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Atlas Copco GA 160 VSD, Instruction Book

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Atlas Copco GA 160 VSD Instruction Book Download Page 19

3

Elektronikon regulator

3.1

Elektronikon control system

Main functions

In general, the Elektronikon regulator has the following functions:

• Controlling the motor speed (Variable Speed Drive), reducing the power consumption and pressure band.
• Controlling the speed of the fans of the coolers, reducing the power consumption and noise level.
• Protecting the compressor.
• Monitoring components - service warning.
• Automatic restart after voltage failure.

Controlling the compressor speed - reducing power consumption and pressure band

VSD compressors optimise the power consumption and reduce the operating pressure band by matching the
motor speed to the air net pressure.

The regulator will continuously vary the motor speed maintaining the net pressure as close as possible to the
programmed pressure set-point. The pressure fluctuations will be very low.

Indirect stopping

Example of a pressure/time diagram

Ref.

Designation

(1)

Pressure

(2)

Direct stop offset

(3)

Set-point

(4)

Motor speed

(5)

Minimum

(6)

Time

Instruction book

APF192090

17

Summary of Contents for GA 160 VSD

Page 1: ...GA 160 VSD APF192090 Instruction book ...

Page 2: ......

Page 3: ...ents 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 2014 10 www atlascopco com ...

Page 4: ...OIL SYSTEM 12 2 3 COOLING AND CONDENSATE SYSTEM 16 3 Elektronikon regulator 17 3 1 ELEKTRONIKON CONTROL SYSTEM 17 3 2 CONTROL PANEL 19 3 3 FUNCTION KEYS 20 3 4 SCROLL KEYS 21 3 5 EMERGENCY STOP BUTTON 22 3 6 CONTROL PROGRAMS 22 3 7 CALLING UP MENUS 24 3 8 MAIN SCREEN MENU 25 3 9 STATUS DATA MENU 26 3 10 MEASURED DATA MENU 29 3 11 COUNTERS MENU 30 3 12 TEST MENU 31 3 13 MODIFY PARAMETERS 31 3 14 MO...

Page 5: ...FUSES 54 4 4 ELECTRIC CONNECTIONS 55 4 5 QUALITY OF SAFETY COMPONENTS 63 4 6 INSTALLATION INSTRUCTIONS FOR CUBICLE FAN 63 4 7 INSTALLATION INSTRUCTIONS FOR HEAVY DUTY FILTER FOR VSD CUBICLE 66 4 8 INSTALLATION INSTRUCTIONS FOR DRYER BY PASS 69 4 9 INSTALLATION INSTRUCTIONS GSM ALARM 71 4 10 PICTOGRAPHS 74 5 Operating instructions 76 5 1 INITIAL START UP 76 5 2 BEFORE STARTING 78 5 3 STARTING 78 5 ...

Page 6: ...NTERVALS 91 7 3 FILTER ELEMENT CHANGE 91 7 4 FILTER DISPOSAL 92 7 5 REFERENCE CONDITIONS 92 7 6 PRINCIPAL DATA 92 8 Integrated dryer 93 8 1 CONDENSATE DRAIN SYSTEM 93 8 2 MAINTENANCE INSTRUCTIONS 94 8 3 PROBLEM SOLVING 95 9 Adjustments and servicing procedures 96 9 1 AIR FILTERS 96 9 2 COOLERS 98 9 3 SAFETY VALVE 100 10 Problem solving 101 10 1 PROBLEM SOLVING 101 11 Technical data 103 Instruction...

Page 7: ... 11 2 REFERENCE CONDITIONS 104 11 3 LIMITS 104 11 4 SETTINGS OF SAFETY VALVE 104 11 5 SETTINGS OF CIRCUIT BREAKERS 104 11 6 COMPRESSOR DATA 105 12 Pressure equipment directives 106 13 Documentation 108 Instruction book APF192090 5 ...

Page 8: ...ff the voltage Depressurize the compressor Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work always disconnect and ch...

Page 9: ...ressor 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 10: ...rer 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 remote...

Page 11: ...ervance 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 maintena...

Page 12: ...ring 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 13: ...r pulsation free air By continuously matching the speed of the drive motor to the air net pressure the compressor optimizes energy consumption and reduces the operating pressure band GA VSD compressors are air cooled Pipe connections NPT connections Roto Xtend Duty Fluid Roto Xtend Duty Fluid is a special long life lubricant for GA oil injected screw compressors It provides better cooling and exte...

