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Atlas Copco GA 11 VSD+, Instruction Book

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Atlas Copco GA 11 VSD+ Instruction Book Download Page 85

Energy recovery unit (ER-unit)

Main components of the ER unit (typical installation)

Reference

Designation

1

Water inlet pipe

2

Water outlet pipe

3

Temperature sensor, water inlet pipe

4

Temperature sensor, water outlet pipe

5

Oil drain valve

6

Oil line from compressor oil separator vessel to ER unit

7

Oil line from ER unit to oil filter housing

BV2

Location of heat exchanger by-pass valve (BV2)

HE

Heat exchanger

V1

Selector valve

AR

Oil separator vessel

OF

Oil filter housing

BV1

Location of oil cooler bypass valve (BV1)

Instruction book

2920 7109 23

83

Summary of Contents for GA 11 VSD+

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

Page 2: ......

Page 3: ...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 2015 01 No 2920 7109 23 www atlascopco c...

Page 4: ...TION 10 2 2 FLOW DIAGRAM 14 2 3 CONDENSATE SYSTEM 16 2 4 REGULATING SYSTEM 18 2 5 ELECTRICAL SYSTEM 18 2 6 AIR DRYER 20 3 Elektronikon Graphic controller 22 3 1 ELEKTRONIKON GRAPHIC CONTROLLER 22 3 2 CONTROL PANEL 24 3 3 ICONS USED 25 3 4 MAIN SCREEN 29 3 5 CALLING UP MENUS 33 3 6 INPUTS MENU 34 3 7 OUTPUTS MENU 36 3 8 COUNTERS 38 3 9 CONTROL MODE SELECTION 40 3 10 SERVICE MENU 41 3 11 MODIFYING T...

Page 5: ... CONNECTIONS 78 4 4 PICTOGRAPHS 81 5 Options 82 5 1 ENERGY RECOVERY 82 5 2 MAIN SWITCH 95 6 Operating instructions 97 7 Maintenance 102 7 1 PREVENTIVE MAINTENANCE SCHEDULE 102 7 2 OIL SPECIFICATIONS 105 7 3 DRIVE MOTOR 106 7 4 AIR FILTER 106 7 5 OIL OIL FILTER AND OIL SEPARATOR CHANGE 107 7 6 COOLERS 109 7 7 DRYER MAINTENANCE INSTRUCTIONS 110 7 8 SAFETY VALVES 111 7 9 DD PD FILTERS SERVICE INTERVA...

Page 6: ...N DISPLAY 118 9 2 ELECTRIC CABLE SIZE AND FUSES 119 9 3 REFERENCE CONDITIONS AND LIMITATIONS 124 9 4 COMPRESSOR DATA 125 9 5 TECHNICAL DATA ELEKTRONIKON CONTROLLER 127 10 Instructions for use 129 11 Guidelines for inspection 130 12 Pressure equipment directives 131 13 Declaration of conformity 132 Instruction book 4 2920 7109 23 ...

Page 7: ...nd depressurize the compressor In addition the power isolating switch must be opened and locked The units are powered by a frequency converter wait 10 minutes before starting any electrical repair In a domestic environment this product may cause radio interference in which case supplementary mitigation measures are required If the machine is equipped with an automatic restart after voltage failure...

Page 8: ...essor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials 9 No external force may be exerted on the air outlet valve the connected pipe must be free of 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 ...

Page 9: ...r Precautions during operation 1 Never touch any piping or components of the machine during operation 2 Use only the correct type and size of hose end fittings and connections When blowing through a hose or air line ensure that the open end is held securely A free end will whip and may cause injury Make sure that a hose is fully depressurized before disconnecting it 3 Persons switching on remotely...

Page 10: ...vance 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 maintenance or repair 1 Always use the correct safety equipment such as safety glasses gloves safety shoes etc 2 Use only the correct tools for maintenance and repair work 3 Use only genuine spare parts for maintenanc...

Page 11: ...ing them e g when steam cleaning 19 Make sure that all sound damping material and vibration dampers e g damping material on the bodywork and in the air inlet and outlet systems of the compressor is in good condition If damaged replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing 20 Never use caustic solvents which can damage materials of the air ...

Page 12: ...hic 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 VSD Variable Speed Drive technology This means automatic adjustment of the motor speed depending on the compressed air demand The compressors are air cooled and are enclosed in a sound insulated bodywork GA Workplace Front view ...

Page 13: ...ull 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 2920 7109 23 11 ...

