Scheme 3 (6) Modify • Check the status of the Week Timer Use the Escape key on the controller to go back to the main Week Timer menu. Select the status of the Week Timer.
Instruction book (1) Week Timer (2) Week (3) Week Timer Inactive (4) Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active. (1) Week Timer (2) Week Action Schemes (3) Week Cycle (4) Status (5) Remaining Running Time • Press the Escape key on the controller to go to the main Week Timer menu. Select Remaining Running Time from the list and press the Enter key on the controller to Modify.
Instruction book (1) Week Timer (2) Week Action Schemes (3) Week Cycle (4) Status (5) Remaining Running Time • This timer is used when the week timer is set and for certain reasons the compressor must continue working, for example, 1 hour, it can be set in this screen. This timer is prior to the Week Timer action. (1) Week Timer (2) Week action schemes (3) Remaining Running Time 3.
Instruction book or Function • To carry out a display test, i.e. to check whether the display and LEDs are still intact.
Instruction book 3.17 User password menu Control panel (1) Scroll keys (2) Enter key (3) Escape key Menu icon, Password Function If the password option is activated, it is impossible for not authorized persons to modify any setting. Procedure Starting from the Main screen (see Main screen), • Move the cursor to
Instruction book • Move the cursor to the Password icon (see above, section Menu icon) • Select using the Scroll keys and press the Enter key. Next, modify the password as required. 3.18 Web server All Elektronikon controllers have a built-in web server that allows direct connection to the company network or to a dedicated PC via a local area network (LAN). This allows to consult certain data and settings via a PC instead of via the display of the controller.
Instruction book Configuration of the network card • Go to My Network places (1). • Click on View Network connections (1). • Select the Local Area connection (1), which is connected to the controller. • Click with the right button and select properties (1).
Instruction book • Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked. After selecting TCP/IP, click on the Properties button (2) to change the settings. • Use the following settings: • IP Address 192.168.100.200 • Subnetmask 255.255.255.0 Click OK and close network connections. Configuration of the web server Configure the web interface The internal web server is designed and tested for Microsoft® Internet Explorer 6, 7 and 8.
Instruction book • Click on the Connections tab (1) and then click on the LAN settings button (2). • In the Proxy server Group box, click on the Advanced button (1).
Instruction book • In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given but they must be separated with semicolons (;). Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture). Click OK (2) to close the window.
Instruction book All screen shots are indicative. The number of displayed fields depends on the selected options. • Open your browser and type the IP address of the controller you want to view in your browser (in this example http://192.168.100.100). The interface opens: Navigation and options • The banner shows the compressor type and the language selector. In this example, three languages are available on the controller.
Instruction book Compressor settings All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen. Analog inputs Lists all current analog input values. The measurement units can be changed in the preference button from the navigation menu. Counters Lists all current counter values from controller and compressor.
Instruction book Digital outputs Lists all Digital outputs and their status. Special protections Lists all special protections of the compressor. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours. It is also possible to show the current status of the service interval. ES screen controller If an ESi license is provided, the ES button is displayed in the navigation menu. At the left all compressors in the ES are shown.
Instruction book A possible ESi screen 3.19 Programmable settings Compressor/motor Minimum setting Factory setting Maximum setting Set-point 1 and 2, Workplace compressors bar(e) 5.5 7 13 Set-point 1 and 2, Workplace compressors psig 80 100 188 Set-point 1 and 2, Workplace Full-Feature compressors bar(e) 5.5 6.8 12.8 Set-point 1 and 2, Workplace Full-Feature compressors psig 80 99 186 Indirect stop level bar 0.1 0.3 1 Indirect stop level psi 1.45 4.35 14.
Instruction book Protections Minimum setting Factory setting Maximum setting Compressor element outlet temperature (shut-down warning level) ˚C 50 110 119 Compressor element outlet temperature (shut-down warning level) ˚F 122 230 246 Compressor element outlet temperature (shut-down level) ˚C 111 120 120 Compressor element outlet temperature (shut-down level) ˚F 232 248 248 Minimum setting Factory setting Maximum setting Specific protections for Full-Feature compressors: Dewpoint
Instruction book Term Explanation Proportional band The settings for the Proportional band and integration time are determined by experiment. and integration Altering these settings may damage the compressor. Consult Atlas Copco.
