Atlas Copco GA 30+ Instruction Book
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Atlas Copco GA 30+ Instruction Book

Oil-injected rotary screw compressors
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Oil-injected rotary screw compressors
GA 30+, GA 37, GA 45
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  • Page 1 Atlas Copco Oil-injected rotary screw compressors GA 30+, GA 37, GA 45 Instruction book...
  • Page 3 Atlas Copco Oil-injected rotary screw compressors GA 30+, GA 37, GA 45 From following serial No. onwards: API 571 000 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................7 ........................... 7 AFETY ICONS ......................7 ENERAL SAFETY PRECAUTIONS ................... 8 AFETY PRECAUTIONS DURING INSTALLATION ....................9 AFETY PRECAUTIONS DURING OPERATION ................. 10 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description...................... 12 ..........................12 NTRODUCTION .........................
  • Page 5 Instruction book 3.12 .......................42 ALLING UP MODULE HOURS 3.13 ......................43 ALLING UP LOADING HOURS 3.14 ........................43 ALLING UP LOAD RELAY 3.15 ..................44 ALLING UP RESETTING THE SERVICE TIMER 3.16 ................ 45 ELECTION BETWEEN LOCAL REMOTE OR CONTROL 3.17 ....................
  • Page 6 Instruction book ..........................83 UTPUTS MENU ............................84 OUNTERS ........................85 ONTROL MODE SELECTION 4.10 ..........................87 ERVICE MENU 4.11 ..........................91 ETPOINT MENU 4.12 ........................93 VENT HISTORY MENU 4.13 ......................94 ODIFYING GENERAL SETTINGS 4.14 ............................95 NFO MENU 4.15 ...........................96 EEK TIMER MENU 4.16 ...........................
  • Page 7 Instruction book ..........................142 EFORE STARTING ............................ 144 TARTING ........................145 URING OPERATION ........................147 HECKING THE DISPLAY ............................148 TOPPING ......................149 AKING OUT OF OPERATION Maintenance........................ 151 ....................151 REVENTIVE MAINTENANCE SCHEDULE ........................153 IL SPECIFICATIONS ..........................154 RIVE MOTOR ............................155 IR FILTER ......................156 IL AND OIL FILTER CHANGE .............................
  • Page 8 Instruction book Instructions for use....................181 Guidelines for inspection...................182 Pressure equipment directives................. 183 Declaration of conformity..................184 2920 7180 30...

  • Page 9: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger to life Warning Important note General safety precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.

  • Page 10: Safety Precautions During Installation

    Instruction book 9. If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer centre for advice on specific filtration.

  • Page 11: Safety Precautions During Operation

    Instruction book 14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non- return valves (check valves) must not be relied upon for isolating pressure systems. 15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure relieving device or devices as required.

  • Page 12: Safety Precautions During Maintenance Or Repair

    Instruction book • All fasteners are tight • All electrical leads are secure and in good order • Safety valves and other pressure relief devices are not obstructed by dirt or paint • Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse •...
  • Page 13 Instruction book 10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed openings with a clean cloth, paper or tape. 11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g.

  • Page 14: General Description

    Instruction book General description Introduction GA 30 , GA 37 and GA 45 are single-stage, oil-injected screw compressors, driven by an electric motor. The compressors are air cooled. ® The compressors are controlled by an Elektronikon controller. GA 30 has an Elektronikon controller with graphical display, while the basic version of the GA 37 and GA 45 have a basic version of the Elektronikon controller.
  • Page 15 Instruction book Motor side view, GA 30 up to GA 45 Pack 2920 7180 30...
  • Page 16 Instruction book Service side view, GA 30 up to GA 45 Pack 2920 7180 30...
  • Page 17 Instruction book Motor side view, GA 30 up to GA 45 Full-Feature 2920 7180 30...
  • Page 18 Instruction book Service side view, GA 30 up to GA 45 Full-Feature References Electric cabinet Outlet valve Air cooler Oil cooler Compressor element ® Elektronikon controller Cooling fan Motor of the compressor Emergency stop button Unloader Da (Dm) Condensate outlets Air filter Air receiver (oil separator tank) Oil filter...