Page 14: ...Front view GA VSD Workplace Full Feature Open side view GA VSD Workplace Full Feature Reference Name AF Air filter AR Air receiver Instruction book 12 2920 7109 23 ...

Page 15: ...te 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 Instruction book 2920 7109 23 13 ...

Page 16: ...2 2 Flow diagram GA 7 VSD up to GA 15 VSD Workplace Instruction book 14 2920 7109 23 ...

Page 17: ...GA 7 VSD up to GA 15 VSD Workplace Full Feature Reference Description A Air inlet B Air oil mixture C Oil D Wet compressed air E Condensate Instruction book 2920 7109 23 15 ...

Page 18: ...in the lower part of the air receiver AR which serves as oil tank The oil system has a thermostatic bypass valve BV When the oil temperature is below 71 C 160 F the bypass valve shuts off the oil supply from the oil cooler Co Air pressure forces the oil from air receiver AR through the oil filter OF The oil cooler Co is bypassed When the oil temperature has increased up to 71 C 160 F bypass valve ...

Page 19: ... cooler On a GA Workplace Full Feature the water in the air collects in the water separator of the heat exchanger evaporator When the condensate in the electronic drain ED reaches a certain level it is drained via the automatic drain outlet Da Condensate drain connections GA Workplace Reference Designation Da Automatic drain connection Dm Manual drain connection Instruction book 2920 7109 23 17 ...

Page 20: ...irect stop level typically 0 3 bar above the setpoint see section Programmable settings Should the net pressure rise very quickly to a value equal to the setpoint plus the direct stop level typically 1 bar above the setpoint see section Programmable settings the compressor is stopped immediately without first decreasing the motor speed No compressed air is lost when the compressor is stopped in au...

Page 21: ...ce 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 2920 7109 23 19 ...

Page 22: ...rant condenser 7 Liquid refrigerant dryer filter 8 Capillary 9 Bypass valve 10 Condenser cooling fan 11 Pressure switch fan control 12 Liquid separator Compressed air circuit Compressed air comes in the heat exchanger 1 and the outgoing cold dried air cools the incoming compressed air Water in air starts to condense Then the air flows through the heat exchanger evaporator 2 where the refrigerant e...

Page 23: ...ressure refrigerant gas which flows through the refrigerant condenser 6 Most of the refrigerant condenses The liquid refrigerant flows through the liquid refrigerant dryer filter 7 to the capillary tube 8 The refrigerant leaves the capillary tube at about evaporating pressure The refrigerant enters the evaporator 2 where it gets heat from the compressed air by further evaporation at about constant...

Page 24: ...grammable settings e g the setpoint the minimum stop time and the maximum number of motor starts and several other parameters are hereby taken into account The controller stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases In case of risk for condensate forming in the oil the compressor activates the condensate preven...

Page 25: ... message will appear if on Full Feature compressors the dew point temperature is too high in relation to the ambient temperature 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 Serv...

Page 26: ...f service is needed 7 Automatic operation LED Indicates that the regulator is automatically controlling the compressor 8 Voltage on LED Indicates that the voltage is switched on 9 Pictograph Voltage 10 Enter key Use this button to confirm the last action 11 Escape key Use this button to go to previous screen or to end the current action 12 Scroll keys Keys to scroll through the menu 13 Stop button...

Page 27: ...pressor is running the icon is rotating Compressor status Motor stopped Running unloaded Running loaded Machine control mode or Local start stop Remote start stop Network control Automatic restart after voltage failure Automatic restart after voltage failure is active Week timer Week timer is active Instruction book 2920 7109 23 25 ...

Page 28: ...wn 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 Instruction book 26 2920 7109 23 ...

Page 29: ...ressor element LP HP Dryer Fan Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Menu icons Icon Description Inputs Outputs Alarms Warnings shutdowns Counters Instruction book 2920 7109 23 27 ...

Page 30: ...Icon Description or Test Settings Service Event history saved data Access key User password Network Setpoint Info Navigation arrows Icon Description Up Down Instruction book 28 2920 7109 23 ...

Page 31: ...d off automatically after a few minutes when no keys are pushed Typically 5 different main screen views can be chosen 1 Two value lines 2 Four value lines 3 Chart High resolution 4 Chart Medium resolution 5 Chart Low resolution Two and four value lines screens This type of Main screen shows the value of 2 or 4 parameters see section Inputs menu Typical Main screen 2 value lines Instruction book 29...