Page 14: ...2 2 Air and oil system Flow diagrams Flow diagram for air cooled GA VSD compressors Energy recovery model year 2007 Instruction book 12 APF192090 ...

Page 15: ...oled GA VSD compressors Energy recovery model year 2014 Drawing Reference Description In parentheses 1 Air outlet 2 Air inlet 3 Condensate drain of the compressor 4 Condensate drain of the dryer Instruction book APF192090 13 ...

Page 16: ...references of options 7 ID Integrated dryer 12 ER Energy recovery 13 DDF DD filter only with option 7 25 SPM Shock Pulse Modulation sensor Balloon references A PT20 and TT19 should be moved if the dryer bypass is installed B TT11 measures at position B on machines with a C146 compressor stage C TT11 measures at position C on machines with a C190 compressor stage Refer to your Atlas Copco Customer ...

Page 17: ...ow a minimum pressure The valve has a built in check valve Oil system Air pressure forces the oil from receiver AR through oil cooler Co filters OF oil stop valve Vs and an oil injection valve to the compressor element E and the lubrication points The oil injection valve will open at higher ambient temperatures to keep the element outlet temperature low A by pass valve by passes the oil cooler Co ...

Page 18: ...f air cooled GA Dac Automatic condensate drain compressor Dmc Manual condensate drain A condensate trap is installed downstream of the air cooler to prevent condensate from entering the air outlet pipe The trap is provided with a float valve for automatically draining condensate and with a manual drain valve Cooling system On air cooled compressors the air and oil coolers are cooled by fans Instru...

Page 19: ...ic restart after voltage failure Controlling the compressor speed reducing power consumption and pressure band VSD compressors optimise the power consumption and reduce the operating pressure band by matching the motor speed to the air net pressure The regulator will continuously vary the motor speed maintaining the net pressure as close as possible to the programmed pressure set point The pressur...

Page 20: ...rload If the element outlet temperature or compressor outlet temperature exceeds the programmed shut down level the compressor will be stopped LED 2 will flash and a message will appear on display 1 The compressor will also be stopped if there is overload of the drive motor On air cooled compressors the compressor will also stop if there is overload of the fan motors Consult the section Maintenanc...

Page 21: ... to the module is restored within a programmed time period The power recovery time the period within which the voltage must be restored to have an automatic restart can be set between 15 and 3600 seconds or to Infinite If the power recovery time is set to Infinite the compressor will always restart after a voltage failure no matter how long it takes to restore the voltage A restart delay can also ...

Page 22: ... Stop button Button to stop the compressor LED 8 goes out S2 Emergency stop button Push button to stop the compressor immediately in the event of an emergency After remedying the trouble unlock the button by pulling it out 3 3 Function keys Control panel Function keys The keys 1 are used To manually load unload the compressor not for VSD compressors To call up or to program settings To reset a mot...

Page 23: ...ified settings Reset To reset a timer or message Return To return to a previously shown option or menu Unload Not used on VSD Variable Speed Drive compressors To unload the compressor manually Extra To find the module configuration of the regulator 3 4 Scroll keys Control panel The keys 1 allow the operator to scroll through the display As long as a downwards pointing arrow is shown at the utmost ...

Page 24: ...n emergency stop the compressor element is stopped immediately and the solenoid valve will be deactivated by Elektronikon regulator No unload status is reached The check valve prevents oil flow back from reversed rotation of the compressor element Before starting any maintenance or repairs wait until the compressor has stopped and open the isolating switch customer s installation to switch off the...

Page 25: ...f the compressor Is the gateway to all functions Status Data Calls up the status of the compressor protection functions shut down shut down warning and service warning Resets a shut down motor overload and service condition Measured Data Calls up the data currently measured and the status of a number of inputs Instruction book APF192090 23 ...

Page 26: ...mmands Configuration time date display language Service Calls up service plans and resets the timers after carrying out the service actions in a service plan Saved Data Calls up the saved data last shut down last emergency stop data Unload Load Loads and unloads the compressor manually 3 7 Calling up menus Description Control panel When the voltage is switched on the Main screen is shown automatic...

Page 27: ...nu shows the status of the compressor operation and is the gateway to all functions implemented in the regulator Procedure The Main screen is shown automatically when the voltage is switched on If the function or arrow keys 1 2 and 3 are not used for some minutes the regulator will automatically return to the Main screen Whenever displayed on a submenu screen press the Mainscreen F1 key to return ...

