Atlas Copco GA 30+ Instruction Book Download

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Motor side view, GA 30

up to GA 45 Full-Feature

Instruction book

2920 7180 30

Summary of Contents for GA 30+

Page 1: ...Atlas Copco Oil injected rotary screw compressors GA 30 GA 37 GA 45 Instruction book ...

Page 2: ......

Page 3: ...pying 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 2016 04 No 2920 7180 30 www atlascopco com ...

Page 4: ... OIL CIRCUIT 17 2 3 COOLING SYSTEM 20 2 4 CONDENSATE SYSTEM 20 2 5 REGULATING SYSTEM 23 2 6 ELECTRICAL SYSTEM 24 2 7 AIR DRYER 25 3 Elektronikon controller 27 3 1 ELEKTRONIKON CONTROLLER 27 3 2 CONTROL PANEL 28 3 3 ICONS USED ON THE DISPLAY 29 3 4 MAIN SCREEN 31 3 5 SHUT DOWN WARNING 32 3 6 SHUT DOWN 33 3 7 SERVICE WARNING 35 3 8 SCROLLING THROUGH ALL SCREENS 36 3 9 CALLING UP TEMPERATURES 40 3 10...

Page 5: ... THE UNIT OF TEMPERATURE 51 3 23 CALLING UP MODIFYING UNIT OF PRESSURE 51 3 24 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE 51 3 25 SELECTION BETWEEN Y D OR DOL STARTING 52 3 26 CALLING UP MODIFYING LOAD DELAY TIME 52 3 27 CALLING UP MODIFYING MINIMUM STOP TIME 53 3 28 ACTIVATING PASSWORD PROTECTION 53 3 29 ACTIVATE LOAD UNLOAD REMOTE PRESSURE SENSING 54 3 30 CALLING UP MODIFYING PROTECTION ...

Page 6: ...6 4 18 WEB SERVER 107 4 19 PROGRAMMABLE SETTINGS 115 5 Energy recovery optional 119 5 1 ENERGY RECOVERY UNIT 119 5 2 ENERGY RECOVERY SYSTEMS 120 5 3 OPERATION 121 5 4 MAINTENANCE 123 5 5 ENERGY RECOVERY DATA 124 5 6 COOLING WATER REQUIREMENTS 126 6 Installation 131 6 1 DIMENSION DRAWINGS 131 6 2 INSTALLATION PROPOSAL 131 6 3 ELECTRICAL CONNECTIONS 135 6 4 PICTOGRAPHS 137 7 Operating instructions 1...

Page 7: ...LTER CHANGE 156 8 6 COOLERS 157 8 7 SAFETY VALVES 159 8 8 DRYER MAINTENANCE INSTRUCTIONS 159 8 9 SERVICE KITS 160 8 10 STORAGE AFTER INSTALLATION 160 8 11 DISPOSAL OF USED MATERIAL 161 9 Problem solving 162 10 Technical data 166 10 1 READINGS ON DISPLAY 166 10 2 ELECTRIC CABLE SIZE AND FUSES 167 10 3 PROTECTION SETTINGS 173 10 4 DRYER SWITCHES 174 10 5 REFERENCE CONDITIONS AND LIMITATIONS 174 10 6...

Page 8: ...11 Instructions for use 181 12 Guidelines for inspection 182 13 Pressure equipment directives 183 14 Declaration of conformity 184 Instruction book 6 2920 7180 30 ...

Page 9: ... the voltage Depressurize the machine 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 check w...

Page 10: ...ct size and suitable for the working pressure 6 In case the device is a compressor the aspirated air must be free of flammable fumes vapors and particles e g paint solvents that can lead to internal fire or explosion 7 In case the device is a compressor arrange the air intake so that loose clothing worn by people cannot be drawn in 8 Ensure that the discharge pipe from the compressor to the afterc...

Page 11: ...quipment hence some statements may not apply to your machine 1 4 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation maintenance and repair even if not expressly stated will be disclaimed by the manufacturer Precautions during operation 1 Neve...

Page 12: ... the application which are not included herein Some precautions are general and cover several machine types and equipment hence some statements may not apply to your machine 1 5 Safety precautions during maintenance or repair All responsibility for any damage or injury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation m...

Page 13: ...oil separator vessel for carbon deposits if excessive the deposits should be removed 18 Protect the motor air filter electrical and regulating components etc to prevent moisture from entering 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 condit...

Page 14: ...the GA37 and the GA 45 the Elektronikon controller with graphical display is available as standard option The controller is fitted to the right hand door panel on the front side An electric cabinet comprising the motor starter is located behind this panel The compressors are enclosed in a sound insulated bodywork There are 2 versions of the compressor Workplace Pack without integrated dryer and Wo...

Page 15: ...Motor side view GA 30 up to GA 45 Pack Instruction book 2920 7180 30 13 ...

Page 16: ...Service side view GA 30 up to GA 45 Pack Instruction book 14 2920 7180 30 ...

Page 17: ...Motor side view GA 30 up to GA 45 Full Feature Instruction book 2920 7180 30 15 ...

Page 18: ...r Co Oil cooler E Compressor element ER Elektronikon controller FN Cooling fan M1 Motor of the compressor S3 Emergency stop button UA Unloader Da Dm Condensate outlets AF Air filter AR Air receiver oil separator tank OF Oil filter DR Dryer only on units with integrated dryer Instruction book 16 2920 7180 30 ...

Page 19: ...2 2 Air and oil circuit Air circuit Flow diagram air circuit compressors without integrated dryer Instruction book 2920 7180 30 17 ...

Page 20: ...receiver oil separator tank AR The air is discharged through outlet valve AV via minimum pressure valve Vp and air cooler Ca The air cooler is provided with a moisture trap MT On compressors with integrated dryer the air flows through air dryer DR before it is discharged through outlet valve AV Also see section Air dryer Under all circumstances the minimum pressure valve Vp keeps the pressure in t...

Page 21: ...R most of the oil is separated from the air oil mixture by gravity and inertia The remaining oil is separated by oil separator OS The oil collects in the lower part of air receiver oil separator AR The oil circuit is provided with a thermostatic bypass valve BV When the oil temperature is below its setpoint the oil cooler is bypassed Bypass valve BV starts opening the supply to cooler Co when the ...

Page 22: ...air flow is generated by fan FN 2 4 Condensate system The condensate collected in the moisture trap of the air cooler is evacuated via an automatic drain A compressor with integrated dryer has an additional drain on the moisture trap of the dryer Each drain is connected to its outlet connection Da and a manual drain valve Dm Mechanical drains GA 37 and GA 45 have a mechanical condensate drain MWD ...

Page 23: ...ature GA 30 compressors an additional electronic water drain is provided The condensate accumulates in the collector of the drain When the condensate reaches a certain level it is discharged through the automatic drain outlet Da Testing the electronic water drain can be done by briefly pressing the test button 1 on top of the drain Electronic condensate drains Instruction book 2920 7180 30 21 ...

Page 24: ...ence Designation Da Automatic drain connection Dm Manual drain valve Da1 Automatic drain connection of the dryer only on units with integrated dryer Dm1 Manual drain valve of the dryer only on units with integrated dryer Instruction book 22 2920 7180 30 ...