Page 32: ...with a frequency converter the load degree flow is given in of the maximum flow Section B shows Status icons Following icon types are shown in this field Fixed icons These icons are always shown in the main screen and cannot be selected by the cursor e g Compressor stopped or running Compressor status running running unloaded or motor stopped Optional icons These icons are only shown if their corr...

Page 33: ... or message To activate an action button highlight the button by using the Scroll keys and press the Enter key To go back to the previous menu press the Escape key Chart views Instead of viewing values it is also possible to view a graph of one of the input signals see section Inputs menu in function of the time When Chart High Resolution is selected the chart shows the variation of the selected i...

Page 34: ... 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 See also section Inputs...

Page 35: ...ription 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 Menu 3 using the Scroll keys Press the Enter key to select the menu Following screen appears Instruction book 2920 7109 23 33 ...

Page 36: ...e actual value of the measured data analog inputs 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 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 mo...

Page 37: ...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 screen similar to the one below appears The first item in the list is highlighted In this example the Net Pressure is selected ...

Page 38: ...Outputs menu 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 Following screen appears Instruction book 36 2920 7109 23 ...

Page 39: ...the one below appears Outputs screen typical Text on image 1 Outputs 2 Fan motor 3 Blowoff 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 Instruction book 2920 7109 23 37 ...

Page 40: ...f motor starts The number of hours that the regulator has been powered The number of load cycles The number of recirculation cycles The number of recirculation cycle failures 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 38 2920 7109 23 ...

Page 41: ...ey Following screen appears Text on figure 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 6 Recirculation Cycles 7 Recirculation Failures The screen shows a list of all counters with their actual readings Instruction book 2920 7109 23 39 ...

Page 42: ...l mode i e whether the compressor is in local control remote control or controlled via a local area network LAN Procedure Starting from the main screen make sure the button Menu 1 is selected Next use the scroll buttons to go to the regulation icon 2 and press the enter button Instruction book 40 2920 7109 23 ...

Page 43: ...ning of the icons 3 10 Service menu 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 Following screen ap...

Page 44: ... 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 For Service interval A the programmed number of running hours is 4000 hours upper row and the programmed number of real time hours is 8760 hours which corresponds to one year second row This m...

Page 45: ...mber of service actions to be carried out at the time intervals programmed in the Elektronikon controller When a service plan interval is reached a message will appear on the screen After carrying out the service actions related to the indicated levels the timers must be reset From the Service menu above select Service plan 3 and press Enter Following screen appears Text on image 1 Service Plan 2 ...

Page 46: ...ample above the A Service level is programmed at 4000 running hours of which 0 hours have passed History The History screen shows a list of all service actions done in the past sorted by date The date at the top is the most recent service 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 p...

Page 47: ...s 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 Following screen appears Instruction book 2920 7109 23 45 ...

Page 48: ...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 Use the Scroll keys 1 to highlight the setting to be modified and press the Enter key 2 Following screen appears Instruction book 46 2920 7109 23 ...

Page 49: ... 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 Both settings Indirect stop level and Direct stop level are programmable see section Programmable settings 3 12 Event history menu Menu icon Event History Function To call up the last shutdown and last emergency stop data Procedure Starting from the ...

Page 50: ... occurred 3 13 Modifying general settings 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 Text on image 1 Menu 2 Regulation Next move the cursor to the Settings icon see above section menu icon using the Scroll keys Press the Enter key Following ...

Page 51: ...e Selecting the General Settings icon gives the possibility to change e g the language the date the date format etc Text on image 1 General 2 Language in Use 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 t...

Page 52: ...en 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 Info icon see above section Menu icon Press the Enter key The Atlas Copco internet address appears on the screen Instruction book 50 2920 7109 23 ...

Page 53: ...eek 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 It is however not possible to program 2 actions at the same time The solution leave at least 1 minute in between 2 actions Example Start Compressor 5 00 AM Pressure Setpoint 2 5 01 AM or later Procedure Starting from the Main screen ...

Page 54: ...ining 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 52 2920 7109 23 ...

Page 55: ...matically selected and highlighted in red Press the Enter key on the controller to set an action for this day 1 Week Action Scheme 1 2 Monday 3 Tuesday 4 Wednesday 5 Thursday 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 Instruction book 2920 7109 23 53 ...

Page 56: ...s 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 The action is now visible in the first day of the week Instruction book 54 2920 7109 23 ...