  • Page 19: Air And Oil Circuit

    Instruction book Air and oil circuit Air circuit Flow diagram, air circuit (compressors without integrated dryer) 2920 7180 30...
  • Page 20 Instruction book Flow diagram, air circuit (compressors with integrated dryer) Reference Description Intake air Air/oil mixture Wet compressed air Condensate Dried compressed air Description Air drawn through inlet filter (AF) and open inlet valve (IV) of the unloader is compressed in compressor element (E).
  • Page 21 Instruction book valve prevents the compressed air downstream the minimum pressure valve from being vented to atmosphere during unloaded operation. When the compressor is stopped, inlet valve (IV) closes, preventing compressed air (and oil) to be vented into the air filter. Oil circuit Flow diagram, oil circuit Reference...

  • Page 22: Cooling System

    Instruction book Cooling system Diagram Reference Description Intake air Air/oil mixture Wet compressed air Condensate Description The cooling system on air-cooled compressors comprises air cooler (Ca) and oil cooler (Co). The cooling air flow is generated by fan (FN). Condensate system The condensate, collected in the moisture trap of the air cooler, is evacuated via an automatic drain.
  • Page 23 Instruction book Mechanical condensate drain A float opens or closes the outlet dependant on the level of the condensate in the bowl. Electronic drains The GA 30 Pack has an electronic water drain (EWD). On Full-Feature GA 30 compressors, an additional electronic water drain is provided.
  • Page 24 Instruction book Drain connections Condensate drain connections Reference Designation Automatic drain connection Manual drain valve Automatic drain connection of the dryer (only on units with integrated dryer) Manual drain valve of the dryer (only on units with integrated dryer) 2920 7180 30...

  • Page 25: Regulating System

    Instruction book Regulating system Load/unload regulating system Regulating system (loaded condition) Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results: • The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank pressure (1) via the solenoid valve.

  • Page 26: Electrical System

    Instruction book Electrical system Electrical components The electrical system comprises following components: Typical example of electric cubicle Reference Designation Fuse Fuse Fuse F7/8/9 Fuses (only on units with integrated dryer) Overload relay, compressor motor Circuit breaker, fan motor (on air-cooled compressors) Auxiliary relay 2920 7180 30...

  • Page 27: Air Dryer

    Instruction book Reference Designation Auxiliary contactor (only on units with integrated dryer) Auxiliary contactor (only on units with integrated dryer) Phase sequence relay Smartbox Line contactor Star contactor Delta contactor Transformer 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.
  • Page 28 Instruction book Reference Name Air outlet Air/air heat exchanger Air/refrigerant heat exchanger/evaporator Condensate separator Automatic drain / condensate outlet Refrigerant compressor Refrigerant condenser Liquid refrigerant dryer/filter Capillary Bypass valve Condenser cooling fan Pressure switch, fan control Liquid separator Compressed air circuit Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air.

  • Page 29: Elektronikon® Controller

    Instruction book Elektronikon® controller ® Elektronikon controller Control panel Introduction ® The Elektronikon controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) Automatic control of the compressor The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor.

  • Page 30: Control Panel

    Instruction book A shutdown warning level is a programmable level below the shutdown level. If one of the measurements exceeds the programmed shutdown warning level, this will also be indicated to warn the operator before the shutdown level is reached. Service warning If the service timer exceeds a programmed value, this will be indicated on the display to warn the operator to carry out some service actions.

  • Page 31: Icons Used On The Display

    Instruction book Reference Designation Function LED, Automatic operation Indicates that the regulator is automatically controlling the compressor: the compressor is loaded, unloaded, stopped and restarted depending on the air consumption and the limitations programmed in the regulator. Warning symbol LED, Warning Is lit if a warning condition exists.
  • Page 32 Instruction book Function Icon Description Automatic restart after Automatic restart after voltage failure is active voltage failure Timer Active protection functions Emergency stop Service Service required Units Pressure unit (Mega Pascal) Pressure unit (pounds per square inch) Pressure unit (bar) Temperature unit (degree Centigrade) Temperature unit (degree Fahrenheit) Hours (always shown together with seconds)

  • Page 33: 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". 2920 7180 30...

  • Page 34: Shut-Down Warning

    Instruction book Shut-down warning Description A shut-down warning will appear in the event of: • Too high a temperature at the outlet of the compressor element • Too fast increase of temperature at the outlet of the compressor element • Too high a dewpoint temperature (Full-Feature compressors) Compressor element outlet temperature •...