Page 25: ...ompressor the net pressure increases When the net pressure reaches the unloading pressure solenoid valve Y1 is de energised Results The pressure above unloading valve blow off valve UV is released to atmosphere and the space above valve UV is no longer in connection with the oil separator tank pressure 1 Unloading valve blow off valve UV moves upwards connecting the oil separator tank pressure 1 w...

Page 26: ... components Typical example of electric cubicle Reference Designation F1 Fuse F2 Fuse F3 Fuse F7 8 9 Fuses only on units with integrated dryer F21 Overload relay compressor motor Q15 Circuit breaker fan motor on air cooled compressors K5 Auxiliary relay Instruction book 24 2920 7180 30 ...

Page 27: ...ine contactor K22 Star contactor K23 Delta contactor T1 Transformer PE Earth terminal Electrical diagram 9828 5102 00 Service diagram The complete electrical diagram can be found in the electric cubicle and on the CD ROM supplied with the machine 2 7 Air dryer On compressors with integrated dryer only Flow diagram Air dryer Reference Name AI Air inlet Instruction book 2920 7180 30 25 ...

Page 28: ...arator 3 where all the condensate is separated from the air The condensate is automatically drained through condensate drain 4 The cold dried air flows through heat exchanger 1 where it is warmed up by the incoming air Refrigerant circuit Compressor 5 delivers hot high pressure refrigerant gas which flows through condenser 6 where most of the refrigerant condenses The liquid refrigerant flows thro...

Page 29: ...oller stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases If the expected unloading period is to short the compressor is kept running to prevent too short stand still periods Protecting the compressor Several sensors are provided on the compressor If one of the measured signals exceeds the programmed shutdown level th...

Page 30: ...start after voltage failure The controller has a built in function to automatically restart the compressor when the voltage is restored after voltage failure For compressors leaving the factory this function is made inactive If desired the function can be activated The ARAVF label 1079 9932 74 see section Pictographs shall be glued near to the controller Consult your local supplier If activated an...

Page 31: ...n starts the compressor Automatic operation LED 3 lights up The Elektronikon is operative 11 Stop button This button is used to stop the compressor Automatic operation LED 3 goes out 12 Scroll buttons Use these buttons to scroll through the menu 13 Enter button Use this button to confirm the last action 14 Escape button Use this button to go to previous screen or to end the current action 3 3 Icon...

Page 32: ...it pounds per square inch Pressure unit bar Temperature unit degree Centigrade Temperature unit degree Fahrenheit Hours always shown together with seconds Percent The value shown must be multiplied by 10 to get the actual value The value shown must be multiplied by 100 to get the actual value The value shown must be multiplied by 1000 to get the actual value Motor overload Element outlet temperatu...

Page 33: ... this chapter are available on every machine 3 4 Main screen When the voltage is switched on the first screen is a test screen The next screen is the Main screen shown automatically The Main screen shows The compressor status by means of pictographs The air outlet pressure Always consult Atlas Copco if the pressure on the display is preceded by a t Instruction book 2920 7180 30 31 ...

Page 34: ...croll down button 12 The screen shows the temperature at the compressor element outlet It remains possible to scroll through other screens using the Scroll buttons up and down 12 to check the actual status of other parameters Press button 11 to stop the compressor and wait until the compressor has stopped Switch off the voltage inspect the compressor and remedy The warning message will disappear a...

Page 35: ...ther parameters Press button 11 to stop the compressor and wait until the compressor has stopped Switch off the voltage inspect the compressor and remedy The warning message will disappear as soon as the warning condition disappears 3 6 Shut down Description The compressor will be shut down In case the temperature at the outlet of the compressor element exceeds the shut down level In case of error...

Page 36: ... flashing Press Scroll buttons 12 until the actual compressor element temperature appears Shut down screen element outlet temperature The screen shows that the temperature at the outlet of the compressor element is 120 C Switch off the voltage and remedy the trouble After remedying and when the shut down condition has disappeared switch on the voltage and restart the compressor Motor overload In t...

Page 37: ...ed the programmed time interval If the service timer exceeds the programmed time interval service LED 9 will light up To display the service timer press Scroll buttons 12 to scroll to d 6 the service symbol is shown Next press the Enter button 13 The reading of the service timer is shown in hrs or x1000 hrs if the service timer value is higher than 9999 Example of the service timer screen The exam...

Page 38: ... Calling up resetting the service timer 3 8 Scrolling through all screens Control panel Control panel Scroll buttons 12 can be used to scroll through all screens The screens are divided into register screens measured data screens digital input screens numbered as d in d 1 parameter screens numbered as P 1 P 2 protections screens numbered as Pr 1 and test screens numbered as t 1 During scrolling th...

Page 39: ...nd Subnet mask See section Calling up modifying IP Gateway and Subnetmask P 4 Pressure band settings See section Calling up modifying pressure band settings P 5 Setting a pressure band selection See section Modifying pressure band selection P 6 Modifying a service timer See section Calling up modifying service timer settings P 7 Setting of unit for temperature See section Calling up modifying unit...

Page 40: ...ns screens See section Calling up modifying protection settings Test screens Designation Related topic t 1 Display test See sections Test screens t 2 Safety valve test See sections Test screens t 3 Production test See sections Test screens Instruction book 38 2920 7180 30 ...

Page 41: ...n Ref Description 1 Compressor outlet pressure 16 Pressure band selection 2 Compressor outlet temperature 17 Service timer settings 3 Dewpoint temperature 18 Temperature unit 4 Digital input status 19 Unit pressure Instruction book 2920 7180 30 39 ...

Page 42: ...ettings 10 Service timer reading 25 Remote pressure sensing 11 Actual program version 26 Protections 12 LAN selection 27 Display test 13 Settings node ID 28 Safety valve test 14 IP settings 29 Production test 15 Pressure band settings 3 9 Calling up temperatures Control panel Starting from the Main screen Press Scroll button 12 The outlet temperature will be shown Instruction book 40 2920 7180 30 ...

Page 43: ...The screen shows that the dew point temperature is 3 C 3 10 Calling up running hours Control panel Starting from the Main screen Press Scroll button 12 until d 1 is shown and then press Enter button 13 The screen shows the unit used x1000 hrs and the value 11 25 the running hours of the compressor are 11250 hours Instruction book 2920 7180 30 41 ...

Page 44: ...ollowing appears This screen shows the number of motor starts x 1 or if x1000 lights up x 1000 In the above example the number of motor starts is 10100 3 12 Calling up module hours Control panel Starting from the Main screen press Scroll button 12 until d 3 is shown and then press Enter button 13 A screen similar to the following appears Instruction book 42 2920 7180 30 ...

Page 45: ...ter button 13 The screen shows the unit used hrs or x1000 hrs and the value 1755 the compressor has been running loaded during 1755 hours 3 14 Calling up load relay Starting from the Main screen Press Scroll button 12 until d 5 is shown and then press Enter button 13 This screen shows the number of unload to load actions x 1 or if x1000 lights up x 1000 In the above example the number of unload to...