Page 57: ...Start 3 Save 4 Modify 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 1 Monday 2 Time 3 Save 4 Modify Press the Escape key on the controller The action button Modify is selected Use the Scroll keys to select the action Save Instruction book 2920 7109 23 55 ...

Page 58: ...n 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 1 Week Action Scheme 1 Instruction book 56 2920 7109 23 ...

Page 59: ... 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 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Week Timer Inactive 6 Remaining Running Time A list of 10 weeks is shown 1 Week Cycle 2 Week 1 3 Week 2 Instruction book 2920 7109 23 57 ...

Page 60: ...me 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 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Week Timer Inactive 6 Remaining Running Time A new window opens Select Week 1 to set the Week Timer active Instruction book 58 2920 71...

Page 61: ...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 2920 7109 23 59 ...

Page 62: ... 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 16 Test menu Menu icon Test or Function To carry out a display test i e to check whether the display and LED s are still intact Procedure Starting from the Main screen Move the cursor to the action button Menu and press the enter key 2 following screen appears Instruction ...

Page 63: ...tected by a security code Select the item display test and press the enter key A screen is shown to inspect the display at the same time all LED s are lit 3 17 User password menu 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 section Main screen Move the cursor to Menu and...

Page 64: ... allows to consult certain data and settings via a PC instead of the display of the controller Getting started If the compressor is equipped with a SMARTBOX the network connection of the Elektronikon is already in use To allow the web server functionality the network cable that is connected to the SMARTBOX should be unplugged and replaced by the cable of the company network If both the web server ...

Page 65: ...ter Use a UTP cable CAT 5e to connect to the controller see picture below Configuration of the network card in Windows XP Go to My Network places 1 Click on View Network connections 1 Instruction book 2920 7109 23 63 ...

Page 66: ... with the right button and select properties 1 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 Instruction book 64 2920 7109 23 ...

Page 67: ...k OK and close network connections Configuration of the web server Configure the web interface for Internet Explorer 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 Instruction book 2920 7109 23 65 ...

Page 68: ...r Group box click on the Advanced button 1 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 Instruction book 66 2920 7109 23 ...

Page 69: ...ons between them 1 see picture Click OK 2 to close the window Viewing the controller data 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 Instruction book 2920 7109 23 67 ...

Page 70: ...ettings 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 Instruction book 68 2920 7109 23 ...

Page 71: ...from controller and compressor Info status Machine status is always shown on the web interface Digital inputs Lists all Digital inputs and their status Digital outputs Lists all Digital outputs and their status Instruction book 2920 7109 23 69 ...

Page 72: ...s 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 5 Direct st...

Page 73: ...evel 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 Specific protections for Full Feature compressors Minimum setting Factory setting Maximum setting Dewpoint warning temperature ºC 10 25 99 Dewpoint warning temperature ºF 10 77 210 Service plan The built in service timers will give a Service war...

Page 74: ...onsistent 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 signal Is the time period during which the warning signal must exist before the warning message appears Delay at start Is the time period after starting which must expir...

Page 75: ...Installation 4 1 Dimension drawings Centre of gravity and weight Type L mm B mm H mm Weight kg GA 7 VSD 335 315 600 188 GA 11 VSD 325 300 610 191 GA 15 VSD 315 290 630 194 Instruction book 2920 7109 23 73 ...

Page 76: ...00 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 Instruction book 74 2920 7109 23 ...

Page 77: ...on 1 Electric cable entry for 380 V 460 V 2 Compressor cooling air outlet 3 Compressor air outlet 4 Compressor and cooling air inlet 5 Manual drain compressor 6 Automatic drain compressor 7 Cubicle and converter cooling air inlet 8 Oil level indicator 9 Dryer cooling air inlet 10 Electric cable entry for 200 230 V and 500 575 V 11 Dryer cooling air outlet 12 Water inlet Energy recovery 13 Water ou...

Page 78: ...ation proposals 2 Minimum free area to be reserved for the compressor installation Description 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 76 2920 7109 23 ...

Page 79: ...ain pipes Connect the condensate drain outlets to a drain collector See section Condensate system for the position of the outlets The drain pipes to the drain collector must not dip into the water If the pipes lead outside the room where freezing is possible they must be insulated Atlas Copco has oil water separators type OSD or OSCi to separate the major part of the oil from the condensate to ens...

Page 80: ...also be lifted after inserting beams in the slots Make sure that the beams cannot slide and that they protrude from the frame equally The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor The lifting equipment must be placed in such a way that the compressor is lifted perpendicularly Lift gently and avoid twisting In case of units equipped with t...

