Atlas Copco GA 11 VSD MED Instruction Book Download Page 19

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Specific components

Pressure switch on oil separator vessel

This switch, referred to as FTGOL (Failed To Go On Load), gives feedback to the regulation system that
pressure is built up in the vessel when the compressor is loaded. It is a normally open switch, and it closes
when the pressure is above 2-3 bar.

Temperature sensor at outlet

Instruction book

2920 7104 10

Summary of Contents for GA 11 VSD MED

Page 1: ...Atlas Copco Oil injected rotary screw compressors GA 5 VSD MED GA 7 VSD MED GA 11 VSD MED GA 15 VSD MED Medical Instruction book ...

Page 2: ......

Page 3: ...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 11 No 2920 7104 10...

Page 4: ...ption 10 2 1 INTRODUCTION 10 2 2 AIR FLOW 11 2 3 OIL FLOW 12 2 4 COOLING SYSTEM 13 2 5 CONDENSATE SYSTEM 14 2 6 REGULATING SYSTEM 14 2 7 ELECTRICAL SYSTEM 15 2 8 ELECTRICAL DIAGRAM 16 2 9 AIR RECEIVER 18 3 Elektronikon Graphic controller 19 3 1 GENERAL 19 3 2 CONTROL PANEL 21 3 3 ICONS USED 22 3 4 MAIN SCREEN 26 3 5 CALLING UP MENUS 30 3 6 INPUTS MENU 32 3 7 OUTPUTS MENU 35 3 8 COUNTERS 36 3 9 LAN...

Page 5: ...ODE 58 3 20 PROGRAMMABLE SETTINGS 59 4 Installation 61 4 1 DIMENSION DRAWINGS 61 4 2 INSTALLATION PROPOSAL 62 4 3 ELECTRICAL CONNECTIONS 64 4 4 PICTOGRAPHS 65 5 Operating instructions 66 5 1 INITIAL START UP 66 5 2 STARTING 68 5 3 DURING OPERATION 69 5 4 CHECKING THE DISPLAY 71 5 5 STOPPING 72 5 6 TAKING OUT OF OPERATION 72 6 Maintenance 74 6 1 PREVENTIVE MAINTENANCE SCHEDULE 74 6 2 OIL SPECIFICAT...

Page 6: ...ING AND REPLACEMENT 81 7 7 SAFETY VALVES 83 8 Problem solving 85 9 Technical data 88 9 1 READINGS ON DISPLAY 88 9 2 ELECTRIC CABLE SIZE AND MAIN FUSES 88 9 3 REFERENCE CONDITIONS AND LIMITATIONS 91 9 4 COMPRESSOR DATA 92 9 5 TECHNICAL DATA ELEKTRONIKON CONTROLLER 94 10 Instructions for use 96 11 Guidelines for inspection 97 12 Pressure equipment directives 98 13 Declaration of conformity 99 Instru...

Page 7: ...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 On units powered by a frequency converter wait six minutes before starting any electrical repair If the machine is equipped with an automatic restart after voltage failure function and if this function is active be aware that the mac...

Page 8: ... strain 10 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 precautio...

Page 9: ... be affixed to the remote start equipment 4 Never operate the machine when there is a possibility of taking in flammable or toxic fumes vapors or particles 5 Never operate the machine below or in excess of its limit ratings 6 Keep all bodywork doors shut during operation The doors may be opened for short periods only e g to carry out routine checks Wear ear protectors when opening a door On compre...

Page 10: ...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 vapours 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 per...

Page 11: ...ng 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 Also consult followin...

Page 12: ...sors driven by an electric motor The compressors are air cooled The motor is powered by a frequency converter allowing to adapt the speed to the air demand for optimal power consumption The compressors are controlled by an Elektronikon Graphic controller Front view of the compressor Instruction book 10 2920 7104 10 ...

Page 13: ...es the compressor current S1 Hand Auto Local LAN switch In the Auto LAN position the pump will be controlled by the ES MED In Hand Local position the compressor will be controlled by the settings programmed in its own controller bypassing the control from the ES MED LED s indicate the active running mode 2 2 Air flow Flow diagram Reference Description A Intake air B Air oil mixture C Oil D Wet com...