Page 46: ...n 1191 hours since the previous service Resetting the service timer After servicing see section Service warning the timer has to be reset Scroll to register screen d 6 and press Enter button 13 The reading e g 4000 will appear Press Enter button 13 and if a password is set enter the password The icon will flash indicating that resetting is possible Press Enter button 13 to reset the timer to 0 000...

Page 47: ...ncel 3 17 Calling up modifying CAN address Calling up Starting from the main screen press the Scroll button 12 until P 2 is shown and then press Enter button 13 If necessary enter the password The next screen shows that the function is ON or OFF Press the Enter button 13 to change this mode Use the Scroll buttons 12 to select On or OFF and press Enter to program When this function is ON use the Sc...

Page 48: ...n act as a Mk IV controller a previous version of the controller To set the channels go to the screen where the node ID is visible Press the Scroll button down 12 The following screen appears Press the Enter button 13 to modify the setting The utmost left value will blink Change this value by using the Scroll buttons 12 Press the Enter button 13 to confirm Change the other values in the same way a...

Page 49: ...to OFF Use the Scroll buttons Up or Down 12 to scroll between the items in this list IP for IP address Sub for Subnetmask or GAtE for Gateway Modification Press the Enter button 13 and if necessary enter the password The first digits are blinking Use the Scroll buttons Up or Down 12 to modify the settings and press Enter 13 to confirm Modify the next digits the same way The standard IP address is ...

Page 50: ...3 19 Calling up modifying pressure band settings Calling up the settings Instruction book 48 2920 7180 30 ...

Page 51: ...ed pressure band The load level of the selected pressure band appears Button 12 can be used to scroll to the unload level Loading pressure Unloading pressure Modification Press Enter button 13 to modify the load level value starts blinking A password may be required Use Scroll buttons 12 to change the loading pressure Press Enter button 13 to program the new values or press the Escape button 14 to...

Page 52: ... band Press Enter button 13 to confirm or the Escape button 14 to cancel 3 21 Calling up modifying service timer settings Control panel Starting from the Main screen Press Scroll button 12 until P 6 is shown and then press Enter button 13 the setting of the service timer is shown in hrs hours or x1000 hrs hours x 1000 Example 4000 hrs means the timer is set at 4000 running hours Press Enter button...

Page 53: ...s Enter button 13 and the actually used unit is shown Press Enter button 13 unit starts blinking and use the Scroll buttons 12 to select another unit of pressure Press Enter button 13 to program the new unit of pressure Press the escape button 14 to return to the parameter screens 3 24 Activating automatic restart after voltage failure Description This function allows the compressor to restart aut...

Page 54: ...Line For obvious reasons this parameter must normally not be altered Therefore it can only be modified after entering a secure code Consult Atlas Copco if the parameter is to be changed Example of Y D setting 3 26 Calling up modifying load delay time Control panel Starting from the Main screen press Scroll button 12 until P 11 and the compressor load pictograph is shown and press the Enter button ...

Page 55: ... the Enter button 13 This screen shows the minimum stop time 20 and the unit s seconds To modify this value press the Enter button 13 The value starts blinking and Scroll buttons 12 can be used to modify this value Press Enter button 13 to program the new value The minimum and maximum values depend on the parameters 3 28 Activating password protection Important settings such as the setting of the ...

Page 56: ... Save the password carefully 3 29 Activate load unload remote pressure sensing Starting from the Main screen Press the Scroll button 12 until P 14 appears Press the Enter button 13 The function of this screen is to activate the remote load unload relay To be able to activate this remote Load Unload functionality a physical digital input with function Load Unload is required Once this parameter is ...

Page 57: ... temperature protections Pr combined with the ambient temperature pictograph shows the ambient temperature protections Following protection settings are available A low warning level shown on the display as AL L A high warning level shown on the display as AL H A low shutdown level shown on the display as Sd L A high shutdown level shown on the display as Sd H A low service level shown on the disp...

Page 58: ...y the value Press the Enter button 13 to program the new value Programmable settings can only be modified within allowed limits 3 31 Test screens Display test Starting from the Main screen press Scroll buttons 12 until t 1 is shown and then press Enter button 13 The display now shows all icons that can be displayed Safety valve test In the test screen t 2 a safety valve test is provided The safety...

Page 59: ...t allows direct connection to the company network or to a dedicated PC via a local area network LAN This allows to consult certain data and settings via a PC instead of the display of the controller Getting started Make sure you are logged in as administrator Use the internal network card from your computer or a USB to LAN adapter Use a UTP cable CAT 5e to connect to the controller see picture bel...

Page 60: ...n which is connected to the controller Click with the right button and select Properties 1 Use the check box Internet Protocol version 4 TCP IPv4 1 see picture To avoid conflicts uncheck other properties if they are checked After selecting TCP IPv4 click on the Properties button 2 to change the settings Instruction book 58 2920 7180 30 ...

Page 61: ...te a fixed IP address in your company s network That IP address will be excluded from the DNS server so it will be reserved for the Elektronikon Mk5 Also get the correct Gateway and Subnet mask settings For example IP 10 25 43 200 Gateway 10 25 42 250 Subnet mask 255 255 254 0 Connect your Elektronikon Mk5 to the company s network LAN by using a UTP cable min CAT 5e Instruction book 2920 7180 30 5...

Page 62: ... Adapt the network settings in the Elektronikon Mk5 Go to Main Menu Go to Settings 1 Go to Network 1 Instruction book 60 2920 7180 30 ...

Page 63: ...thernet 1 Switch Off 1 the Ethernet communication to allow editing the settings Adapt IP Address 1 Adapt Gateway IP 2 Adapt Subnet Mask 3 Switch On 4 the Ethernet communication Instruction book 2920 7180 30 61 ...

Page 64: ...net Explorer Also Opera Mozilla Firefox Safari and Chrome should work 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 62 2920 7180 30 ...

Page 65: ...e available on the controller On the left side of the interface you can find the navigation menu If a license for ESi is foreseen the menu contains 3 buttons Machine shows all generator settings ES shows the ESi status if a license is provided Preferences allows to change temperature and pressure unit Instruction book 2920 7180 30 63 ...

Page 66: ...alog inputs Lists all current analog input values The measurement units can be changed in the preference button from the navigation menu Counters Lists all current counter values from controller and unit 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...

Page 67: ...tory setting Maximum setting Unloading pressures Unloading pressure 7 5 bar compressors bar e 4 1 7 7 5 Unloading pressure 7 5 bar compressors psig 59 5 101 5 108 8 Unloading pressure 8 5 bar compressors bar e 4 1 8 8 5 Unloading pressure 8 5 bar compressors psig 59 5 116 123 5 Unloading pressure 10 bar compressors bar e 4 1 9 5 10 Unloading pressure 10 bar compressors psig 59 5 137 8 145 0 Unload...

Page 68: ...essure 100 psi compressors psig 58 91 4 105 9 Loading pressure 125 psi compressors bar e 4 8 9 Loading pressure 125 psi compressors psig 58 116 130 5 Loading pressure 150 psi compressors bar e 4 9 7 10 7 Loading pressure 150 psi compressors psig 58 140 7 155 2 Loading pressure 175 psi compressors bar e 4 11 4 12 4 Loading pressure 175 psi compressors psig 58 165 3 179 8 Parameters unloading loadin...