  • Page 35: Shut-Down

    Instruction book Main screen with the dewpoint temperature warning The related pictograph will appear flashing Press the Scroll button (12) until the actual dewpoint temperature appears. Warning screen, dewpoint temperature The screen shows that the dewpoint temperature is 9˚C. • It remains possible to scroll through other screens (using Scroll buttons 12) to check the actual status of other parameters.
  • Page 36 Instruction book Compressor element outlet temperature • If the outlet temperature of the compressor element exceeds the shut-down level (factory setting 120 ˚C / 248 ˚F, programmable) the compressor will be shut-down, alarm LED (5) will flash, automatic operation LED (3) will go out and the following screen will appear: Main screen with shut-down indication, element outlet temperature The related pictograph will appear flashing.

  • Page 37: Service Warning

    Instruction book Main screen with shut-down indication, motor overload • 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. Service warning Description A service warning will appear when the service timer has reached the programmed time interval. If the service timer exceeds the programmed time interval, service LED (9) will light up.

  • Page 38: Scrolling Through All Screens

    Instruction book Stop the compressor, switch off the voltage and carry out the required service actions. See section Preventive Maintenance. • The longer interval service actions must also include the shorter interval actions. In the example above, carry out all service operations belonging to the 8000 running hours interval as well as those belonging to the 4000 running hours interval.
  • Page 39 <P. 9> Selection for function: Automatic restart See section Activating automatic restart after voltage failure (active or not, only for Atlas Copco) <P. 10> Selection between Y-D or DOL starting See section Selection between Y-D or DOL starting <P. 11>...
  • Page 40 Instruction book Protections Designation Related topic screens <Pr. 1> Protections screens See section Calling up/modifying protection <Pr. 2> settings <Pr. 3> Test screens Designation Related topic <t. 1> Display test See sections Test screens <t. 2> Safety valve test See sections Test screens <t.
  • Page 41 Instruction book Menu flow Simplified menu flow Ref. Description Ref. Description Compressor outlet pressure (16) Pressure band selection Compressor outlet temperature (17) Service timer settings Dewpoint temperature (18) Temperature unit Digital input status (19) Unit pressure 2920 7180 30...

  • Page 42: Calling Up Temperatures

    Instruction book Ref. Description Ref. Description Running hours (20) Auto restart Motor starts (21) Selection Y-D/DOL Module hours (22) Load delay time Loading hours (23) Minimum stop time Load relay (24) Password settings (10) Service timer reading (25) Remote pressure sensing (11) Actual program version (26)

  • Page 43: Calling Up Running Hours

    Instruction book The screen shows that the outlet temperature is 82 ˚C. • For Full-Feature compressors: Press Scroll button (12). The dew point temperature will be shown: The screen shows that the dew point temperature is 3 ˚C. 3.10 Calling up running hours Control panel Starting from the Main screen: •...

  • Page 44: Calling Up Motor Starts

    Instruction book 3.11 Calling up motor starts Control panel Starting from the Main screen, press Scroll button (12) until <d. 2> is shown and then press Enter button (13). A screen similar to the following 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.

  • Page 45: Calling Up Loading Hours

    Instruction book In the example shown, the screen shows the unit used (hrs) and the value (5000): the regulator module has been in service during 5000 hours. 3.13 Calling up loading hours Starting from the Main screen: • Press Scroll button (12) until <d.4> is shown and then press Enter button (13): The screen shows the unit used <hrs>...

  • Page 46: Calling Up/Resetting The Service Timer

    Instruction book 3.15 Calling up/resetting the service timer Calling up the service timer Starting from the Main screen: • Press Scroll button (12) until <d.6> is shown and then press Enter button (13): This screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1191>. In the example shown, the compressor has run 1191 hours since the previous service.

  • Page 47: Selection Between Local, Remote Or Lan Control

    Instruction book 3.16 Selection between local, remote or LAN control Starting from the Main screen, press Scroll button (12) until <P. 1> is shown and then press Enter button (13). The actually selected control mode is shown: <LOC> for local control, <rE> for remote control or <LAn>...
  • Page 48 Instruction book Modifying the node ID The node ID can be changed; use a value between 1 and 31. When the function is ON, the parameters cannot be modified. Change the function to OFF to change the node ID. It is also possible to change the channels. The controller has 4 channels. When changing the channels, the controller can act as a Mk IV controller (a previous version of the controller).