Page 81: ...l commercial or residential environments with a shared supply network or in an IT network extra measures can be required contact Atlas Copco Electrical connections for GA 7 VSD up to GA 15 VSD 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 Inst...

Page 82: ...s entered by means of the buttons on the control panel Compressor start stop commands via Clock function are active if programmed Remote control The compressor will react to commands from external switches Emergency stop remains active Compressor start stop commands via Clock function are still possible Have the modifications checked by Atlas Copco Stop the compressor and switch off the voltage be...

Page 83: ...ghten by hand approx half a turn 5 Warning hot surface 6 Stop the compressor before cleaning the coolers 7 Warning voltage 8 Switch off the voltage and wait at least 10 minutes before maintenance 9 Compressor remains pressurized for 180 seconds after switching off the voltage 10 If the rotation direction is wrong open the isolating switch in the voltage supply line and reverse two incoming electri...

Page 84: ...mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance The water can be used for diverse applications Components The energy recovery system is completely integrated and mainly comprises Stainless steel oil water heat exchanger Thermostatic by pass valve for energy recovery heat exchanger BV2 Two temperature sensors for water inlet and o...

Page 85: ... pipe 4 Temperature sensor water outlet pipe 5 Oil drain valve 6 Oil line from compressor oil separator vessel to ER unit 7 Oil line from ER unit to oil filter housing BV2 Location of heat exchanger by pass valve BV2 HE Heat exchanger V1 Selector valve AR Oil separator vessel OF Oil filter housing BV1 Location of oil cooler bypass valve BV1 Instruction book 2920 7109 23 83 ...

Page 86: ... e g pre heating of boiler feed water Recovery water flow The recovery water enters the unit at inlet connection 1 In heat exchanger HE the compression heat is transferred from the compressor oil to the water The water leaves heat exchanger HE via outlet connection 2 Water requirements for closed water circuits The use of a closed water circuit minimises make up water requirements Therefore the us...

Page 87: ...overy Bypass valve BV1 is integrated in the oil filter housing of the compressor and controls the oil flow to the heat exchanger HE and the main oil cooler Co of the compressor Bypass valve BV2 controls the oil flow through the oil water heat exchanger HE of the ER unit Both valves consist of an insert thermostat mounted in a housing Instruction book 2920 7109 23 85 ...

Page 88: ...Flow diagram of compressor with energy recovery system Instruction book 86 2920 7109 23 ...

Page 89: ...uit BV2 starts closing the bypass line over the ER heat exchanger HE at the lower limit of its temperature range At the upper limit of its temperature range the bypass line is completely closed and all the oil flows through the main oil cooler Co Bypass valve BV1 starts opening at 71 C 160 F and is completely open at 85 C 185 F Bypass valve BV2 starts opening at 75 C 167 F and is completely open a...

Page 90: ...etween position BV1 must have a higher opening temperature set point than BV2 in order to prevent the heat from being dissipated in the compressor oil cooler Co rather than in the oil water heat exchanger HE when using the compression heat as source for energy recovery Instruction book 88 2920 7109 23 ...

Page 91: ...erature of the oil leaving heat exchanger HE rises When the temperature rises above its set point oil cooler bypass valve BV2 will gradually allow the oil to be cooled in the oil cooler Co Recovery water flow too high temperature too low In this case bypass valve BV1 will open the bypass line allowing oil from heat exchanger HE to be mixed with oil from separator AR Energy is transferred from the ...

Page 92: ...er where strict limits apply a statement is made in the specification The water requirements refer to untreated water When water is treated some parameters will change Water treatments should be carried out by a specialized water treatment company taking the responsibility for the performance of the treated cooling water and the compatibility with the materials in the cooling circuit This includes...

Page 93: ...determine the equilibrium situation of the water determined and specified by the RSI In addition the calcium hardness must be limited to Ca ppm Ca CO3 Type of cooling system Standard Energy recovery Single pass 500 2 Recirculating with tower 500 not applicable Closed loop 1000 50 4 The Ryznar Stability Index RSI The Ryznar Stability Index is a parameter for predicting whether water will tend to di...