Page 69: ...ompressors bar e 4 11 9 12 7 Loading pressure 13 bar compressors psig 58 172 6 184 Loading pressure 100 psi compressors bar e 4 6 3 7 1 Loading pressure 100 psi compressors psig 58 91 4 103 Loading pressure 125 psi compressors bar e 4 8 8 8 Loading pressure 125 psi compressors psig 58 116 127 5 Loading pressure 150 psi compressors bar e 4 9 7 10 5 Loading pressure 150 psi compressors psig 58 140 7...

Page 70: ...te the automatic restart function consult Atlas Copco Restart delay This parameter allows to programme that not all compressors are restarted at the same time after a power failure ARAVF active Compressor element outlet The regulator does not accept inconsistent 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 recomme...

Page 71: ...tings e g the unloading and loading pressures for fixed speed compressors the setpoint for compressors with frequency converter the minimum stop time and the maximum number of motor starts and several other parameters are taken into account The controller stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases If the expe...

Page 72: ...ion disappears A warning will also appear if the dew point temperature is too high on compressors with integrated dryer Service warning A number of service operations are grouped called Service Plans Each Service Plan has a programmed time interval If the service timer exceeds a programmed value this will be indicated on the display to warn the operator to carry out the service actions belonging t...

Page 73: ...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 74: ...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 72 2920 7180 30 ...

Page 75: ... Service required Main screen display Value lines display icon Chart display icon General icons No communication network problem Not valid General alarm Input icons Icon Description Pressure Temperature Digital input Special protection Instruction book 2920 7180 30 73 ...

Page 76: ...r element Dryer Fan Frequency converter Drain Filter Motor Failure expansion module Menu icons Icon Description Inputs Outputs Alarms Warnings shutdowns Counters Test Settings Service Event history saved data Instruction book 74 2920 7180 30 ...

Page 77: ...ntioned in this chapter are applicable to every machine 4 4 Main screen Control panel 1 Scroll keys 2 Enter key 3 Escape key Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed It is switched off automatically after a few minutes when no keys are pushed Instruction book 2920 7180 30 75 ...

Page 78: ...s see section Inputs menu Typical Main screen 2 value lines fixed speed compressors Text on image 1 Compressor Outlet 2 Element Outlet 3 Load shutdown text varies upon the compressors actual condition 4 Menu 5 Unload ES text varies upon the compressors actual condition Typical Main screen 4 value lines fixed speed compressors Text on image 1 Compressor Outlet 2 Load Relay one of the input signals ...

Page 79: ...ngs shutdowns service To call up more information about the icons shown select the icon concerned using the scroll keys and press the enter key Section C is called the Status bar This bar shows the text that corresponds to the selected icon Section D shows the Action buttons These buttons are used To call up or program settings To reset a motor overload service message or emergency stop To have ac...

Page 80: ...tton icon for selecting other screens is changed into a small Chart and is highlighted active When the Chart Medium Resolution is selected the chart shows the variation of the selected input per hour The screen shows the last 4 hours When the Chart Low Resolution is selected the chart shows the variation of the selected input per day The screen shows the evolution over the last 10 days Instruction...

Page 81: ...ction Icons used and press the Enter key A screen similar to the one below opens Select the layout required and press the Enter key See also section Inputs menu 4 5 Calling up menus Control panel Control panel 1 Scroll keys 2 Enter key 3 Escape key Description When the voltage is switched on the main screen is shown automatically see section Main screen Instruction book 2920 7180 30 79 ...

Page 82: ...ht Menu using the Scroll keys Press the Enter key to select the menu Following screen appears Typical menu screen The screen shows a number of icons Each icon indicates a menu item By default the Pressure Settings Regulation icon is selected The status bar shows the name of the menu that corresponds with the selected icon Use the Scroll keys to select an icon Press the Escape key to return to the ...

Page 83: ... the Inputs icon see above section Menu icon Press the Enter key A screen similar to the one below appears Text on image 1 Inputs 2 Compressor Outlet 3 Element Outlet 4 Ambient Air 5 Emergency Stop The screen shows a list of all inputs with their corresponding icons and readings If an input is in warning or shutdown the original icon is replaced by the warning or shutdown icon respectively i c the...

Page 84: ...item in the list is highlighted In this example the Net Pressure is selected chart icon To change press the Enter button again a pop up window opens Press Enter again to remove this input from the chart Another confirmation pop up opens Select Yes to remove or No to quit the current action In a similar way another input signal can be highlighted and selected as Main Chart signal Instruction book 8...

Page 85: ... 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 Text on image 1 Menu 2 Regulation Move the cursor to the Outputs icon see above section Menu icon using the Scroll keys Press the Enter key A screen similar to the one below appears Instruction book 2920 7180 30 83 ...

Page 86: ...inal icon is replaced by the warning or shutdown icon respectively 4 8 Counters Menu icon Counters Function To call up The running hours The loaded hours The number of motor starts The number of hours that the regulator has been powered The number of load cycles Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following scree...

Page 87: ...pressors with frequency converter The screen shows a list of all counters with their actual readings Note the example above is for a frequency converter driven compressor For a fixed speed compressor the actual screen will be somewhat different 4 9 Control mode selection Function To select the control mode i e whether the compressor is in local control remote control or controlled via a local area...

Page 88: ...er button There are 3 possibilities Local control Remote control LAN network control After selecting the required regulation mode press the enter button on the controller to confirm your selection The new setting is now visible on the main screen See section Used icons for the meaning of the icons Instruction book 86 2920 7180 30 ...

Page 89: ...rried 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 appears Text on image 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Service icon see above section Menu icon Instruction book 2920 7180 30 87 ...

Page 90: ...ice 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 means that the controller will launch a service warning when either 4000 running hours or 8760 real hours are reached whichever comes fi...

Page 91: ...on 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 Level 3 Running hours 4 Real Time Hours 5 Modify Modifying a service plan Dependant on the o...

Page 92: ...ctual In the example 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 desir...

Page 93: ...is also used to select the active pressure band Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on image 1 Menu 2 Regulation Move the cursor to the Setpoint icon see above section menu icon using the Scroll keys Press the Enter key Following screen appears Instruction book 2920 7180 30 91 ...

Page 94: ...ss the Enter key Following screen appears The first line of the screen is highlighted in red Use the Scroll keys to highlight the setting to be modified and press the Enter key Following screen appears Text on image 1 Regulation 2 Unloading Pressure 1 3 Modify The upper and lower limit of the setting is shown in grey the actual setting is shown in black Use the or key of the Scroll keys to modify ...

Page 95: ... key Following screen appears Text on image 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Event History icon see above section Menu icon The list of last shutdown and emergency stop cases is shown Example of Event History screen Scroll through the items to select the desired shutdown or emergency stop event Press the Enter key to find the date time and other data reflecting the ...

Page 96: ...con see above section menu icon using the Scroll keys Press the Enter key Following screen appears This screen shows again a number of icons By default the User Password icon is selected The status bar shows the description that corresponds with the selected icon Each icon covers one or more items such as Access key User password Main chart General Automatic restart after voltage failure ARAVF Net...