  • Page 49: Calling Up/Modifying Ip, Gateway And Subnetmask

    Instruction book 3.18 Calling up/modifying IP, Gateway and Subnetmask Calling up Starting from the Main screen, press the Scroll button (12) until <P. 3> is shown and then press Enter button (13). The next screen shows either <OFF> or <On>. If <On>, press the Enter button (13) to modify it to <OFF>. Use the Scroll buttons Up or Down (12) to scroll between the items in this list (<IP>...

  • Page 50: Calling Up/Modifying Pressure Band Settings

    Instruction book 3.19 Calling up/modifying pressure band settings Calling up the settings 2920 7180 30...
  • Page 51 Instruction book Starting from the Main screen: • Press Scroll button (12) until <P.04> is shown and then press Enter button (13). Pressure band 1 (<Pb. 1>) is shown on the display. Button (12) can be used to scroll to pressure band 2 (<Pb.2>). •...

  • Page 52: Modifying The Pressure Band Selection

    Instruction book 3.20 Modifying the pressure band selection Control panel Starting from the Main screen: • Press Scroll button (12) until <P.05> is shown and then press Enter button (13). The active pressure band 1 (<Pb.1>) is shown on the display. •...

  • Page 53: Calling Up/Modifying The Unit Of Temperature

    Instruction book 3.22 Calling up/modifying the unit of temperature Control panel Starting from the Main screen: • Press Scroll button (12) until <P.07> is shown and then press Enter button (13). The actually used unit is shown. Possible settings are <˚C> and <˚F>. •...

  • Page 54: Selection Between Y-Dor Dol Starting

    (13). The actually used starting mode is shown: <Y-D> (star-delta) or <doL> (Direct-On-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...

  • Page 55: Calling Up Modifying Minimum Stop Time

    Instruction book • This screen shows the load delay time (10) and the unit (s= seconds). To modify this value press the Enter button (13) (a password may be required). • The value starts blinking and Scroll buttons (12) can be used to modify the value. •...

  • Page 56: Activate Load/Unload Remote Pressure Sensing

    Instruction book • The screen shows the password status (ON (<On>) or OFF (<OFF>). Press Enter button (13) to modify. • Change the value with Scroll buttons (12). • Select <On> and press Enter button (13). • Enter the new password and press Enter button (13) to confirm. •...
  • Page 57 Instruction book A number of protection settings are provided. The protection screens are labelled <Pr.>. The pictograph shown with the protection screen indicates the purpose of the protection. Possible combinations are <Pr.>, followed by a number and one of the next pictographs: Pictograph Designation <Pr.>...

  • Page 58: Test Screens

    Safety valve test In the test screen <t. 2>, a safety valve test is provided. The safety valves can only be tested after entering a code. Consult Atlas Copco if the safety valves are to be tested. Production test Test screen <t. 3> is only intended for production test. If the Main screen shows following screen, the...

  • Page 59: Web Server

    Instruction book How to solve? Use the Scroll buttons (12) and scroll to menu <t. 3>. The screen shows: Press the Enter button (13): the text starts blinking. Press enter again and the menu disappears. 3.32 Web server All controllers have a built-in web server that allows direct connection to the company network or to a dedicated PC via a local area network (LAN).
  • Page 60 Instruction book Configuration of the network card • Go to Network and Sharing Center (1). • Click on Change adapter settings (1). • Select the Local Area Connection, which is connected to the controller. • Click with the right button and select Properties (1). •...
  • Page 61 Instruction book • Use the following settings: • IP Address 192.168.100.200 (1) • Subnetmask 255.255.255.0 (2) Click OK (3) and close network connections. Configure a company network (LAN) connection • Ask your IT department to generate a fixed IP address in your company’s network. •...
  • Page 62 Instruction book • Adapt the network settings in the Elektronikon Mk5: • Go to Main Menu • Go to Settings (1) • Go to Network (1) 2920 7180 30...
  • Page 63 Instruction book • Go to Ethernet (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 2920 7180 30...
  • Page 64 Instruction book • Wait a few minutes so the LAN network can connect to the Elektronikon Mk5 Configuration of the web server ® The internal web server is designed and tested for Microsoft Internet Explorer. Also "Opera", "Mozilla Firefox", "Safari"and "Chrome" should work. Viewing the controller data All screen shots are indicative.
  • Page 65 Instruction book Screen shot (example!) Navigation and options • The banner shows the unit type and the language selector. In this example, three languages are 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.
  • Page 66 Instruction book Unit settings All unit settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen. Analog inputs Lists all current analog input values.