Page 94: ... 3 74 79 0 9 224 281 2 0 224 281 2 4 80 85 0 8 282 355 2 1 282 355 2 5 86 91 0 7 356 446 2 2 356 446 2 6 92 95 0 6 447 563 2 3 447 563 2 7 564 707 2 4 564 707 2 8 708 892 2 5 708 892 2 9 893 1000 2 6 893 1000 3 0 Interpretation of the values obtained RSI 6 boiler scale formation 6 RSI 7 neutral water RSI 7 corrosive water As a general rule the RSI index should be between 5 6 and 7 5 If that is not...

Page 95: ... 05 The values in bold are rejection limits 9 Copper Copper ppm Type of cooling system Standard Energy recovery Single pass 1 0 2 Recirculating with tower 1 not applicable Closed loop 1 0 2 10 Ammonium The limit of 0 5 ppm is a rejection limit The limitation only applies for copper containing systems 11 Suspended solids Large particles size 10 µm should not be present as they can be filtered out S...

Page 96: ... capacity of the additives X the percentage of additives 5 1 6 Energy recovery data Reference conditions See section Reference conditions and limitations Effective working pressure Consult section Compressor data for the normal working pressure Maximum allowed pressure of the heat exchanger Oil side 15 bar 217 psi Water side 10 bar 145 psi Reading settings In addition to other data the following t...

Page 97: ...e C In the tables below typical examples are given Data for low temperature rise high water flow systems Parameter Unit GA7 VSD GA11 VSD GA15 VSD Recoverable energy kW 6 2 9 7 13 2 Recoverable energy hp 8 4 13 2 18 0 Temperature at inlet C 50 50 50 Temperature at inlet F 122 122 122 Temperature at outlet C 60 60 60 Temperature at inlet F 140 140 140 Data for high temperature rise low water flow sy...

Page 98: ...ions Electric connection diagram typical example Reference Designation 1 Main Switch 2 Customer s installation Note The complete electrical diagram can be found in the electrical cubicle Instruction book 96 2920 7109 23 ...

Page 99: ...r the motor 2 Check that the electrical connections correspond to the local 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 3 Check the voltage selecting wires at the primary side of transformer T1 4 Fit air outlet va...

Page 100: ...tarted automatically The compressor may be remotely controlled 8 Check the rotation direction of the fan motor For this purpose a sheet is fixed to the top grating of the compressor 1 Switch on the voltage 2 Start the compressor and stop it immediately If the rotation direction is correct the sheet will be blown upwards If the sheet remains in place the rotation direction is incorrect 3 If the rot...

Page 101: ...art button 1 on the control panel The compressor starts running and the automatic operation LED 8 lights up During operation Keep the panels closed during operation When the motors are stopped and LED 8 automatic operation is alight the motors may start automatically When the automatic operation LED 8 is lit the regulator is automatically controlling the compressor i e loading unloading stopping o...

Page 102: ...l reaches the filler opening Fit and tighten the plug FC Unlock the emergency stop button 10 select the STOP icon on the display and press reset before restarting Regularly check that condensate is discharged during operation See section Condensate system The amount of condensate depends on environmental and working conditions Regularly check the Elektronikon display Control panel Elektronikon Gra...

Page 103: ...press emergency stop button 10 Alarm LED flashes 7 Remedy the problem cause Next unlock the button by pulling it out Next navigate to the Stop icon on the display by means of the navigation keys 3 4 and press the Select key Press Reset Do not use emergency stop button 10 for normal stopping Taking out of operation Step Action 1 Disconnect the compressor from the mains 2 Unscrew the oil filler plug...

Page 104: ...vice contracts Atlas Copco offers several types of service contracts relieving you of all preventive maintenance work Consult your Atlas Copco Customer Centre General When servicing replace all removed O rings and washers Intervals The local Atlas Copco Customer Centre may overrule the maintenance schedule especially the service intervals depending on the environmental and working conditions of th...

Page 105: ...eck list for compressors with dryer Period Operation Daily Check that condensate is discharged during operation Monthly 1 Drain inspection Check that condensate is discharged when pressing the test button on top of the electronic water drain s Condenser cleaning Stop the compressor close the air outlet valve and switch off the voltage Remove any dirt on the condenser inlet with a vacuum cleaner Ne...

Page 106: ...ir and oil leakages Have safety valve tested 1 or yearly whichever comes first 2 or every 2 years whichever comes first 3 For all 8000 hours actions contact Atlas Copco The indicated oil exchange intervals are valid for standard operating conditions see section Reference conditions and limitations and nominal operating pressure see section Compressor data Exposure of the compressor to external pol...