Instruction book 4 Installation 4.
Instruction book Centre of gravity and weight 76 Type L (mm) B (mm) H (mm) Weight (kg) GA 7 VSD+ 200-230V GA 7 VSD+ 500-575V 475 440 340 330 560 580 287 253 GA 7 VSD+ FF 200-230V GA 7 VSD+ FF 380-460V GA 7 VSD+ FF 500-575V 520 475 500 340 320 330 580 610 600 332 268 298 GA 11 VSD+ 200-230V GA 11 VSD+ 500-575V 485 445 330 320 570 590 314 268 2920 7109 21
Instruction book Type L (mm) B (mm) H (mm) Weight (kg) GA 11 VSD+ FF 200-230V GA 11 VSD+ FF 380-460V GA 11 VSD+ FF 500-575V 525 465 500 330 300 320 590 620 610 359 271 313 GA 15 VSD+ 200-230V GA 15 VSD+ 500-575V 495 445 320 310 580 600 345 281 GA 15 VSD+ FF 200-230V GA 15 VSD+ FF 380-460V GA 15 VSD+ FF 500-575V 535 465 500 320 290 310 600 630 620 395 279 331 Dimensions +/- 10 mm Weights (oil included) +/- 10 kg Reference Designation 1 Electric cable entry for 380 V - 460 V 2 Compre
Instruction book 4.2 Installation proposal Compressor room example Compressor room example Text on figure 1 Ventilation proposals 2 Minimum free area to be reserved for the compressor installation Description 78 1 Compressor unit: Install the compressor unit on a solid, level floor suitable for taking the weight. 2 Position of the compressed air outlet valve.
Instruction book 3 Delivery pipe: The pressure drop over the air delivery pipe can be calculated as follows: Δp = (L x 450 x Qc1.85) / (d5 x P), with d = inner diameter of the pipe in mm Δp = pressure drop (recommended maximum: 0.1 bar (1.5 psi) L = length of the pipe in m P = absolute pressure at the compressor outlet in bar(a) Qc = free air delivery of the compressor in l/s Connect air outlet pipe of the compressor on top of the main air net pipe.
Instruction book Safety Apply all relevant safety precautions, including those mentioned in this book. Outdoor/altitude operation The compressors are not designed for outdoor use. The compressors can only be used in temperatures above 0 °C (+32 °F). If frost might occur, the appropriate measures should be taken to avoid damage to the machine and its ancillary equipment. In this case, consult Atlas Copco. Also if operating above 1000 m (3300 ft), consult Atlas Copco.
Instruction book Electrical connections diagram, typical example Reference Designation (1) Customer’s installation (2) Power circuit (3) Motor (4) Dryer Note The complete electrical diagram can be found in the electrical cubicle. Description You find the correct position for the electrical connection on the Dimension drawings. 1. 2. 3. 4. 5. Provide an isolating switch. Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals. Check the fuses.
Instruction book 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. Compressor control modes See also section Control mode selection. The following control modes can be selected: • Local control: The compressor will react to commands entered by means of the buttons on the control panel.
Instruction book 4.4 Pictographs Pictographs Reference Designation 1 Switch off the voltage and depressurize the compressor before starting maintenance or repairs 2 Automatic condensate drain 3 Manual condensate drain 4 Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx.
Instruction book 5 Operating instructions Initial start-up The operator must apply all relevant Safety precautions. Also consult section Problem solving. For the location of the air outlet valve and the drain connections, see sections Introduction and Condensate system. 84 - Remove the 2 transport fixtures under motor (1), painted in red. - Check that the electrical connections correspond to the local codes and that all wires are clamped tight to their terminals.
Instruction book - Check the oil level, the oil level should reach the bottom of the oil filler neck (FC). Minimum level should reach the oil sight glass (GI) when the compressor is stopped. If needed, top up the oil. Take care that no dirt drops into the oil system. Refit and tighten the filler plug (FC). - Provide labels, warning the operator that: • The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco).