Page 97: ...o the one above is shown the first item Language is highlighted Use the key of the Scroll keys to select the setting to be modified and press the Enter key A pop up screen appears Use the or key to select the required value and press the Enter key to confirm 4 14 Info menu Menu icon Info Function To show the Atlas Copco internet address Procedure Starting from the Main screen Move the cursor to th...

Page 98: ...e can be programmed a week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed week schemes can be chosen Important remark In the Elektronikon you can select different timers on one day up to 8 actions 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...

Page 99: ...nactive 6 Remaining Running Time The first item in this list is highlighted 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 Press the Enter key on the controller to modify Week Action Scheme 1 Instruction book 2920 7180 30 97 ...

Page 100: ...utomatically selected and highlighted Press the Enter key on the controller to set an action for this day Text on image 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 98 2920 7180 30 ...

Page 101: ... list by using the Scroll keys on the controller When ready press the Enter key to confirm Text on image 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 2920 7180 30 99 ...

Page 102: ...y of Scroll keys to modify the values of the hours Use the or Scroll keys to go to the minutes Press the Escape key on the controller The action button Modify is selected Use the Scroll keys to select the action Save A new pop up window opens Use the Scroll keys on the controller to select the correct actions Press the Enter key to confirm Instruction book 100 2920 7180 30 ...

Page 103: ...planned Text on image 1 Week Action Scheme 1 2 Monday 3 Tuesday 4 Wednesday 5 Thursday 6 Friday 7 Saturday 8 Sunday Press the Escape key on the controller to leave this screen Programming the week cycle A week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed week schemes can be chosen Instruction book 2920 7180 30 101 ...

Page 104: ...tatus 5 Week Timer Inactive 6 Remaining Running Time A list of 10 weeks is shown Text on image 1 Week Cycle 2 Week 1 3 Week 2 4 Week 3 5 Week 4 6 Modify Press twice the Enter key on the controller to modify the first week A new window opens Select the action example Week Action Scheme 1 Instruction book 102 2920 7180 30 ...

Page 105: ...e 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 Text on image 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 2920 7180 30 103 ...

Page 106: ...tatus shows that week 1 is active Text on image 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 104 2920 7180 30 ...

Page 107: ...continue working for example 1 hour it can be set in this screen This timer is prior to the Week Timer action Text on image 1 Week Timer 2 Week Action Schemes 3 Remaining Running Time 4 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 Instruction book 2920 7180 30 105 ...

Page 108: ...e performed by authorized personnel and is protected 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 4 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 s...

Page 109: ... a built in web server that allows direct connection to the company network or to a dedicated PC via a local area network LAN This allows to consult certain data and settings via a PC instead of the display of the controller Getting started Make sure you are logged in as administrator Use the internal network card from your computer or a USB to LAN adapter Use a UTP cable CAT 5e to connect to the ...

Page 110: ...ler Click with the right button and select Properties 1 Use the check box Internet Protocol version 4 TCP IPv4 1 see picture To avoid conflicts uncheck other properties if they are checked After selecting TCP IPv4 click on the Properties button 2 to change the settings Instruction book 108 2920 7180 30 ...

Page 111: ...te a fixed IP address in your company s network That IP address will be excluded from the DNS server so it will be reserved for the Elektronikon Mk5 Also get the correct Gateway and Subnet mask settings For example IP 10 25 43 200 Gateway 10 25 42 250 Subnet mask 255 255 254 0 Connect your Elektronikon Mk5 to the company s network LAN by using a UTP cable min CAT 5e Instruction book 2920 7180 30 1...

Page 112: ... Adapt the network settings in the Elektronikon Mk5 Go to Main Menu Go to Settings 1 Go to Network 1 Instruction book 110 2920 7180 30 ...

Page 113: ...thernet 1 Switch Off 1 the Ethernet communication to allow editing the settings Adapt IP Address 1 Adapt Gateway IP 2 Adapt Subnet Mask 3 Switch On 4 the Ethernet communication Instruction book 2920 7180 30 111 ...

Page 114: ...et Explorer Also Opera Mozilla Firefox Safari and Chrome should work 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 112 2920 7180 30 ...

Page 115: ...e available on the controller On the left side of the interface you can find the navigation menu If a license for ESi is foreseen the menu contains 3 buttons Machine shows all generator settings ES shows the ESi status if a license is provided Preferences allows to change temperature and pressure unit Instruction book 2920 7180 30 113 ...

Page 116: ...alog inputs Lists all current analog input values The measurement units can be changed in the preference button from the navigation menu Counters Lists all current counter values from controller and unit 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...

Page 117: ...ry setting Maximum setting Unloading pressures Unloading pressure 7 5 bar compressors bar e 4 1 7 7 5 Unloading pressure 7 5 bar compressors psig 59 5 101 5 108 8 Unloading pressure 8 5 bar compressors bar e 4 1 8 0 8 5 Unloading pressure 8 5 bar compressors psig 59 5 116 0 123 3 Unloading pressure 10 bar compressors bar e 4 1 9 5 10 Unloading pressure 10 bar compressors psig 59 5 137 8 145 0 Unlo...

Page 118: ...ssure 100 psi compressors psig 58 91 4 105 9 Loading pressure 125 psi compressors bar e 4 8 9 Loading pressure 125 psi compressors psig 58 116 130 5 Loading pressure 150 psi compressors bar e 4 9 7 10 7 Loading pressure 150 psi compressors psig 58 140 7 155 2 Loading pressure 175 psi compressors bar e 4 11 4 12 4 Loading pressure 175 psi compressors psig 58 165 3 179 8 Parameters unloading loading...

Page 119: ...ompressors bar e 4 11 9 12 7 Loading pressure 13 bar compressors psig 58 172 6 184 Loading pressure 100 psi compressors bar e 4 6 3 7 1 Loading pressure 100 psi compressors psig 58 91 4 103 Loading pressure 125 psi compressors bar e 4 8 8 8 Loading pressure 125 psi compressors psig 58 116 127 5 Loading pressure 150 psi compressors bar e 4 9 7 10 5 Loading pressure 150 psi compressors psig 58 140 7...

Page 120: ...er a power failure ARAVF active Compressor element outlet The recommended minimum setting is 70 C 158 F For testing the temperature sensor the setting can be decreased to 50 C 122 F Reset the value after testing The regulator does not accept illogical settings e g if the warning level is programmed at 95 C 203 F the minimum limit for the shut down level changes to 96 C 204 F The recommended differ...

Page 121: ...nsforming 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 s BV2 Two temperature sensors for water inlet and outlet control 3 and...

Page 122: ...e applied as low temperature rise high water flow systems or as high temperature rise low water flow systems Low temperature rise high water flow systems For this type of application the temperature difference between the water in the energy recovery system and the compressor oil is low As a consequence a high water flow is needed for maximum energy recovery Example The heated water is used to kee...

Page 123: ...ne glycol to the water in proportion to the expected temperature to avoid freezing Water requirements for open water circuits For open non recirculation water circuits the major problems usually encountered are related to deposit control corrosion control and microbiological growth control To minimize these problems the water should meet a number of requirements See section Cooling water requireme...