Page 107: ...nject Fluid Atlas Copco s Roto Inject Fluid is a specially developed lubricant for use in single stage oil injected screw compressors Its specific composition keeps the compressor in excellent condition Roto Inject Fluid can be used for compressors operating at ambient temperatures between 0 C 32 F and 40 C 104 F If the compressor is regularly operating in ambient temperatures above 35 C 95 F oil ...

Page 108: ...ly operating in ambient temperatures above 35 C 95 F oil lifetime is reduced see table oil lifetime Preventive maintenance schedule 7 3 Drive motor Bearing maintenance The motor bearing is lubricated by oil injection Re greasing is not necessary 7 4 Air filter Location of air filter Procedure 1 Stop the compressor Switch off the voltage 2 Remove the cover of the air filter AF by turning it anti cl...

Page 109: ...eiver oil tank If the compressor is equipped with an Energy Recovery unit also consult Maintenance for Energy Recovery Systems Procedure 1 Run the compressor until warm and stop the compressor 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 to depressurise the cooler see condensate system and close a...

Page 110: ...ad connection 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 Clean the seat on the manifold Lubricate the gasket of the new oil filter and screw it into place Tighten firmly by hand Clean the seat on the manifold Lubricate the gasket of the new oil...

Page 111: ...he 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 see Operating instructions During operation Refit and tighten filler plug FC When the oil level is too low go back to step 7 7 6 Coolers General Keep the coolers clean to maintain their efficiency Procedure Stop the compressor clo...

Page 112: ... Clean with an air jet in the reverse direction to normal flow Clean the condenser area with a fibre brush 7 7 Dryer maintenance instructions Safety precautions Refrigeration dryers of ID type contain refrigerant HFC When handling refrigerant all applicable safety precautions must be observed Please be specifically aware of the following points Contact of refrigerant with the skin will cause freez...

Page 113: ...s function must be undertaken by an authorised control body The installation should be checked once a year by an authorised control body 7 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 ...

Page 114: ...e compressor regularly e g twice a week until warm If the compressor is going to be stored without running from time to time protective measures must be taken Consult your supplier 7 12 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 loc...

Page 115: ...ocking edge on the valve body Fit the screw The operator must apply all relevant Safety precautions Before electrical maintenance Wait for at least 10 minutes before starting any electrical repairs as dangerous high voltage remains on the capacitors of the start and speed regulation unit during some minutes after switching off the voltage Faults and remedies compressor If the alarm LED is lit or f...

Page 116: ...tion of the compressor room Avoid recirculating of cooling air If installed check capacity of compressor room fan Oil cooler clogged Clean cooler By pass valve malfunctioning Have valve tested Air cooler clogged Clean cooler Compressor element out of order Consult Atlas Copco Degraded oil Check service intervals see Preventive maintenance schedule Condition Fault Remedy Low Load Alarm triggered Co...

Page 117: ... Shutdown Navigate to the Stop icon or to the Protections icon and press Enter 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 Instruction book 2920 7109 23 115 ...

Page 118: ...Contact Atlas Copco Over torque detection Contact Atlas Copco Under torque detection Contact Atlas Copco 1024 Over speed Contact Atlas Copco Safe torque off Check for loose wiring at inverter Push emergency stop button Check temperature switch 8192 Output phase loss Contact Atlas Copco Input phase loss Check supply voltage Check for loose wiring wiring errors Check supply voltage during start up C...

Page 119: ...rupted Check and correct as necessary Thermal protection of refrigerant compressor motor has tripped Motor will restart when motor windings have cooled down Electronic condensate drain remains inoperative Electronic drain system clogged Have system inspected Clean the filter of the automatic drain by opening the manual drain valve Check functioning of the drain by pushing the test button Condensat...

Page 120: ...eference conditions see section Reference conditions and limtations Reference Reading Air outlet pressure Depends on the setpoint desired net pressure Compressor element outlet temperature Approx 80 C 176 F ambient temperature 20 C 60 C Dewpoint temperature on Full Feature compressors Approx 4 C 39 F Instruction book 118 2920 7109 23 ...

Page 121: ...le size Cable length should not exceed the maximum length according to IEC60204 table 10 Leakage breaker optional If the installation requires a leakage breaker always use an all current sensitive leakage breaker RCM or RCD Type B according to IEC EN 60755 with a sufficient trip level Currents and fuses Compressor type Imax 1 Max fuse 1 Imax 2 Max fuse 2 GA 7 VSD IEC 50 Hz 200 V 36 8 A 40 A 39 9 A...