Page 28: ...et valve and depressurize the air system Function Control panel The Status data submenu gives information regarding the status of the compressor protection functions shut down shut down warning and service warning and allows resetting of a shut down motor overload and service condition Procedure Starting from the Main screen see Main screen menu Press the key Menu F1 the option Status Data will be...

Page 29: ...eset Switch off the voltage and remedy the trouble After remedying and when the shut down condition has disappeared switch on the voltage and press the key Reset F3 Press the keys Menu and Mainscreen to return to the Main screen and restart the compressor by means of start button 3 A shut down warning message exists A shut down warning level is a programmable level below the shut down level If a s...

Page 30: ...pears Press the key Menu F1 and the tabulator key 2 to select the Status data menu the option Service is blinking Scroll to this option and select it by pressing the tabulator key 2 two options may blink Inputs if the programmed service level of a component is exceeded e g the maximum pressure drop of the air filter Plan if a service plan interval is exceeded Stop the compressor and switch off the...

Page 31: ...reen menu Press the key Menu F1 Press the arrow down key 1 until Measured Data is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 By pressing the scroll keys 1 a number of actually measured data can be found If one of the sensors is linked to a shut down service or warning function both the actually measured value as well as the corresponding shut down warning or s...

Page 32: ...Procedure Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Counters is followed by a horizontal arrow Press the tabulator key 2 to activate the menu By pressing the arrow key 1 the above mentioned data can be found Example of a Counters screen Running Hours 2455 hrs Loaded Hours 1973 hrs Motor Starts 945 Menu F1 F2 F3 Instruction book 30 APF...

Page 33: ...rns on the display which enable the operator to check that each pixel still functions normally the LEDs are lit at the same time Press the Menu key F1 to return to the submenu 3 13 Modify parameters Function To modify a number of programmable settings Compressor motor settings see section Modifying compressor motor settings Fan motor settings see section Modifying fan motor settings Parameters see...

Page 34: ...ollowed by a horizontal arrow For each parameter the modifying procedure is similar to the example below Modifying the net pressure setpoints If desired the operator can program two setpoints Setpoint 1 and Setpoint 2 Consult the section above for selecting the option Setpoint 1 The screen shows that the current setting is 7 0 bar e To modify this setting press the key Modify F2 The setting will b...

Page 35: ...ngs Control panel Function To modify the fan motor operation mode Consult the menu flow in section Control programs Procedure Starting from the Main screen see section Main screen menu Press the key Menu F1 Press the arrow down key 1 until Modify Parameters is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 The first item Fan Motor will be followed by a horizontal ...

Page 36: ...e arrow down key until the option Parameters is followed by a horizontal arrow Press the tabulator key 2 the first item and its setting will appear Press the arrow down key 1 until the parameter to be modified is followed by a horizontal arrow To modify this setting press the key Modify the setting starts blinking The key Limits can be used to find out the limitations for the parameter Use the arr...

Page 37: ...rting from the Main screen see Main screen menu Press the Menu F1 key Press the arrow down key 1 until Modify parameters is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 Press the arrow down key 1 until Protections is followed by a horizontal arrow Press the tabulator key 2 the first items will appear Press the arrow down key 1 until the item to be modified is fo...

Page 38: ...u Modify F1 F2 F3 The regulator will not accept new values beyond the limits Press the key Limits to check the limits for the parameter Consult Programmable settings for the most important settings 3 18 Modifying service plans Function To modify the hour intervals for the service levels Service plans The service actions to be carried out are grouped in plans called Service level A B C or D When re...

Page 39: ...r to pressure band 2 On Saturday at 18 00 stopping Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Modify Parameters is followed by a horizontal arrow Activate the menu by pressing tabulator key 2 Use the arrow down key 1 to scroll until the option Clock Function is followed by a horizontal arrow Activate the menu by pressing tabulator key ...

Page 40: ... and modify this line in a similar way to the following command 06 15 Pressure Band 1 Press the key Menu F1 and scroll to Friday Thursday Friday Saturday Menu Delete F1 F2 F3 Programming the command to change over at 18 o clock to Pressure Band2 is carried out in a similar way as described above Press the key Menu F1 and scroll to Saturday Programming the command 18 00 Compressor Stop is carried o...

Page 41: ...difying a command Suppose the command to stop the compressor on Saturday 18 00 is to be modified i e stopping at 17 o clock instead of 18 o clock Starting from the Main screen press the key Menu F1 press the arrow down key 1 until the option Modify Parameters is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 Use the arrow down key 1 to scroll until the option Cloc...