Page 124: ...essure lower than 13 bar 175 psi BV2 starts opening at 40 C 104 F and is completely open at 55 C 131 F On compressors with a maximal pressure of 13 bar 175 psi BV2 starts opening at 60 C 140 F and is completely open at 75 C 167 F The oil cooler bypass valve BV1 starts closing the bypass over the oil cooler C0 at the lower limit of its temperature range At the upper limit of its temperature range t...

Page 125: ...ow its setpoint Operation principle at different loads Low consumption of recovered energy The temperature of the oil leaving heat exchanger HE rises When the temperature rises above its set point oil cooler bypass valve BV1 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 BV2 will open the bypass line allowin...

Page 126: ...orking conditions the heat exchanger should be inspected To clean the oil side soak the heat exchanger in a degreasing solution To remove scale formation in the water compartment a proper descaling process should be applied Consult your customer centre 5 5 Energy recovery data Reference conditions See section Reference conditions and limitations Effective working pressure Consult section Compresso...

Page 127: ...ypical examples are given Data for low temperature rise low water flow systems Parameter Unit GA 30 GA 37 GA 45 Recoverable energy kW 27 5 32 5 39 5 Recoverable energy hp 36 8 43 5 53 Water flow l min 39 4 46 6 56 6 Water flow cfm 1 4 1 6 2 Temperature at inlet C 50 50 50 Temperature at inlet F 122 122 122 Temperature at outlet C 60 60 60 Temperature at outlet F 140 140 140 Data for high temperatu...

Page 128: ...ation monitoring of concentrations and properties prevention of sludge formation and maintenance of the system This applies also to treatment with antifreeze products They must be provided with suitable stabilizers and inhibitors Specifications are also depending on the type of cooling circuit open once through recirculating with tower closed and on the application Standard max 65 C cooling water ...

Page 129: ...um carbonate The adhesion of scaling depositions and their effect are different on different materials but the equilibrium of the water scaling or corrosive is only determined by its actual pH value and by the saturation pH value pHs The saturation pH value is determined by the relationship between the calcium hardness the total alkalinity the total solids concentration and the temperature The Ryz...

Page 130: ... 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 the case contact a specialist 5 Free chlorine Cl2 Disinfecting with chlorine is not done in closed systems neither in energy recovery systems A continuous level of 0 5 ppm should not be exceeded For shock treatments a maximum ...

Page 131: ...ass 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 Small particles 0 5 µm are not taken into account For particles between 0 5 µm and 10 µm the following limits apply Suspe...

Page 132: ...ws the recommended values The values in bold are rejection limits If additives are used in the cooling water take into account that the cooling capacity will change Δm Cpw Cpa X Cpw 1 X X Cpa 100 with Δm change of mass flow of the coolant Cpw specific heat capacity of water Cpa specific heat capacity of the additives X the percentage of additives Instruction book 130 2920 7180 30 ...

Page 133: ...let Doors fully open Dimensions with doors fully open Cooling air inlet of dryer Dryer cooling air inlet Cooling air outlet of dryer Dryer cooling air outlet Centre of gravity Centre of gravity Approx mass Approximate mass of the machine Manual drain of after cooler Manual drain aftercooler Automatic drain of after cooler Connection of the automatic drain of the aftercooler Manual drain of dryer M...

Page 134: ...ks protrude from the other side of the frame The compressor can 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...

Page 135: ... proposals 2 Minimum free area to be reserved for the compressor installation All piping to be connected stress free to the compressor Installation guidelines 1 Install the compressor unit on a solid level floor suitable for taking its weight Instruction book 2920 7180 30 133 ...

Page 136: ...W ΔT Temperature increase in the compressor room in C 5 The drain pipes to the drain collector must not dip into the water of the drain collector Any flow back must be avoided Oil water separators to separate the major part of the oil from the condensate to ensure that the condensate meets the requirements of the environmental codes are available 6 Control module with monitoring panel 7 Position o...

Page 137: ...er cable gland when connecting the supply cable to the compressor Electrical connections Reference Designation 1 Customer s installation 2 All voltages 50 and 60 Hz Instructions 1 Provide an isolating switch 2 Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals 3 Check the fuses and the setting of the overload relay See section Electrical cable si...

Page 138: ...n controller consult section Selection between local remote and LAN control if it is desired to switch to another control mode On compressors equipped with an Elektronikon Graphic controller consult section Control mode selection if it is desired to switch to another control mode The following control modes can be selected Local control The compressor will react to commands entered by means of the...

Page 139: ...6 4 Pictographs Description Pictographs 1 2 3 4 5 6 7 8 9 10 11 12 Instruction book 2920 7180 30 137 ...

Page 140: ...Lightly oil the gasket of the oil filter screw it on and tighten by hand approx half a turn 8 Before connecting the compressor electrically consult the Instruction book for the motor rotation direction 9 Compressor remains pressurized for 180 seconds after switching off the voltage 10 Torques for steel Fe or brass CuZn bolts 11 Switch off the voltage and wait at least 6 minutes before removing the...

Page 141: ...under the motor 1 Bolts and bushes under the gear casing 2 Bolts or bolts and bushes under the oil separator vessel 3 3 Check that the electrical connections correspond to the applicable codes and that all wires are clamped tight to their terminals The installation must be earthed and protected against short circuits by fuses of the inert type in all phases An isolating switch must be installed ne...

Page 142: ... to a drain collector See section Condensate system The drain pipes to the drain collector must not dip into the water If there is a risk for freezing the pipes must be insulated For draining of pure condensate water install an oil water separator which is available from Atlas Copco as an option 8 For compressors with a DD or a DD and PD filter connect the automatic drain of the filters to a suita...

Page 143: ...e inlet hose 2 Remove the unloader UA 3 Pour approximately 0 75 l 0 20 US gal 0 17 Imp gal of compressor oil into the compressor element inlet For oil specifications see section Oil specifications 4 Reinstall the unloader and reconnect the inlet hose Make sure that all connections are tight Location of unloader 1 Check the oil level before starting The oil level should be between the oil filler ne...

Page 144: ...incorrect open the isolating switch and reverse two incoming electric connections at the terminals of circuit breaker Q15 4 Check the programmed settings For compressors equipped with an Elektronikon controller consult section Programmable settings 5 Check the programmed settings For compressors equipped with an Elektronikon Graphic controller consult section Programmable settings 6 Start and run ...

Page 145: ...see section Air filter If the red part of the air filter service indicator shows full out replace the air filter element Reset the service indicator VI by pushing the knob in the extremity of the indicator Position of air filter and service indicator Instruction book 2920 7180 30 143 ...

Page 146: ...kon Graphic Procedure 1 Open the air outlet valve 2 Switch on the voltage Check that voltage on LED 6 lights up 3 Press start button 1 on the control panel The compressor starts running and the automatic operation LED 8 lights up Ten seconds after starting the drive motor switches over from star to delta and the compressor starts running loaded Instruction book 144 2920 7180 30 ...

Page 147: ... Keep the doors closed during operation They may be opened for short periods only to carry out checks When the motors are stopped and LED 8 automatic operation is alight the motors may start automatically Checking the oil level Control panel Elektronikon Control panel Elektronikon Graphic Instruction book 2920 7180 30 145 ...