Page 14: ... downstream the valve from being vented to atmosphere during unloaded operation When the compressor is stopped inlet valve IV closes preventing compressed air and oil to be vented into the air filter A condensate trap MT downstream the air cooler is included 2 3 Oil flow Flow diagram Reference Description A Intake air B Air oil mixture C Oil D Wet compressed air E Condensate Description The air oi...

Page 15: ... OF towards compressor element E The system comprises a thermostatic bypass valve BV Only when the oil is warm the valve allows the oil to pass through the oil cooler 2 4 Cooling system Reference Description A Intake air B Air oil mixture C Oil D Wet compressed air E Condensate Description The cooling system comprises air cooler Ca and oil cooler Co The cooling air flow is generated by fan FN Inst...

Page 16: ...l decrease the motor speed If the net pressure keeps on rising when the motor runs at minimum speed the regulator stops the motor If the motor is stopped automatically and the net pressure approaches the set point the regulator will restart the motor Unloaded operation If the air consumption is less than the air output of the compressor the net pressure increases When the net pressure reaches the ...

Page 17: ...aded Loaded operation When the net pressure is below the loading pressure solenoid valve Y1 is energised Control pressure is fed from the oil separator vessel via solenoid valve Y1 to loading plunger LP and unloading valve UV Unloading valve UV closes the air blow off opening Loading plunger LP moves downwards and causes inlet valve IV to open fully Air delivery is resumed 100 the compressor runs ...

Page 18: ...contactor Q2 Fan motor circuit breaker U1 Frequency converter X12 CAN bus connector SSA SSB Service switch External box Reference Description F6 Fuses PE Earth terminal Q1 Main switch S1 Local LAN switch P3 Ammeter 2 8 Electrical diagram The complete electrical diagram can be found in the electric cubicle Instruction book 16 2920 7104 10 ...

Page 19: ...to as FTGOL Failed To Go On Load gives feedback to the regulation system that pressure is built up in the vessel when the compressor is loaded It is a normally open switch and it closes when the pressure is above 2 3 bar Temperature sensor at outlet Instruction book 2920 7104 10 17 ...

Page 20: ...e compressor during periods of light demand The reservoir is a welded mild steel construction designed and tested in accordance with European Standard EN 286 1 Test details are annotated on a plate permanently fixed to the reservoir and copies of the appropriate test certificates are supplied with each plant The reservoir incorporates access covers to facilitate future insurance internal inspectio...

Page 21: ...of programmable settings e g the unloading and loading pressures the minimum stop time and the maximum number of motor starts are taken into account The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases In case the expected unloading period is too short the compressor is kept running to prevent too short s...

Page 22: ...rning level is exceeded The message disappears as soon as the warning condition disappears Service warning A number of service operations are grouped called Service Plans Each Service Plan has a programmed time interval If a time interval is exceeded a message will appear on display 1 to warn the operator to carry out the service actions belonging to that Service Plan Automatic restart after volta...

Page 23: ...icates that the regulator is automatically controlling the compressor 8 Voltage on LED Indicates that the voltage is switched on 9 Pictograph Voltage on 10 Enter key Key to select the parameter indicated by the horizontal arrow Only the parameters followed by an arrow pointing to the right can be modified 11 Escape key To go to previous screen or to end the current action 12 Scroll keys Keys to sc...

Page 24: ...s rotating Compressor status Motor stopped Running unloaded Running loaded Machine control mode or Local start stop Remote start stop Network control Steady LAN network control Blinking forced local control Automatic restart after voltage failure Automatic restart after voltage failure is active Week timer Week timer is active Instruction book 22 2920 7104 10 ...

Page 25: ... 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 System icons Icon Description Instruction book 2920 7104 10 23 ...

Page 26: ...m Specific icons on ES MED Icon Description Temperature element outlet Temperature compressor outlet Failed to go load no pressure 3bar detected while compressor is loaded Motor overload motor draws too much current No answer compressor doesn t respond to ES commands Menu icons Icon Description Instruction book 24 2920 7104 10 ...