Page 42: ...llowing screen appears Monday Tuesday Wednesday Menu Delete F1 F2 F3 Scroll through the display until Monday is followed by a horizontal arrow Press the tabulator key 2 Scroll through the compressor start stop pressure band commands until the first empty command line is indicated by the horizontal arrow Press the key Modify the first two digits start blinking Enter 18 00 Compressor Stop using the ...

Page 43: ...ng screen appears Clock Function Not Activated Menu Modify Delete F1 F2 F3 Deleting all commands Press the key Delete in the screen above A question to confirm the deleting operation will appear Deleting all commands of a specific day Scroll through the display until the desired day is followed by a horizontal arrow Press the key Delete a question to confirm the deleting operation will appear Dele...

Page 44: ...key Modify F2 the first field 14 will blink Use the scroll keys 1 to change the setting then press the tabulator key 2 to go to the next field 30 The setting of this field can now be modified using the scroll keys 1 Press the key Program F1 to program the new value or the key Cancel F3 to cancel the modification operation the original value will be retained The procedure to modify other parameters...

Page 45: ...the Elektronikon regulator When a service plan interval is reached a message will appear on the screen see section Status data After carrying out the service actions related to the indicated levels the timers are to be reset Example Service plans Intervals Service plan A Every 4000 running hours Service plan B Every 8000 running hours Service plan C Every 16000 running hours Service actions accord...

Page 46: ...urs Press the arrow down key 1 to find out which service plans were carried out previously following screen appears Previous Timer Level A 4008 hrs Back F1 F2 F3 The screen shows that plan A was carried out at 4008 running hours Stop the compressor switch off the voltage and carry out the service operations related to the indicated service plans see section Preventive maintenance schedule Switch o...

Page 47: ... key 2 The first option is shown Last shutdown 1 Press the tabulator key 2 to find out the date time and other data reflecting the status of the compressor at the last shut down If desired scroll through the other items 3 23 Programmable settings Compressor motor Minimum setting Factory setting Maximum setting Set point 1 2 GA VSD 125 psi 8 6 bar Pack compressor bar e 5 8 6 9 1 Indirect stop level...

Page 48: ...ure Shut down warning level C 20 66 80 Shut down level C 20 80 80 Compressor element outlet temperature Shut down warning level C 80 114 120 Shut down level C 80 120 120 Cooling medium temperature Air cooled compressors shut down warning level C 0 50 55 Air cooled compressors shut down level C 0 55 55 Delay at signal sec 0 20 60 Ambient temperature Shut down warning level C 0 50 55 Shut down level...

Page 49: ...e remark 2000 See remark Analogue signals Minimum setting Factory setting Maximum setting Dp of oil separator shut down warning level bar 0 0 8 1 0 Delay at signal Dp of oil separator sec 0 60 255 Dp of air filter Shut down warning level mbar 85 80 0 Shut down level mbar 85 85 0 Delay at signal Dp of air filter sec 0 60 255 Dp of DD filter mbar 100 350 350 Delay at signal sec 0 60 255 Remark A num...

Page 50: ...e and required stop period is expected However if the decrease in net air pressure should require a new start of the compressor the regulator will start the compressor after the minimum stop time Power recovery time Is the period within which the voltage must be restored to have an automatic restart Is accessible if the automatic restart is activated To activate the automatic restart function cons...

Page 51: ...4 Installation 4 1 Dimension drawing Compressor dimensions Dimension drawing of air cooled Pack VSD compressors Instruction book APF192090 49 ...

Page 52: ...iew 10 Manual drain 11 Automatic drain 12 Detail X 15 Front view 16 Top view 17 Slotted holes for horizontally pulling unit out of container 18 Manual drain aftercooler 19 Automatic drain aftercooler 20 z height of compressor 21 Type 25 Compressed air outlet Pack compressor 31 Cooling air outlet VSD cubicle 32 VSD cubicle ventilation 33 Electric cable entry VSD cubicle 34 Motor and canopy ventilat...

Page 53: ...4 2 Installation proposal Compressor room example Compressor room example of GA VSD air cooled compressor Text on drawing Instruction book APF192090 51 ...

Page 54: ...ed 14 Only C and G can be ducted 15 Cubicle ventilation inlet 16 Cubicle ventilation outlet 17 C F if ducted should be ducted separately 18 Cooling air inlet 19 Only C F and G can be ducted 20 Motor ventilation air inlet and dryer cooling air inlet 21 Only C E and D can be ducted 22 C E if ducted should be ducted separately 23 Only F E and B can be ducted 24 F E if ducted should be ducted separate...