Page 148: ...lly depressurized See section Condensate system for location of the outlet valve and water drain 5 Unscrew oil filler plug FC one turn to permit any pressure left in the system to escape Wait a few minutes 6 Remove the plug and add oil until the level reaches the filler opening 7 Fit and tighten the plug FC On compressors equipped with an Elektronikon controller unlock the emergency stop button 10...

Page 149: ...the service indicator by pushing the knob in the extremity of the indicator body Drains Regularly check that condensate is discharged during operation See section Condensate system The amount of condensate depends on environmental and working conditions 7 5 Checking the display Compressors with Elektronikon controller Control panel Elektronikon Instruction book 2920 7180 30 147 ...

Page 150: ...timer see section Service warning Compressors with Elektronikon Graphic controller Control panel Elektronikon Graphic Check the display 2 regularly for readings and messages The display normally shows the compressor outlet pressure while the status of the compressor is indicated by means of a number of icons Remedy the trouble if alarm LED 7 is lit or flashes see section Icons used The display 2 w...

Page 151: ...ller remedy the problem cause and unlock the button by pulling it out 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 3 Close the air outlet valve 4 Press the test button on top of the electronic water drain s if supplied to the depressurize the piping between air receiver and ...

Page 152: ...ns Open the condensate drain valve s Dm Unscrew the oil filler plug only one turn to permit any pressure in the system to escape Consult section Oil and oil filter change to locate the filler plug Shut off and depressurise the part of the air net which is connected to the outlet valve Disconnect the compressor air outlet pipe from the air net Drain the oil Drain the condensate circuit and disconne...

Page 153: ...when the power is restored if it was running when the power was interrupted Warranty Product Liability Use only authorized parts Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability Service kits For overhauling or carrying out preventive maintenance service kits are available Consult the Spare Parts list for part numbers Service contract...

Page 154: ... to clean the condenser Every 5 years or 40000 hours 2 Replace all hoses and flexibles 1 More frequently when operating in a dusty atmosphere 2 Whichever comes first Programmed service interventions Apart from the above mentioned actions a number of service interventions see the table below are programmed in the controller Each plan has a programmed time interval at which all service actions belon...

Page 155: ...r in extreme conditions consult your customer centre Any leakage should be attended to immediately Damaged hoses or flexible joints must be replaced 8 2 Oil specifications It is strongly recommended to use genuine lubricants from your manufacturer They are the result of years of field experience and research See section Preventive maintenance schedule for the advised replacement intervals and cons...

Page 156: ...m 35 C 95 F up to 40 C 104 F from 100 C 212 F up to 105 C 221 F 6000 2 year above 40 C 104 F above 105 C 221 F 5000 2 year Roto Foodgrade Fluid Atlas Copco s Roto Foodgrade Fluid is a unique high quality synthetic lubricant specially created for oil injected screw compressors that provide air for the food industry See the table below for oil exchange intervals Ambient temperature Element outlet te...

Page 157: ...age 2 Release the snap clips of air filter AF and remove the cover and the air filter element Discard the filter element 3 Fit the new element and the cover 4 Reset service indicator VI by pushing the knob in the extremity of the body 5 Reset the air filter service warning For compressors equipped with a standard controller see section Service warning For compressors equipped with a graphic contro...

Page 158: ...il Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties A label indicating the type of oil filled ex factory is stuck on the air receiver oil tank If the compressor is equipped with an Energy Recovery system also consult Maintenance for Energy Recovery Systems Procedure Oil drain and filler plug on the oil separator vessel Ve...

Page 159: ...eceiver AR with oil until the level reaches the filler neck Take care that no dirt drops into the system Refit and tighten filler plug FC 7 Run the compressor loaded for a few minutes Stop the compressor and wait a few minutes to allow the oil to settle 8 Depressurise the system by unscrewing filler plug FC just one turn to permit any pressure in the system to escape Remove the plug Fill the air r...

Page 160: ...e brush Next clean with an air jet in the reverse direction to normal flow Use low pressure air If necessary the pressure may be increased up to 6 bar e 87 psig If it is necessary to wash the coolers with a cleaning agent consult your supplier Remove the cover used during cleaning Mount the service plates 1 Instruction book 158 2920 7180 30 ...

Page 161: ...tamped on the valve it needs to be replaced Warning No adjustments are allowed Never run the compressor without safety valve 8 8 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 ski...

Page 162: ...e dryer clean Brush or blow off the finned surface of condenser monthly Stop the compressor close the air outlet valve and switch off the voltage Remove any dirt on the condenser inlet with a vacuum cleaner Next clean with an air jet in the reverse direction to normal flow Use low pressure air If necessary the pressure may be increased up to 6 bar e 87 psig Clean the condenser area with a vacuum c...

Page 163: ...osed of in an environmentally friendly and safe manner and in line with the local recommendations and environmental legislation Electronic components are subject to the EU Directive 2012 19 EC for Waste Electrical and Electronic Equipment WEEE As such these parts must not be disposed of at a municipal waste collection point Refer to local regulations for directions on how to dispose of this produc...

Page 164: ...ew Always switch off the voltage Only pressing the emergency stop button is not sufficient to make the compressor voltage free If the machine is equipped with an automatic restart after voltage failure function and if this function is active be aware that the machine will restart automatically when the power is restored if it was running when the power was interrupted Faults and remedies compresso...

Page 165: ...ensate separator during loading Discharge tube clogged Check and correct as necessary Compressor air output or pressure below normal Air consumption exceeds air delivery of compressor Check the connected equipment Choked air filter element Replace filter element Solenoid valve malfunctioning Replace valve Leak in control air tubes Replace leaking tubes Oil separator element clogged Have element re...

Page 166: ...d too high oil consumption or less FAD Fan rotates in the wrong direction due to wrong electrical connection Faults and remedies dryer For all references hereafter consult section Air dryer Condition Fault Remedy Pressure dew point too high Air inlet temperature too high Check and correct if necessary clean the aftercooler of the compressor Ambient temperature too high Check and correct if necessa...

Page 167: ...e drain by opening the manual drain valve On units with an electronic drain check functioning of the drain by pushing the test button Condensate trap continuously discharges air and water Drain out of order Have system checked If necessary replace the drain Evaporator pressure is too high or too low at unload Hot gas bypass valve incorrectly set or out of order Have hot gas bypass valve adjusted C...

Page 168: ...der the reference conditions see section Reference conditions and limitations Reference Reading Air outlet pressure Modulates between programmed unloading and loading pressures Compressor element outlet temperature Approx 60 C 108 F above cooling air inlet temperature Dewpoint temperature See section Compressor data Instruction book 166 2920 7180 30 ...

Page 169: ...nd when connecting the supply cable to the compressor Local regulations remain applicable if they are stricter than the values proposed below Currents are calculated with the full service factor but we suggest to add 10 due to over and under voltage Fuses are maximum allowed values calculated for full service factor and 10 over and under voltage Caution Always double check the fuse size versus the...