Page 27: ...tputs Alarms Warnings shutdowns Counters Test Settings Service Event history saved data Access key User password Network Setpoint Info Navigation arrows Icon Description Up Down Instruction book 2920 7104 10 25 ...

Page 28: ...off automatically after a few minutes when no keys are pushed Typically 4 different main screen views can be chosen 1 Two or four value lines 2 Chart High resolution 3 Chart Medium resolution 4 Chart Low resolution Two or four value lines screens This type of Main screen shows the value of 2 or 4 parameters see section Inputs menu By default the 4 value lines screen is activated Instruction book 2...

Page 29: ...or motor stopped Optional icons These icons are only shown if their corresponding function is activated e g week timer automatic restart after voltage failure etc Pop up icons These icons pop up if an abnormal condition occurs warnings shutdowns service To call up more information about the icons shown select the icon concerned using the scroll keys and press the enter key Section C is called the ...

Page 30: ...the time When Chart High Resolution is selected the chart shows the variation of the selected input in this case the pressure per minute Also the instantaneous value is displayed The screen shows the last 4 minutes The switch button icon for selecting other screens is changed into a small Chart and is highlighted active When the Chart Medium Resolution is selected the chart shows the variation of ...

Page 31: ... 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 See also section Inputs menu Instruction book 2920 7104 10 29 ...

Page 32: ... 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 fixed speed compressors Instruction book 30 2920 7104 10 ...

Page 33: ...roll keys Press the Enter key to select the menu Following screen appears 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 Instruction book 2920 7104 1...

Page 34: ...ts and the status of the digital inputs e g emergency stop contact motor overload relay etc To select the digital input to be shown on the chart in the main screen Procedure Starting from the main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on image Instruction book 32 2920 7104 10 ...

Page 35: ...tdown icon respectively i c the Stop icon and the Warning icon in the screen shown above A small chart icon shown below an item in the list means this input signal is shown on the chart at the main screen Any analog input can be selected Selecting another input signal as main chart signal With the Modify button active light grey background in above screen press the Enter button on the controller A...

Page 36: ...he chart Another confirmation pop up opens Select Yes to remove or No to quit the current action In a similar way another input signal can be highlighted and selected as Main Chart signal 1 Set as main chart signal Instruction book 34 2920 7104 10 ...

Page 37: ...e 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 see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on figure Instruction book 2920 7104 10 35 ...

Page 38: ... screen typical Text on figure 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 If an output is in warning or shutdown the original icon is replaced by the warning or shutdown icon respectively 3 8 Counters Control panel Instruction book 36 2920 7104 10 ...

Page 39: ...wered 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 Following screen appears Text on figure 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Counters icon see above section Menu icon Press the Enter key Following screen appears Text on figure Instruction book 2920 7104 10 37 ...

Page 40: ...ng the ON button should have no effect When coming from the OFF state see next combination pressing the ON button will put the Slave in charge to control its compressor based on its pressure sensor This combination is referred to as the local automatic state The LAN symbol should disappear the local symbol should appear This mode is usually only needed during service or problem solving 3 Flipping ...

Page 41: ...3 11 Service menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Instruction book 2920 7104 10 39 ...

Page 42: ...in screen see 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 Service icon see above section Menu icon Press the Enter key Following screen appears Text on figure 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 ...

Page 43: ...ler is not powered 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 actio...

Page 44: ... the Scroll keys to select the value to be modified A screen similar to the one below appears Press the Enter key Following screen appears 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 figure Instruction book 42 2920 7104 10 ...

Page 45: ...ervice action To see the details of a completed service action e g Service level Running hours or Real time hours use the Scroll keys to select the desired action and press the Enter key 3 12 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 setp...

Page 46: ...lation Activate the menu by pressing the enter key A screen similar to the one below appears Text on figure 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 Instruction book 44 2920 7104 10 ...