Page 55: ...let pipe in m p Absolute pressure at the compressor outlet in bar a Qc Free air delivery of the compressor in l s It is recommended that the connection of the compressor air outlet pipe is made on top of the main air net pipe in order to minimize carry over of possible condensate residue As a rule of thumb the following formula can be used to calculate the recommended volume of the air net V 30 x ...

Page 56: ...ual condensate drain valve Lay out the drain piping towards the condensate collector The drain pipes must not dip into the water of the drain collector It is recommended to provide a funnel to allow visual inspection of the condensate flow 6 Location of the Elektronikon regulator 7 See Electric cable size for the recommended size of the supply cables Check that the electrical connections correspon...

Page 57: ...nstalled If the customer wishes to or needs to install a leakage detection device it should be of type B and should comply with IEC755 Amendment 2 General requirements for residual current operated protective devices Atlas Copco advises customers to install the following earth leakage detection device BENDER RCMA 470LY with external current transformer http www bender org prod html Network type TT...

Page 58: ...tion system provides a direct earth to the exposed conductive parts of the installation The connection is made through the PEN conductor Within the TN power distribution system there are three sub types TN S TN C and TN C S identified according to neutral and protective earth conductors Nearly 85 to 90 of industrial networks are TN type Network type TN S Terra Neutral Separate The TN S power distr...

Page 59: ...ition the exposed conductive parts of the installation are connected to earth electrodes that are independent from the power system s earth A Power system earth B Exposed conductive parts Network type IT Impedance Terra The IT power distribution system has no direct connection to Protective Earth PE It is earthed via a high ohmic impedance so that the network is effectively behaving like an uneart...

Page 60: ...e Air temperature No frost allowed Relative humidity 5 to 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels No conducting dust allowed Chemical gasses Class 3C2 Solid particles Class 3S2 Vibration I IEC 60068 2 Maximum 1 mm 0 04 in 5 to 13 2 Hz Maximum 7 m s2 23 ft s2 13 2 to 100 Hz sinusoidal Shock IEC 60068 2 29 Not allowed...

Page 61: ...Electric cabinet Cabinet with VSD Variable Speed Drive unit of GA 132 160 VSD Instruction book APF192090 59 ...

Page 62: ... Circuit breakers condensate circuit K13 Auxiliary relay motor running indication K21 Contactor emergency stop M Drive motor M25 Fan motor air cooler M26 Fan motor air cooler Q1 Circuit breaker control circuit Q2 Circuit breaker compressor motor of dryer Q20 Circuit breaker supply circuit of cooler block fan motors Q25 Circuit breaker fan motor M25 Q26 Circuit breaker cooler fan motor T1 T2 Transf...

Page 63: ... cooled 3 Fan motor air cooled 4 Drive motor of dryer 5 Fan motor of dryer air cooled Cable connection for GA 110 VSD GA 132 VSD and GA 160 VSD Always use cable glands A plate 1 has to be made by the customer to cover up the hole in the cubicle and to install cable glands Instruction book APF192090 61 ...

Page 64: ...Instruction book 62 APF192090 ...

Page 65: ... following B10d values are advised Emergency stop button 500 000 Main contactor 1 333 333 4 6 Installation instructions for cubicle fan Description The fan must be installed on the cubicle roof with 8 bolts 0147 1963 08 as follows Take off the top of the fan assembly fan stays Mount the fan with 8 bolts to the roof as shown in figure A the fan is made invisible to show the bolt positions Reinstall...

Page 66: ...Figure A Instruction book 64 APF192090 ...

Page 67: ...Figure B Instruction book APF192090 65 ...

Page 68: ...ompleted assembly of the cubicle fan 4 7 Installation instructions for heavy duty filter for VSD cubicle Description 1 Remove the original filters 1 Remove the red plates 2 Instruction book 66 APF192090 ...

Page 69: ...als 3 on the back side of the box then install the box to the cubicle door using rivets The ordering number for the seals is 1619 5188 00 3 Install the heavy duty filters as shown below Instruction book APF192090 67 ...

Page 70: ...Text on figure Instruction book 68 APF192090 ...

Page 71: ...yer is required connect the compressor to the air net as shown below The compressed air outlet temperature sensor G3 8 and the pressure transducer 1 4 18 NPT must be relocated to the delivery pipe upstream of the shut off valve The new location is indicated by x The temperature sensor and pressure transducer must be positioned perpendicular to the air flow at all time as shown Instruction book APF...