  • Page 67: Programmable Settings

    Instruction book Special protections Lists all special protections of the unit. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours. It is also possible to show the current status of the service interval. 3.33 Programmable settings Parameters: unloading/loading pressures for compressors without built-in refrigeration dryer Minimum...
  • Page 68 Instruction book Minimum Factory Maximum setting setting setting Unloading pressure (100 psi compressors) psig 59.5 107.3 Unloading pressure (125 psi compressors) bar(e) Unloading pressure (125 psi compressors) psig 59.5 Unloading pressure (150 psi compressors) bar(e) 10.3 10.8 Unloading pressure (150 psi compressors) psig 59.5 156.6...
  • Page 69 Instruction book Minimum Factory Maximum setting setting setting Unloading pressure (125 psi compressors) psig Unloading pressure (150 psi compressors) bar(e) 10.3 10.6 Unloading pressure (150 psi compressors) psig 153.5 Unloading pressure (175 psi compressors) bar(e) 12.3 Unloading pressure (175 psi compressors) psig 178.4 Loading pressures...
  • Page 70 Minimum stop Once the compressor has automatically stopped, it will remain stopped for the minimum time stop time, whatever happens with the net air pressure. Consult Atlas Copco if a setting lower than 20 seconds is required. Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is Loading pressure programmed at 7.0 bar(e) (101 psi(g)), the maximum limit for the loading pressure...

  • Page 71: Elektronikon® Graphic Controller

    Instruction book Elektronikon® Graphic controller Controller ® The Elektronikon Graphic controller Introduction ® The Elektronikon controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (ARAVF) Automatic control of the compressor The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor (fixed speed compressors) or by adapting the motor speed (compressors with...

  • Page 72: Automatic Restart After Voltage Failure

    For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. If the function is activated and provided the regulator was in the automatic operation mode, the compressor will automatically restart if the supply voltage to the module is restored.

  • Page 73: Control Panel

    Instruction book Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Display Shows the compressor operating condition and a number of icons to navigate through the menu. Pictograph Automatic operation Pictograph General alarm Alarm LED Flashes in case of a shut-down, is lit in case of a warning condition.

  • Page 74: Icons Used

    Instruction book Icons used Status icons Name Icon Description Stopped / Running When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating. Compressor status Motor stopped Running unloaded Running loaded Machine control mode Local start / stop Remote start / stop Network control...
  • Page 75 Instruction book Active protection functions Emergency stop Shutdown Warning Service Service required Main screen display Value lines display icon Chart display icon General icons No communication / network problem Not valid General alarm Input icons Icon Description Pressure Temperature Digital input Special protection 2920 7180 30...
  • Page 76 Instruction book System icons Icon Description Compressor element Dryer 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) 2920 7180 30...

  • Page 77: Main Screen

    Instruction book Access key / User password Network Setpoint Info Navigation arrows Icon Description Down This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to every machine. Main screen Control panel Scroll keys Enter key Escape key...
  • Page 78 Instruction book Typically, 5 different main screen views can be chosen: 1. Two value lines 2. Four value lines 3. Chart (High resolution) 4. Chart (Medium resolution) 5. Chart (Low resolution) Two and four value lines screens This type of Main screen shows the value of 2 or 4 parameters (see section Inputs menu).
  • Page 79 Instruction book Off, Shutdown,... (text varies upon the compressors actual condition) Menu Running Hours Element Outlet Load, Unload,... (text varies upon the compressors actual condition) • Section A shows information regarding the compressor operation (e.g. the outlet pressure or the temperature at the compressor outlet).
  • Page 80 Instruction book When Chart (High Resolution) is selected, the chart shows the variation of the selected input (in this case the pressure) per minute. Also the instantaneous value is displayed. The screen shows the last 4 minutes. The switch button (icon) for selecting other screens is changed into a small Chart and is highlighted (active).