Page 47: ... lower limit of the setting is shown in grey the actual setting is shown in black Use the or key of the Scroll keys to modify the settings as required and press the Enter key to accept If necessary change the other settings as required in the same way as described above 3 13 Event history menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Instruction book 2920 7104 10 45 ...

Page 48: ...e 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 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 14 Modifying general setting...

Page 49: ...ng the Scroll keys move the cursor to the Settings icon see above section menu icon Press the Enter key Following screen appears Text on figure 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 a red selection bar is covering the first item Language Use the key o...

Page 50: ... 15 Info menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Info Function To show the Atlas Copco internet address Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Instruction book 48 2920 7104 10 ...

Page 51: ...nction To carry out a display test i e to check whether the display and LEDs are still intact Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the enter key 2 following screen appears Using the scroll keys 1 move the cursor to the test icon see above section Menu icon Press the enter key 2 following screen appears Instruction book 2920 710...

Page 52: ...en is shown to inspect the display at the same time all LED s are lit 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 Instruction book 50 2920 7104 10 ...

Page 53: ...lektronikon 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 Getting started Make sure you are logged in as administrator Use the internal network card from your computer or a USB to LAN adapter see pictu...

Page 54: ...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 Instruction book 52 2920 7104 10 ...

Page 55: ...sk 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 Other web browsers like Opera and Firefox do not support this internal web server When using Opera or Firefox a redirect page opens Click on the hyperlink to connect to the download server from M...

Page 56: ... Open Internet Explorer and click on Tools Internet options 2 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 54 2920 7104 10 ...

Page 57: ... 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 Viewing the controller data 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 Instruction book 2920 7104 10 55 ...

Page 58: ... controller On the left side of the interface you can find the navigation menu see picture below If a license for ESi is foreseen the menu contains 3 buttons Compressor shows all compressor settings Es shows the ESi status if a license is provided Preferences allows to change temperature and pressure unit Instruction book 56 2920 7104 10 ...

Page 59: ...ain screen Analog inputs The units of measure can be changed in the preference button from the navigation menu Counters Counters give an overview of all actual counters from controller and compressor Info status Machine status is always shown on the web interface Digital inputs Gives an overview of all Digital inputs and status Instruction book 2920 7104 10 57 ...

Page 60: ...e plan and status This screen only shows the running hours It is also possible to show the actual status of the service interval 3 19 Cascading load cut in values in local mode To prevent compressors from all starting up at the same time in local mode load settings are slightly different per compressor dependent on CAN address according to the following formula Instruction book 58 2920 7104 10 ...

Page 61: ...21 8 Proportional band 6 10 15 Integration time sec 5 6 10 Minimum motor speed rpm 1500 1500 2000 Maximum speed reduction 75 100 100 Parameters Minimum setting Factory setting Maximum setting Minimum stop time sec 5 5 30 Power recovery time sec 10 10 3600 Restart delay sec 0 0 1200 Communication time out sec 10 30 60 Fan motor starts per day air cooled compressors 1 240 240 Protections Minimum set...

Page 62: ...ecreased to 50 C 122 F Reset the value after testing The regulator does not accept illogical settings e g if the warning level is programmed at 95 C 203 F the minimum limit for the shut down level changes to 96 C 204 F The recommended difference between the warning level and shut down level is 10 C 18 F Delay at shut down signal Is the time for which the signal must exist before the compressor is ...

Page 63: ...4 Installation 4 1 Dimension drawings Instruction book 2920 7104 10 61 ...

Page 64: ...4 2 Installation proposal Instruction book 62 2920 7104 10 ...

Page 65: ...e calculated from Qv 0 92 N ΔT Qv Required ventilation capacity in m3 s N Shaft input of compressor in kW ΔT Temperature increase in the compressor room in C 5 Mains cable entry 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 Installa...

Page 66: ...side of the cubicle When the compressor is last in line the upper CAN connector must be chosen and the dip switch on the CAN connector inside the cubicle must be switched to ON In other cases the dip switch should be set to OFF Compressor control modes on compressors with Elektronikon Graphic controller The following control modes can be selected Local control The compressor will react to commands...