Page 72: ...V1 Shut off valve air net V2 By pass valve compressor V3 By pass valve dryer X New location for temperature sensor and pressure transducer 1 Pipe towards air net 2 Nipple Instruction book 70 APF192090 ...

Page 73: ...wo power wires ordering number 0017 2010 40 one earth wire ordering number 0017 2070 40 connector 12X14 ordering number 1088 0037 62 the connector is supplied loose with the Air contact module Install the power supply cable plug the 3 pole connector 12X14 4 in the Air contact module Plug the LAN cable 1622 0676 20 3 into the Elektronikon Mk4 and in the Aircontact module 5 Instruction book APF19209...

Page 74: ...cable can be led through a present conduit gland preferably the gland which contains the Electronic drain cables or a grommet can be used in a closed hole Once outside the cubicle the wire can be brought to the outside roof of the machine Instruction book 72 APF192090 ...

Page 75: ...Software installation For software installation please contact your local Atlas Copco service center Instruction book APF192090 73 ...

Page 76: ... or repair 17 Before connecting the compressor electrically consult the instruction manual for the motor rotation direction 18 Torques for steel Fe or brass CuZn bolts 19 Consult the instruction manual before greasing 20 Switch off the voltage before removing the protective cover inside the electric cabinet 21 Oil the gaskets screw on the filters and tighten by hand approx one half turn 22 Consult...

Page 77: ...Ref Designation 29 Do not mix oil brands Instruction book APF192090 75 ...

Page 78: ...uch a way that the compressor is lifted perpendicularly Lift gently and avoid twisting General preparations for GA VSD compressors Step Action 1 Install the compressor see the sections Dimension drawing Installation proposal and Electric cable size 2 Stick labels near the control panel to warn the operator that the compressor may start automatically after a voltage failure the compressor is automa...

Page 79: ...Cooling and condensate system 2 Switch on the voltage 3 Start the compressor and stop it immediately Check the rotation direction of the drive motor while the motor is coasting to a stop To determine the rotation direction of the motor look at the fan through the grating at the non drive end of the motor The correct rotation direction is indicated by an arrow on the gear casing and on the fan cowl...

Page 80: ...e air outlet valve Check the oil level The pointer of the oil level gauge should be in the green range or orange range If the compressor has only just stopped wait one minute before checking the level 5 3 Starting Procedure Step Action When the compressor is stopped and the automatic operation LED 3 is lit the compressor may start automatically If the start stop timer is active the compressor may ...

Page 81: ... delivery to the air consumption and the compressor will start and stop whenever necessary Keep all doors closed during operation Example of the main screen Compressor Outlet 6 6 bar Compressor Speed 2100 rpm Menu F1 F2 F3 5 5 Checking the display Warning Before carrying out any maintenance repair work or adjustment stop the compressor press the emergency stop button and switch off the voltage Clo...

Page 82: ...plan interval has been exceeded or if a service level for a monitored component has been exceeded Carry out the service actions of the indicated service plans or replace the component and reset the relevant timer 4 Regularly check the actual compressor status by pressing the arrow down key from the main screen Example of the main menu Status data Measured Data Counters Mainscreen F1 F2 F3 Example ...

Page 83: ... compressor proceed as follows Step Action 1 Stop the compressor and close the air outlet valve 2 Switch off the voltage and disconnect the compressor from the mains 3 Depressurize the compressor by opening the drain valve and loosening the oil filler plug one turn 4 Shut off and depressurize the part of the air net which is connected to the outlet valve Disconnect the compressor air outlet pipe f...

Page 84: ...m Damaged bolts must not be re used O rings must be replaced 5 The safety valve is designed in such a way that the pressure will not permanently exceed the maximum allowable operating pressure of the vessel except for short pressure surges up to 1 1 times the design pressure 6 Only use oil specified by the manufacturer 7 Make sure the vessel is fully depressurised before opening the drain plug or ...

Page 85: ...sed by the use of unauthorized parts is not covered by Warranty or Product Liability General When servicing replace all removed gaskets O rings and washers Preventive maintenance schedule Period Running hours Operation Daily 8 Check readings on display Daily 8 Check that condensate is discharged during loading Daily 8 Check oil level Before starting the level should be in the middle of the sight g...