Page 122: ...5 VSD IEC 50 Hz 400 V N 34 0 A 40 A GA 15 VSD IEC 50 Hz 400 V 31 4 A 32 A 34 0 A 40 A GA 15 VSD IEC 50 Hz 500 V 25 1 A 32 A 27 2 A 32 A GA 15 VSD IEC 60 Hz 200 V 62 8 A 70 A 68 0 A 80 A GA 15 VSD IEC 60 Hz 230 V 54 7 A 70 A 59 9 A 80 A GA 15 VSD IEC 60 Hz 380 V 33 2 A 32 A 35 8 A 40 A GA 15 VSD IEC 60 Hz 460 V 27 4 A 32 A 29 9 A 40 A GA 15 VSD UL cUL 60 Hz 200 V 62 8 A 70 A 68 0 A 80 A GA 15 VSD U...

Page 123: ...allations of buildings part 5 selection and erection equipment and section 52 current carrying capacities in wiring systems The allowed currents are valid for PVC insulated cables with three loaded copper conductors maximum conductor temperature 70 C Installation method B2 according table B 52 1 Multi core cable in conduit on a wooden wall Maximum allowed current in function of the ambient tempera...

Page 124: ... 97 A 84 A 50 mm 167 A 145 A 132 A 119 A 102 A 70 mm 216 A 188 A 171 A 153 A 132 A 95 mm 264 A 230 A 209 A 187 A 161 A 120 mm 308 A 268 A 243 A 219 A 188 A Calculation method for IEC Single supply cables 3 phases PE configuration 1 Add 10 to the total compressor current ItotPack or ItotFF from the tables Install the prescribed fuse on each cable Parallel supply cable 2 x 3 phases PE configuration ...

Page 125: ...rding UL cUL Calculation method according UL 508A table 28 1 column 5 allowable ampacities of insulated copper conductors 75 C 167 F Maximum allowed current in function of the wire size AWG or kcmil Maximum current 10 30 A 8 50 A 6 65 A 4 85 A 3 100 A 2 115 A 1 130 A 1 0 150 A 2 0 175 A 3 0 200 A Calculation method for UL Single supply cables 3 phases 1 PE configuration 1 Add 25 to the total curre...

Page 126: ...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 9 3 Reference conditions and limitations Reference conditions Air inlet pressure abso...

Page 127: ...7 9 5 12 5 Normal effective working pressure psig 80 102 138 181 Maximum effective working pressure Workplace bar e 13 13 13 13 Maximum effective working pressure Workplace psig 189 189 189 189 Maximum effective working pressure Workplace Full Feature bar e 12 75 12 75 12 75 12 75 Maximum effective working pressure Workplace Full Feature psig 185 185 185 185 Maximum motor shaft speed rpm 5250 5250...

Page 128: ... 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 5 Normal effective working pressure psig 80 102 138 181 Maximum effective working pressure Workplace bar e 13 13 13 13 Maximum effective working pressure Workplace psig 189 189 1...

Page 129: ...14 F 140 F 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 1900 5200 19 Type Relay voltage free contacts Rated voltage AC 250 V AC 10 A max Rated voltage DC 30 V DC 10 A max Digital inputs Number of inputs ...

Page 130: ...Number of pressure inputs 2 Elektronikon Graphic controller p n 1900 5200 10 1900 5200 19 Number of temperature inputs 5 Elektronikon Graphic controller p n 1900 5200 10 1900 5200 19 Instruction book 128 2920 7109 23 ...

Page 131: ...al methods without the written permission of the manufacturer The safety valve must correspond with pressure surges of 1 1 times the maximum allowable operating pressure 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 This vessel has been designed and built to guarantee an operati...

Page 132: ...r 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 130 2920 7109 23 ...

Page 133: ...D up to GA 15 VSD 1625 4215 01 Vessel 9 1 l 15 bar e 8 C 120 C 2202 8891 05 Safety valve IV 830 1010 39 Safety valve IV Compressor type Component Description Number of cycles 1 Minimum wall thickness Visual inspection frequency 2 Hydrostatic inspection frequency 2 GA 7 VSD up to GA 15 VSD 1625 4215 01 Vessel 2 x 106 2 mm 1 year 10 years 2202 8891 05 Safety valve 0830 1010 39 Safety valve The compr...

Page 134: ...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 132 2920 7109 23 ...

Page 135: ...er the harmonized 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 device Instruction book 2920 7109 23 133 ...

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Page 138: ...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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