Page 67: ...compressor before cleaning the coolers 7 Lightly oil the gasket of the oil filter screw the filter on and tighten by hand approx half a turn 8 Warning voltage 9 Consult instruction book before greasing 10 Before connecting the compressor electrically consult the Instruction book for the motor rotation direction 11 Compressor remains pressurized for 30 seconds after switching off the voltage 12 Tor...

Page 68: ... and Dimension drawings Check that the electrical connections correspond to the applicable codes and that all wires are clamped tight to their terminals The installation must be earthed and protected against short circuits by fuses of the inert type in all phases An isolating switch must be installed near the compressor Check transformer T1 for correct connection Fit air outlet valve AV see sectio...

Page 69: ...ection to the cooling air outlet of the compressor Consult section Dimension drawings Switch on the voltage Start the compressor and stop it immediately Check the rotation direction of drive motor M1 while the motor is coasting to a stop Check the rotation direction of the motor If the motor rotation direction is correct the sheet on the top grating will be blown upwards If the sheet remains in pl...

Page 70: ... be active indicating that the compressor is in Emergency forced local status In the controller settings navigate to Network CAN and set the CAN address according to the number of the compressor see Airplant dryer instruction book then turn CAN ON See figure below Refer to the Airplant dryer instruction book on how to set up the ES MED When the ES MED is configured switch the local LAN switch to L...

Page 71: ...ion Problem solving If the compressor is stopped because the supply voltage is interrupted please be aware that it will restart automatically when the power is restored When the motors are stopped and LED 8 automatic operation is alight the motors may start automatically Instruction book 2920 7104 10 69 ...

Page 72: ...e again in Integrated mode If the oil level is too low press also the emergency stop button 10 close the air outlet valve and open if provided the manual condensate drains See section Introduction and section Condensate system for location of the outlet valve and the water drain Next depressurise the oil system by unscrewing oil filler plug FC one turn and wait a few minutes Remove the plug and to...

Page 73: ...e Elektronikon Graphic controller Compressors with Elektronikon Graphic controller Check the display 2 regularly for readings and messages The display normally shows the compressor outlet pressure while the status of the compressor is indicated by means of a number of icons Remedy the trouble if alarm LED 7 is lit or flashes see section Icons used The display 2 will show a service message if a ser...

Page 74: ...keys 3 4 and press the Select key Press Reset Do not use emergency stop button 10 for normal stopping Close air outlet valve AV see section Introduction Open the manual drain Dm Switch off the voltage During normal operation the GA MED compressor is in Integrated mode Unless the Slave the GA MED compressor is put in Isolated mode on the ES MED see dryer instruction book a plant fault will be trans...

Page 75: ...ne turn to permit any pressure in the system to escape Consult section Oil and oil filter change to locate the filler plug Shut off and depressurise the part of the air net which is connected to the outlet valve Disconnect the compressor air outlet pipe from the air net Drain the oil Collect the oil and deliver it to the local collection service Drain the condensate circuit and disconnect the cond...

Page 76: ...aintenance repair work or adjustments proceed as follows Stop the compressor Press the emergency stop button Switch off the voltage Close the air outlet valve and open if provided the manual condensate drain valves Depressurise the compressor Failure to adhere to these maintenance recommendations can result in damage fire explosion or injury The operator must apply all relevant Safety precautions ...

Page 77: ...Besides the daily and 3 monthly checks preventive service operations are specified in the schedule below 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 see section Service menu After servicing the intervals must be r...

Page 78: ...e change interval of oil and oil filter in extreme conditions of temperature humidity or cooling air consult your Atlas Copco Customer Centre Any leakage should be attended to immediately Damaged hoses or flexible joints must be replaced 6 2 Oil specifications It is strongly recommended to use genuine Atlas Copco Lubricants They are the result of years of field experience and research See section ...

Page 79: ...ts required for servicing the component and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low Also a full range of extensively tested lubricants suitable for your specific needs is available to keep the compressor in excellent condition Consult the Spare Parts List for part numbers 6 5 Disposal of used material Used filters or any other used material e g desi...