Page 86: ...otal Responsibility Plan Contact your Customer Centre to set up a tailor made service agreement It will ensure optimum operational efficiency minimize downtime and reduce the total life cycle costs Service plan A number of service operations are grouped called Level A Level B Level C Each level stands for a number of service actions to be carried out at the time intervals programmed in the Elektro...

Page 87: ... the compressor in excellent condition Roto Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 C 32 F and 46 C 115 F see section Service kits Important Never mix oils of different brands or types 6 4 Oil change Warning The operator must apply all relevant Safety precautions Control panel Control panel of MkIV regulator Instruction book APF192090 85 ...

Page 88: ...ressurize by unscrewing the vent plug on top of the air receiver to permit any pressure in the system to escape Wait until all the pressure in the system is released 2 Drain the oil by removing the drain plug of the flexible fixed to the bottom of the air receiver Draining the oil cooler on air cooled compressors Instruction book 86 APF192090 ...

Page 89: ...ift the oil cooler and fix the safety support Remove the vent plug at the left side of the cooler The oil is drained via the cooler drain plug at the inlet connection 6 After draining remove the safety support and bring the oil cooler back to its original position Fix the cooler 7 Drain the compressor element as described below 8 Reconnect the cooler inlet 1 and oulet pipe 4 9 Reinstall the stays ...

Page 90: ... flexible to drain the oil from the gearbox 3 Reinstall the drain plugs after draining 4 Disconnect the flexible from the bypass valve 5 to drain the oil from the oil filter housing 5 Reinstall the flexibles to the bypass valve after draining Oil filter change 1 Use an oil pan to avoid oil spillage Unscrew the oil filters 6 Instruction book 88 APF192090 ...

Page 91: ...9 Tighten filler plug FC 10 Tighten the vent plug on top of the air receiver Resetting the Elektronikon regulator After carrying out all service actions in the relevant Service Plan reset the service warning as follows 1 Press the Menu key 3 2 Press key 1 until Service is followed by an arrow pointing to the right Activate the menu by pressing key 2 3 Press key 1 until the related Service Plan is ...

Page 92: ...See Oil specifications Instruction book 90 APF192090 ...

Page 93: ...filter s lifetime will be reduced considerably 7 2 Service intervals The following service intervals should be observed For filters operating less than 4000 hours per year 12 months For filters operating 8000 hours per year 4000 hours or 6 months whichever comes first 7 3 Filter element change Procedure When maintaining the filter keep in mind the following 1 Isolate the filter from the air net 2 ...

Page 94: ...ant e g FOODLUBE EXTREME may be applied to screw threads and O rings to facilitate the assembly 7 4 Filter disposal Used filters must be disposed of in an environmentally friendly and safe manner and in line with the local recommendations and environmental legislation 7 5 Reference conditions Air inlet pressure 7 bar e Air inlet temperature 20 C Ambient temperature 20 C 7 6 Principal data Maximum ...

Page 95: ...phragm 5 opens outlet 6 discharging the condensate When the collector has been emptied the outlet closes quickly without wasting compressed air When the controller registers a malfunction the red alarm LED starts flashing a warning appears on the display of the regulator and the electronic drain valve will automatically change to the alarm mode opening and closing the valve according to a sequence...

Page 96: ...owing points are stressed Contact of refrigerant with the skin will cause freezing Special gloves must be worn and if there is contact with the skin the skin should be rinsed with water On no account may clothing be removed Fluid refrigerant will also cause freezing of the eyes therefore safety glasses must be worn Refrigerant R404a is poisonous Do not inhale refrigerant vapors Check that the work...

Page 97: ...rain system clogged Have the system cleaned Condenser pressure too high or too low Cooling water system or air system clogged Have cooling water system or air system cleaned Cooling water temperature or air temperature too high Check and correct as necessary Compressor stops or does not start Electric power supply to compressor is interrupted Check and correct as necessary Motor overload protectio...

Page 98: ...ning Stop the compressor close the air outlet valve press the emergency stop button and switch off the voltage The operator must apply all relevant Safety precautions Control panel of MkIV regulator Control panel of MkIV regulator Instruction book 96 APF192090 ...

Page 99: ...el 4 5 Reset the message and service timer Press the Menu key 3 Press key 1 until Service is followed by an arrow pointing to the right Activate the menu by pressing key 2 Press key 1 until Air filters is followed by an arrow pointing to the right Activate the menu by pressing key 2 Press Reset key 3 the timer is reset to 0 Instruction book APF192090 97 ...