Page 170: ...00 50 80 9 100 84 8 100 GA 37 460 60 71 4 80 77 8 80 GA 37 500 50 63 2 80 69 5 80 UL cUL approval Compressor type I 1 Max fuse 1 I 2 Max fuse 2 K5 HRC form II K5 HRC form II V Hz A A A A GA 37 230 60 137 6 160 148 160 GA 37 460 60 71 4 80 77 8 80 GA 37 575 60 57 1 63 63 5 80 IEC approval Compressor type I 1 Max fuse 1 I 2 Max fuse 2 gL gG gL gG V Hz A A A A GA 45 230 50 169 2 200 178 9 200 GA 45 2...

Page 171: ...ize is the maximum fuse size in order to protect the motor against short circuit For cUL fuse HRC form II for UL fuse class RK5 Possible configurations There are 3 possible cabling layouts 1 Single supply cables 2 Parallel supply cables 3 is only valid for Y D versions Cable sizing according IEC The tables below indicate the current carrying capacities of cables for commonly used installation meth...

Page 172: ... A 91 A 95 mm 179 A 156 A 141 A 127 A 109 A 120 mm 206 A 179 A 163 A 146 A 126 A Installation method C according table B 52 1 Single core or multi core cable on a wooden wall Maximum allowed current in function of the ambient temperature for installation method C Ambient temperature Cable section 30 C 40 C 45 C 50 C 55 C 4 mm 32 A 28 A 25 A 23 A 20 A 6 mm 41 A 36 A 32 A 29 A 25 A 10 mm 57 A 50 A 4...

Page 173: ...A 573 A 518 A 467 A 402 A Maximum allowed current in function of the ambient temperature for installation method F conductor temperature 90 C Ambient temperature Cable section 30 C 40 C 45 C 50 C 55 C 25 mm 135 A 123 A 117 A 110 A 103 A 35 mm 169 A 154 A 147 A 139 A 128 A 50 mm 207 A 188 A 180 A 170 A 157 A 70 mm 268 A 244 A 233 A 220 A 204 A 95 mm 328 A 298 A 285 A 269 A 249 A 120 mm 383 A 349 A ...

Page 174: ... 45 C allows a maximum current of 323 A for a 185 mm cable So use a 3 x 185 mm 95 mm cable If the table for method F 90 C cable temperature and ambient temperature of 45 C is used 120 mm is sufficient So a single cable 3 x 120 mm 70 mm is sufficient Parallel supply cable 2 x 3 phases PE configuration 2 I 234 A 10 2 234 x 1 1 2 128 7 A Install 160 A fuses on each cable instead of 315 A For a cable ...

Page 175: ...are with value in table below see CEC Part 1 table 17 100 A use AWG8 200 A use AWG6 300 A use AWG4 Always check the voltage drop over the cable less than 5 of the nominal voltage is recommended Example of supply cable calculation Itot 128 A maximum ambient temperature is 45 C recommended fuse 150 A Single supply cables 3 phases 1 PE configuration 1 I 128 A 25 128 x 1 25 160 A For AWG2 0 the maximu...

Page 176: ... 2 4 2 60 460 2 4 2 4 2 4 60 575 1 9 1 9 1 9 10 4 Dryer switches General The regulating and safety devices are factory adjusted to give optimum performance of the dryer Do not alter the setting of any of the devices 10 5 Reference conditions and limitations Reference conditions Air inlet pressure absolute bar 1 Air inlet pressure absolute psi 14 5 Air inlet temperature C 20 Air inlet temperature F...

Page 177: ...re units with integrated dryer bar e 7 3 8 3 9 8 12 8 7 2 8 9 10 6 12 3 Maximum unloading pressure units with integrated dryer psig 106 120 142 186 104 129 154 178 Reference working pressure bar e 7 8 9 5 12 5 6 9 8 6 10 3 12 Reference working pressure psig 102 116 138 181 100 125 150 175 Pressure drop over dryer units with integrated dryer bar e 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 Pressure dr...

Page 178: ...d dryer hp 1 9 1 9 1 9 1 9 2 1 2 1 2 1 2 1 Dryer power at no load units with integrated dryer kW 1 2 1 2 1 2 1 2 1 4 1 4 1 4 1 4 Dryer power at no load units with integrated dryer hp 1 6 1 6 1 6 1 6 1 9 1 9 1 9 1 9 Refrigerant type units with integrated dryer R410A R410A R410A R410A R410A R410A R410A R410A Refrigerant quantity units with integrated dryer kg 0 8 0 8 0 8 0 8 0 9 0 9 0 9 0 9 Refriger...

Page 179: ...ostatic valve F 104 104 104 140 104 104 104 140 Motor shaft speed r min 2956 2956 2956 2956 3565 3565 3565 3565 Nominal motor power kW 37 37 37 37 37 37 37 37 Nominal motor power hp 49 6 49 6 49 6 49 6 49 6 49 6 49 6 49 6 Temperature of air leaving outlet valve C 27 27 27 27 27 27 27 27 Temperature of air leaving outlet valve F 81 81 81 81 81 81 81 81 Pressure dew point units with integrated dryer...

Page 180: ... 7 5 bar 8 5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Frequency Hz 50 50 50 50 60 60 60 60 Maximum unloading pressure bar e 7 5 8 5 10 13 7 4 9 1 10 8 12 5 Maximum unloading pressure psig 109 123 145 189 107 132 157 181 Maximum unloading pressure units with integrated dryer bar e 7 3 8 3 9 8 12 8 7 2 8 9 10 6 12 3 Maximum unloading pressure units with integrated dryer psig 106 120 142 186...

Page 181: ... with integrated dryer F 73 73 73 73 73 73 73 73 Dryer power at full load units with integrated dryer kW 1 34 1 34 1 4 1 4 1 6 1 6 1 6 1 6 Dryer power at full load units with integrated dryer hp 1 8 1 8 1 9 1 9 2 2 2 1 2 1 2 1 Dryer power at no load units with integrated dryer kW 1 2 1 2 1 2 1 2 1 4 1 4 1 4 1 4 Dryer power at no load units with integrated dryer hp 1 6 1 6 1 6 1 6 1 9 1 9 1 9 1 9 R...

Page 182: ... 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 4 Elektronikon controller p n 1900 5200 00 1900 5200 09 10 Elektronikon Graphic controller p n 1900 5200 10 1900 5200 19 Supply by controller 24 V DC Supply protection Short circuit protected to ground Input protection Not isolated Ana...

Page 183: ...t be made to this vessel by welding drilling or other mechanical methods without the written permission of the manufacturer The pressure and temperature of this vessel must be clearly indicated 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 ...

Page 184: ...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 182 2920 7180 30 ...

Page 185: ...GA 30 up to GA 45 1625 430224 Vessel 30l 15 bar e 10 C 120 C II 0830 101068 Safety valve IV 0830 101069 Safety valve IV Compressor type Component Description Number of cycles 1 Minimum wall thickness Inspection frequency 2 GA 30 up to GA 45 1625 5641 99 Vessel 2 x 106 8 mm 10 years 0830 1010 68 Safety valve 0830 1010 69 Safety valve The compressors conform to PED smaller than category II 1 The num...

Page 186: ...ormity 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 2 Applicable directives 3 Standards used Instruction book 184 2920 7180 30 ...

Page 187: ...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 7180 30 185 ...

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Page 190: ...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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