Page 80: ... Recommendations 1 Never remove the element while the compressor is running 2 For minimum downtime replace the dirty element by a new one 3 Discard the element when damaged Procedure 1 Stop the compressor Switch off the voltage 2 Remove the cover of air filter AF by turning it anti clockwise Remove the filter element If necessary clean the cover 3 Fit the new element and the cover 4 Reset the air ...

Page 81: ... opening manual drain valve s Dm Dm1 Wait a few minutes and depressurise the air receiver oil tank OT by unscrewing oil filler plug FC just one turn to permit any pressure in the system to escape 2 Drain the oil by opening valve OD 3 Collect the oil and deliver it to the local collection service Refit and tighten the drain and vent plugs after draining 4 Remove the oil filter OF Clean the seat on ...

Page 82: ...Warning The operator must apply all relevant Safety precautions Procedure Oil system components 1 Run the compressor until warm Stop the compressor close the air outlet valve and switch off the voltage Wait a few minutes and depressurise by unscrewing oil filler plug FC just one turn to permit any pressure in the system to escape 2 Wait 5 minutes and remove the oil separator OS Clean the seat on t...

Page 83: ...normal flow Use low pressure air If necessary the pressure may be increased up to 6 bar e 87 psig If it is necessary to wash the coolers with a cleaning agent consult Atlas Copco 7 6 Belt tensioning and replacement Checking the belt tension Step Action 1 Stop the compressor close the air outlet valve and switch off the voltage 2 Remove the front panel and the right panel 3 The belt tension is corr...

Page 84: ...ce F needed to create a deflection of 5 mm 0 2 in corresponds to the data in the table above 6 Tighten bolts 2 7 Refit the bodywork panels Replacing the belts The belts must always be replaced as a set even if only one of the belts is worn Only use genuine Atlas Copco belts Step Action 1 Stop the compressor close the air outlet valve and switch off the voltage 2 Remove the front panel and the righ...

Page 85: ...alve on oil separator vessel Testing Before removing the valve depressurise the compressor See section Problem solving Valve SV can be tested on a separate air line If the valve does not open at the set pressure stamped on the valve it needs to be replaced Instruction book 2920 7104 10 83 ...

Page 86: ...Warning No adjustments are allowed Never run the compressor without safety valve Instruction book 84 2920 7104 10 ...

Page 87: ...ety precautions Faults and remedies compressor On compressors equipped with an Elektronikon Graphic controller if the alarm LED is lit or flashes consult sections Event history menu or Service menu Condition Fault Remedy Compressor starts running but does not load after a delay time Solenoid valve out of order Replace valve Inlet valve stuck in closed position Have valve checked Leak in control ai...

Page 88: ...alve checked Minimum pressure valve malfunctioning Have valve checked Safety valve out of order Have valve replaced Compressor element out of order Consult Atlas Copco Oil separator element clogged Replace oil separator element Compressor element outlet temperature or delivery air temperature above normal Oil level too low Check and correct On air cooled compressors insufficient cooling air or coo...

Page 89: ...pressure switch in the oil separator vessel doesn t register a pressure above 2 3 bar while the compressor is loaded Verify cable and connections Verify the switch Verify that the air consumption doesn t exceed air delivery of compressors Verify filter element Verify solenoid valve Verify that no parts are leaking Verify inlet valve opening Verify oil separator element Verify safety valve Verify c...

Page 90: ...al 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 Use the original cable entry See section Dimension drawings To preserve the protection degree of the electric cubicle and to protect its components from dust from the environment i...

Page 91: ...otor overload setting NOTE The supply line cable delivered with the compressor MUST be protected by raceway or by a suitable conduit system Possible configurations There are 3 possible configurations 1 Single supply cables For DOL and VSD versions only K21 is used 2 Parallel supply cables 3 is only valid for Y D versions Cable sizing according IEC The tables below indicate the current carrying cap...