  • Page 81: Calling Up Menus

    Instruction book Selection of a main screen view To change between the different screen layouts, select the far right icon in the control icons line (see value lines display icon or chart display icon in section Icons used) and press the Enter key. A screen similar to the one below opens: Select the layout required and press the Enter key.

  • Page 82: Inputs Menu

    Instruction book Typical Main screen (2 value lines), fixed speed compressors Text on image Compressor Outlet Element Outlet Load , shutdown ,.. (text varies upon the compressors actual condition). Menu Unload ,ES, ... (text varies upon the compressors actual condition To go to the Menu screen, highlight Menu, using the Scroll keys.
  • Page 83 Instruction book Function • To display the actual value of the measured data (analog inputs) and the status of the digital inputs (e.g. emergency stop contact, motor overload relay, etc.). • To select the digital input to be shown on the chart in the main screen. Procedure Starting from the main screen, •...
  • Page 84 Instruction book Selecting another input signal as main chart signal With the Modify button active (light grey background in above screen), press the Enter button on the controller. A screen similar to the one below appears: The first item in the list is highlighted. In this example, the Net Pressure is selected (chart icon). To change, press the Enter button again: a pop-up window opens: Press Enter again to remove this input from the chart.

  • Page 85: Outputs Menu

    Instruction book (1): Set as main chart signal Outputs menu Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact (on air cooled compressors), the Emergency stop contact, etc. Procedure Starting from the Main screen, •...

  • Page 86: Counters

    Instruction book Outputs screen (typical) Text on image Outputs Fan motor Blowoff General shutdown Automatic operation • The screen shows a list of all outputs with their corresponding icons and readings. If an output is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively.

  • Page 87: Control Mode Selection

    Instruction book Text on image Menu Regulation • Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon) • Press the Enter key. Following screen appears: Text on image Counters Running Hours Motor Starts Load Relay VSD 1-20 % RPM (the percentage of the time during which the motor speed was between 1 and 20 %) (compressors with frequency converter)
  • Page 88 Instruction book Next, use the scroll buttons to go to the Status icons (see section Main screen) and select the machine control icon (2). Press the enter button. There are 3 possibilities: • Local control • Remote control • LAN (network) control After selecting the required regulation mode, press the enter button on the controller to confirm your selection.

  • Page 89: Service Menu

    Instruction book 4.10 Service menu Control panel Scroll keys Enter key Escape key Menu icon, Service Function • To reset the service plans which are carried out. • To check when the next service plans are to be carried out. •...
  • Page 90 Instruction book • Press the Enter key. Following screen appears: Text on image Service Overview Service Plan Next Service History • Scroll through the items to select the desired item and press the Enter key to see the details as explained below.
  • Page 91 Instruction book The figures within the bars are the number of hours to go till the next service intervention. In the example above, the compressor was just started up, which means it still has 4000 running hours and 8280 hours to go before the next Service intervention.
  • Page 92 Instruction book Modify the value as required using the ↑ or ↓ scroll key and press the Enter key to confirm. Note: Running hours can be modified in steps of 100 hours, real time hours can be modified in steps of 1 hour.

  • Page 93: Setpoint Menu

    Instruction book 4.11 Setpoint menu Control panel Scroll keys Enter key Escape key Menu icon, Setpoint Function On fixed speed compressors , the operator can program two different pressure bands. This menu is also used to select the active pressure band. Procedure Starting from the Main screen (see Main...
  • Page 94 Instruction book Text on image Regulation Unloading Pressure 1 Loading Pressure 1 Unloading Pressure 2 Loading Pressure 2 Modify • The screen shows the actual unloading and loading pressure settings for both pressure bands. To modify the settings, move the cursor to the action button Modify and press the Enter key. Following screen appears: •...

  • Page 95: Event History Menu

    Instruction book If necessary, change the other settings as required in the same way as described above. 4.12 Event history menu Menu icon, Event History Function To call up the last shutdown and last emergency stop data. 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 Menu...