Instruction book Starting Control panel Elektronikon® Graphic Step Action - Open the air outlet valve. - Switch on the voltage. Check that voltage on LED (6) lights up. - Press start button (1) on the control panel. The compressor starts running and the automatic operation LED (8) lights up. Ten seconds after starting, the drive motor switches over from star to delta and the compressor starts running loaded. During operation Keep the panels closed during operation.
Instruction book A few minutes after stopping, the oil level should reach the bottom of the oil filler neck (FC). If the oil level is too low, wait until the compressor has depressurized. Push the emergency stop button (10) to avoid the compressor to start unexpectedly. Next, close the air outlet valve and open the manual drain valve (Dm) until the air system between oil separator/air receiver vessel and outlet valve is fully depressurized.
Instruction book Carry out the service actions of the indicated plans or replace the component and reset the relevant timer, see section Service menu. Stopping - Press stop button (9). Automatic operation LED (8) goes out and the compressor stops. - To stop the compressor in the event of an emergency, press emergency stop button (10). Alarm LED flashes (7). • Remedy the problem cause, unlock the button by pulling it out.
Instruction book 6 Maintenance 6.1 Preventive maintenance schedule Control panel Warning Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Close the air outlet valve and open the condensate drain valve to depressurize the air system between air receiver and outlet valve. • Press the emergency stop button (10). • Switch off the voltage. • Depressurise the compressor. For detailed instructions, see section Problem solving.
Instruction book Each plan has a programmed time interval at which all service actions belonging to that plan are to be carried out. When reaching the interval, a message will appear on the screen indicating which service plans are to be carried out. After servicing, the intervals must be reset, see section Service menu. Preventive maintenance schedule Daily and 3-monthly check list Period Operation Daily Check oil level. Check readings on display. Check that condensate is discharged during operation.
Instruction book Running hours Operation 4000 (1) Change oil and oil filter. (not for Roto-Xtend Duty Fluid) Replace the air filter element. Replace the oil separator element. Check condition of the air intake hose between air filter and compressor element (where applicable). Check pressure and temperature readings. Check operation of cooling fans of converter. Check blow-off solenoid valve after stopping and pressing the emergency stop button. Clean coolers. Check and clean cooling fan assembly.
Instruction book Ambient temperature Element outlet temperature Exchange interval * Maximum time interval * up to 25 °C up to 90 °C 4000 hours 1 year from 25 °C up to 35 °C from 90 °C up to 100 °C 3000 hours 1 year more than 35 °C more than 100 °C 2000 hours 1 year * Whichever comes first. Important • Always consult Atlas Copco if a timer setting has to be changed. • For the change interval of oil and oil filter in extreme conditions of temperature, • 6.
Instruction book Atlas Copco's Roto-Foodgrade Fluid is a unique high quality synthetic lubricant, specially created for oilinjected screw compressors that provide air for the food industry. This lubricant keeps the compressor in excellent condition. Roto-Foodgrade Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 40 ˚C (104 ˚F).
Instruction book 6.5 Oil, oil filter and oil separator change Warning The operator must apply all relevant Safety precautions. Always drain the compressor oil at all drain points. Used oil left in the compressor can contaminate the oil system and can shorten the lifetime of the new oil. Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties. A label, indicating the type of oil filled ex-factory, is stuck on the air receiver/oil tank.
Instruction book 4. • Disconnect the air hose (2) at the top on the vessel. • Move the hose downward to drain the oil from the element. Collect the oil in a collector and deliver it to the local collection service. Refit the vent plugs after draining. 5. • Close the oil drain valve (Do). • Refit the drain hose at the top of the air receiver. 6. • Remove the oil filter (OF). Be aware that this filter has a left thread connection. Clean the seat on the manifold.