Page 92: ...g table B 52 1 Single core or multi core cable on a wooden wall Maximum allowed current in function of the ambient temperature for installation method C Ambient temperature Cable section 30 C 40 C 45 C 50 C 55 C 1 5 mm 17 A 15 A 14 A 12 A 11 A 2 5 mm 24 A 21 A 19 A 17 A 15 A 4 mm 32 A 28 A 25 A 23 A 20 A 6 mm 41 A 36 A 32 A 29 A 25 A 10 mm 57 A 50 A 45 A 40 A 35 A 16 mm 76 A 66 A 60 A 54 A 46 A 25...

Page 93: ... voltage drop over the cable less than 5 of the nominal voltage is recommended Example Itot 89 A maximum ambient temperature is 45 C recommended fuse 100 A Single supply cables 3 phases PE configuration 1 I 89 A 10 89 x 1 1 97 9 A The table for B2 and ambient temperature 45 C allows a maximum current of 93 A for a 50 mm cable For a cable of 70 mm the maximum allowed current is 118 A which is suffi...

Page 94: ...tions Common compressor data Unit Number of compression stages 1 Temperature of the air leaving the outlet valve approx Workplace C 37 Temperature of the air leaving the outlet valve approx Workplace F 99 Specific data for GA 5 VSD Unit GA 5 VSD GA 5 VSD GA 5 VSD GA 5 VSD Normal effective working pressure bar e 5 5 7 9 5 12 5 Normal effective working pressure psig 80 102 138 181 Maximum effective ...

Page 95: ... 7 5 7 5 Nominal motor power hp 10 10 10 10 Oil capacity l 3 7 3 7 3 7 3 7 Oil capacity US gal 0 98 0 98 0 98 0 98 Oil capacity Imp gal 0 81 0 81 0 81 0 81 Oil capacity cu ft 0 13 0 13 0 13 0 13 Sound pressure level according to ISO 2151 2004 dB A 64 64 64 64 Specific data GA 11 VSD Unit GA 11 VSD GA 11 VSD GA 11 VSD GA 11 VSD Normal effective working pressure bar e 5 5 7 9 5 12 5 Normal effective...

Page 96: ...otor power kW 15 15 15 15 Nominal motor power hp 20 1 20 1 20 1 20 1 Oil capacity l 5 2 5 2 5 2 5 2 Oil capacity US gal 1 37 1 37 1 37 1 37 Oil capacity Imp gal 1 14 1 14 1 14 1 14 Oil capacity cu ft 0 18 0 18 0 18 0 18 Sound pressure level according to ISO 2151 2004 dB A 69 3 69 3 69 3 69 3 9 5 Technical data Elektronikon controller General Parameter Value Supply voltage 24 V AC 16 VA 50 60Hz 40 ...

Page 97: ...arameter Value Number of inputs 10 Elektronikon Graphic controller p n 1900 5200 10 1900 5200 19 Supply by controller 24 V DC Supply protection Short circuit protected to ground Input protection Not isolated Analog inputs Parameter Value Pressure inputs 2 Elektronikon Graphic controller p n 1900 5200 10 1900 5200 19 Temperature inputs 5 Elektronikon Graphic controller p n 1900 5200 10 1900 5200 19...

Page 98: ...essure It should guarantee that the pressure will not permanently exceed the maximum allowable operating pressure of the vessel Use only oil as specified by the manufacturer There is no intrinsic need for service inspection of the oil separator vessel when used within the design limits for its intended application Nevertheless in case of misuse of the units very low oil temperature or long interva...

Page 99: ...or 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 Local legal requirements and or use outside the limits and or conditions as specified by the manufacturer may require other inspection periods as mentioned below Instruction book 2920 7104 10 97 ...

Page 100: ...er according to the Pressure Equipment Directive 97 23 EC and all pressure equipment according to the Simple Pressure Vessel Directive 87 404 EEC Compressor type Part number Description PED Class GA 5 VSD MED up to GA 15 VSD MED 2202 8891 01 Safety valve IV 2202 8891 03 Safety valve IV 2202 8891 02 Safety valve IV Overall rating The compressors conform to PED smaller than category I Instruction bo...

Page 101: ...3 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 Instruction book 2920 7104 10 99 ...

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Page 104: ...s 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 www atlascopco com ...

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