Page 100: ...f the cooler cleanliness can be analyzed by comparing this value with the value in the table below depending on the compressor model Substract 3 mm WG from the values in the table when ducting is installed The values are given at maximum fan speed as activated by the cleanliness test Mild clogging means that 25 of the section is blocked Heavy clogging means that 50 of the section is blocked The va...

Page 101: ...cooled compressors proceed as follows Step Action 1 Take off the side panels of the compressor and remove the stays 2 Open the two inside doors 3 Remove any dirt form the coolers with a fibre brush brush in the direction of the fins Also remove any dirt from the fans 4 Clean the coolers with an air jet in the reverse direction to normal flow Use low pressure air if necessary the pressure may be in...

Page 102: ...y precautions Never run the compressor without safety valves No adjustments are allowed Testing The valve can be tested on a separate compressed air line Consult the Atlas Copco Customer Centre if the valve does not open at the correct pressure see the section Settings of safety valve Instruction book 100 APF192090 ...

Page 103: ...pply all relevant Safety precautions Control panel Control panel of MkIV regulator Faults and remedies A service message appears on the display Stop the compressor and carry out the indicated service actions Reset the message see Section Service menu A shut down warning message appears on the display The alarm LED will light up indicating that the temperature at the outlet of the compressor elemen...

Page 104: ...s malfunctioning Remove float valve assembly clean and check EWD electronic water drain malfunctioning Consult Atlas Copco Condition Fault Remedy Compressor air delivery or pressure below normal Air consumption exceeds air delivery of compressor Check equipment connected Choked air filters Replace filters Air leakage Check and correct Condition Fault Remedy Compressor element outlet temperature or...

Page 105: ...Compressor data At pressure set point Reference Units 4 bar e 7 bar e 9 5 bar e 13 5 bar e Dp of air filter approx bar 0 05 0 05 0 05 0 05 Dp of oil separator bar 0 8 0 8 0 8 0 8 Oil injection pressure approx bar 3 1 4 9 6 5 9 0 Compressor outlet temperature C 55 55 55 55 Element out temperature C 100 100 100 100 Cooling medium temperature C 46 46 46 46 Dew point temperature C 3 3 3 3 Instruction ...

Page 106: ...rking pressure See section Compressor data 11 4 Settings of safety valve Compressor type Setting For GA compressors with a maximum working pressure of 5 2 6 9 8 6 10 4 or 13 8 bar until compressor serial number APF189553 15 bar e For GA compressors with a maximum working pressure of 5 2 6 9 8 6 10 4 or 13 8 bar from compressor serial number APF189554 14 bar e 11 5 Settings of circuit breakers IEC ...

Page 107: ...D Q1 A HAT Q20 A STD Q20 A HAT Q2 A Q40 A Q41 A TT TN 460 60 CSA UL 2 5 2 5 28 31 59 9 TT TN 575 60 CSA UL 2 5 2 5 17 17 36 20 9 IT 460 60 CSA UL 2 5 2 5 28 31 59 9 IT 575 60 CSA UL 2 5 2 5 17 17 36 20 9 11 6 Compressor data Data for GA 125 psi 8 6 bar 60 Hz compressors Units GA 160 VSD Maximum working pressure GA Pack bar e 9 1 Nominal working pressure bar e 8 6 Motor shaft speed for Pack compres...

Page 108: ...s of category I according to 97 23 EC are integrated into the machine and fall under the exclusion of article I section 3 6 The following pressure bearing parts are of category higher than I Oil separator vessel Cat IV Design pressure 15 bar e content 290 l Design standard ASME section VIII div 1 Safety valve Cat IV Design code AD Merkblätter A2 Re inspection data Text on figure Instruction book 1...

Page 109: ...ll thickness after corrosion of the vessel 5 5mm 0 216 in Minimum wall thickness after corrosion of the cover 8 mm 0 315 in Lifetime infinite according to AD2000 S1 4 2 2 Delta p 7 5 bar 108 8 psi Casting factor cover 0 8 Welding factor vessel 0 7 Instruction book APF192090 107 ...

Page 110: ...13 Documentation Declaration of conformity Typical example of a Declaration of Conformity document Instruction book 108 APF192090 ...

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Page 112: ...he flexibility to adapt to the diverse demands of the people we cater for It s the commitment to our customers business that drives our effort towards increasing their productivity through better solutions It starts with fully supporting existing products and continuously doing things better but it goes much further creating advances in technology through innovation Not for the sake of technology ...

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