Instruction book 8. Run the compressor loaded for a few minutes. Stop the compressor. 9. • Close the air outlet valve and switch off the voltage. • Wait 3 minutes for the compressor to depressurise the vessel. • Open the condensate drain valve (Dm) to depressurise the cooler. (see Condensate system) and close again. • Unscrew the oil filler plug (FC) just one turn to permit any remaining pressure in the system to escape. 10. • Fill the air receiver (AR) with oil until the level reaches the filler neck.
Instruction book Procedure for compressors with dryer. Location of the condenser of the dryer • Remove dirt on the inlet of the condenser (6) with a fibre brush. • Clean with an air jet in the reverse direction to normal flow. • Clean the condenser area with a fibre brush. 6.7 Dryer maintenance instructions Safety precautions Refrigeration dryers of ID type contain refrigerant HFC. When handling refrigerant, all applicable safety precautions must be observed.
Instruction book 6.8 Safety valves Location of safety valve Testing The safety valve (SV) test can only be performed by authorized personnel and is protected by a security code. Refer to Elektronikon® Graphic controller, Test menu If the safety valve does not open at the set pressure stamped on the valve, it needs to be replaced. Warning No adjustments are allowed. Never run the compressor without safety valve. 6.
Instruction book If the compressor is going to be stored without running from time to time, protective measures must be taken. Consult your supplier. 6.11 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. Be careful when removing the electric motor. The rotor contains magnetic parts.
Instruction book 7 Problem solving Warning Before carrying out any maintenance, repair work or adjustment, stop compressor, wait 3 minutes and close the air outlet valve. Press the test button on top of the electronic water drain until the air system between the air receiver and outlet valve is fully depressurized. Press the emergency stop button and switch off the voltage. Depressurise the compressor by opening the oil filler plug one turn. For location of components, see sections: • Introduction.
Instruction book Condition Fault Remedy Safety valve blows Minimum pressure valve malfunctioning Check and have defective parts replaced Oil separator clogged Have element replaced Safety valve out of order Have valve checked.
Instruction book (1) Protections (1) General The display shows the problem (Main Motor Converter Alarm) and a fault code (31 in this case). (1) Main Motor Converter Alarm (2) Fault Fault code Cause Actions 1 Overcurrent Contact Atlas Copco Ground fault Contact Atlas Copco 2 Too high voltage. The voltage on the Check the supply voltage converter is above the Contact Atlas Copco. specifications. 3 Too low voltage.
Instruction book Fault code Cause Actions 4 Drive overload Contact Atlas Copco 8 Converter overheating (heat sink) Check the ambient temperature Check the cubicle cooling Check airflow around drive Check cooling fan and cooler contamination Contact Atlas Copco 256 Hardware fault Contact Atlas Copco 512 Motor overload Contact Atlas Copco Drive overload Contact Atlas Copco Over-torque detection Contact Atlas Copco Under-torque detection Contact Atlas Copco Over-speed Contact Atlas Copco
Instruction book Condition Fault Remedy Condenser externally clogged Clean condenser Compressor stops or does not Electric power supply to start compressor is interrupted Electronic condensate drain remains inoperative 104 Check and correct as necessary Thermal protection of refrigerant compressor motor has tripped Motor will restart when motor windings have cooled down Electronic drain system clogged Have system inspected Clean the filter of the automatic drain by opening the manual drain valve.
Instruction book 8 Technical data 8.1 Readings on display Elektronikon® Graphic controller Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limtations). Reference Reading Air outlet pressure Depends on the setpoint (desired net pressure). Compressor element outlet temperature Approx. 60 ˚C (108 ˚F) above ambient temperature. Dewpoint temperature (on Full-Feature compressors Approx. 4 ˚C (39 ˚F).
Instruction book 8.2 Electric cable size and fuses Important • 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). If cables are grouped together with other power cables, it may be necessary to use cables of a larger size than those calculated for the standard operating conditions.
Instruction book Compressor type Imax (1) Max fuse (1) Imax (2) gL/gG Max fuse (2) gL/gG V A A A A GA 15 VSD+ 200 62.9 70 68.1 80 GA 15 VSD+ 230 62.9 70 68.1 80 GA 15 VSD+ 400 31.5 32 34.1 40 GA 15 VSD+ 400 + N - - 34.1 40 GA 15 VSD+ 500 25.2 32 27.2 32 Imax (1) Max fuse (1) Imax (2) Max fuse (2) UL/cUL approval Compressor type K5/ HRC form II K5/ HRC form II V A A A A GA 7 VSD+ 200 36.9 40 40.0 50 GA 7 VSD+ 230 36.9 40 40.
Instruction book (2): compressors with integrated dryer Setting for circuit breakers Q1 1A Q15 0.5 A 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 calculations for cUL and UL: The indicated fuse size is the maximum fuse size in order to protect the motor against short circuit.
Instruction book Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm² < 32 A < 28 A < 25 A < 23 A < 20 A 6 mm² < 41 A < 36 A < 32 A < 29 A < 25 A 10 mm² < 57 A < 50 A < 45 A < 40 A < 35 A 16 mm² < 76 A < 66 A < 60 A < 54 A < 46 A 25 mm² < 96 A < 84 A < 76 A < 68 A < 59 A Installation method F according table B.52.1.
Instruction book • Install 50 A fuses on each cable instead of 100 A. Cable sizing according UL/cUL Calculation method according UL 508A, table 28.1 column 5: allowable ampacities of insulated copper conductors (75 °C (167 °F)).
Instruction book • For AWG2/0, the maximum current is 175 A, which is sufficient => use AWG2/0 • Install the prescribed maximum fuse (150 A) on each cable • Parallel supply cable (2 x 3 phases + 2 PE - configuration (2)): • I = (128 A + 25%)/2 = (128 x 1.25)/2 = 80 A • For a AWG4, the maximum current is 85 A x 0.8 = 68 A, which is insufficient. For an AWG3, the maximum current is 100 x 0.8 = 80 A. So 2 parallel cables of 3 x AWG3 + 2 x AWG8 are sufficient. • Install 80 A fuses on each cable. 8.
Instruction book Temperature of the air leaving the outlet valve (approx.), Workplace Full-Feature ˚C 30 Temperature of the air leaving the outlet valve (approx.), Workplace Full-Feature ˚F 86 Refrigerant type, Workplace Full-Feature R134a GA 7 VSD+ Normal effective working pressure bar(e) 5.5 7 9.5 12.
Instruction book Nominal motor power kW 11 Nominal motor power hp 14.75 Total amount of refrigerant, Workplace Full-Feature kg 0.4 Total amount of refrigerant, Workplace Full-Feature lb 0.88 Oil capacity l 7.1 Oil capacity US gal 1.88 Oil capacity Imp. gal 1.56 Oil capacity cu. ft. 0.25 Sound pressure level (according to ISO 2151 (2004)) dB(A) 63 GA 15 VSD+ Normal effective working pressure bar(e) 5.5 7 9.5 12.
Instruction book Ambient and temperature conditions IEC60068-2 • Operating temperature • -10°C…..+60°C (14 °F .....140 °F) • range • Storage temperature range -30°C…..+70°C (-22 °F ......158 °F) Permissible humidity Relative humidity 90% No condensation Noise emission IEC61000-6-3 Noise immunity IEC61000-6-2 Mounting Cabinet door Digital outputs Number of outputs 9 (Elektronikon® Graphic controller - p.n. 1900 5200 10 ….
Instruction book 9 Instructions for use Air/oil separator vessel - This vessel can contain pressurised air; this can be potentially dangerous if the equipment is misused. - This vessel must only be used as a compressed air/oil separator and must be operated within the limits specified on the data plate. - No alterations must be made to this vessel by welding, drilling or any other mechanical methods without the written permission of the manufacturer.
Instruction book 10 Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.
Instruction book 11 Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive The following table contains the necessary information for the inspection of all pressure equipment of category II and higher according to the Pressure Equipment Directive 97/23/EC and all pressure equipment according to the Simple Pressure Vessel Directive 2009/105/EC.
Instruction book 12 Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Atlas Copco Airpower n.v. P.O.
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. No 2920 7109 21 / 2013 - 05 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. www.atlascopco.