  • Page 96: Modifying General Settings

    Instruction book 4.13 Modifying general settings Menu icon, Settings Function To display and modify a number of settings. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on image Menu Regulation...

  • Page 97: Info Menu

    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 the action button Menu and press the Enter key. Following screen appears: 2920 7180 30...

  • Page 98: Week Timer Menu

    Regulation • Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon). • Press the Enter key. The Atlas Copco internet address appears on the screen. 4.15 Week timer menu Menu icon, Week timer Function •...
  • Page 99 Instruction book Text on image Menu Week Timer • Press the Enter key on the controller. Following screen appears: Text on image Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive 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.
  • Page 100 Instruction book Text on image Week Action Schemes Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Week Action Scheme 4 • A weekly list is shown. Monday is automatically selected and highlighted. Press the Enter key on the controller to set an action for this day.
  • Page 101 Instruction book Text on image Monday Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller. When ready press the Enter key to confirm. Text on image Monday Actions Remove Start Stop...
  • Page 102 Instruction book Text on image Monday Start Save Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. • A pop-up window opens. Use the ↑ or ↓ key of Scroll keys to modify the values of the hours. Use the ←...
  • Page 103 Instruction book Text on image Monday Are you sure? Save Modify Press the Escape key to leave this window. • The action is shown below the day the action is planned. Text on image Week Action Scheme 1 Monday Tuesday Wednesday Thursday Friday...
  • Page 104 Instruction book • Select Week Cycle from the main Week Timer menu list. Text on image Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time • A list of 10 weeks is shown. Text on image Week Cycle Week 1 Week 2...
  • Page 105 Instruction book Text on image Week Cycle Week 1 Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Modify • Check the status of the Week Timer Use the Escape key on the controller to go back to the main Week Timer menu. Select the status of the Week Timer.
  • Page 106 Instruction book Text on image Week Timer Week Week Timer Inactive Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active. Text on image Week Timer Week Action Schemes Week Cycle Status Remaining Running Time...

  • Page 107: Test Menu

    Instruction book Text on image Week Timer Week Action Schemes Week Cycle Status Remaining Running Time • This timer is used when the week timer is set and for certain reasons the compressor must continue working, for example, 1 hour, it can be set in this screen. This timer is prior to the Week Timer action.

  • Page 108: User Password Menu

    Instruction book • Move the cursor to the action button Menu and press the enter key (2), following screen appears: • Using the scroll keys (1), move the cursor to the test icon (see above, section Menu icon) • Press the enter key (2), following screen appears: Text on image Test Safety Valve Test...

  • Page 109: Web Server

    Instruction book • Using the Scroll keys, select the Settings icon (see section Modifying general settings) • Press the Enter key. Following screen appears: • Move the cursor to the Password icon (see above, section Menu icon) • Select <Modify> using the Scroll keys and press the Enter key. Next, modify the password as required.
  • Page 110 Instruction book • Click on Change adapter settings (1). • Select the Local Area Connection, 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.
  • Page 111 Instruction book • Use the following settings: • IP Address 192.168.100.200 (1) • Subnetmask 255.255.255.0 (2) Click OK (3) and close network connections. Configure a company network (LAN) connection • Ask your IT department to generate a fixed IP address in your company’s network. •...
  • Page 112 Instruction book • Adapt the network settings in the Elektronikon Mk5: • Go to Main Menu • Go to Settings (1) • Go to Network (1) 2920 7180 30...
  • Page 113 Instruction book • Go to Ethernet (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 2920 7180 30...
  • Page 114 Instruction book • Wait a few minutes so the LAN network can connect to the Elektronikon Mk5 Configuration of the web server ® The internal web server is designed and tested for Microsoft Internet Explorer. Also "Opera", "Mozilla Firefox", "Safari"and "Chrome" should work. Viewing the controller data All screen shots are indicative.
  • Page 115 Instruction book Screen shot (example!) Navigation and options • The banner shows the unit type and the language selector. In this example, three languages are 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.
  • Page 116 Instruction book Unit settings All unit settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen. Analog inputs Lists all current analog input values.

  • Page 117: Programmable Settings

    Instruction book Special protections Lists all special protections of the unit. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours. It is also possible to show the current status of the service interval. 4.19 Programmable settings Parameters: unloading/loading pressures for compressors without built-in refrigeration dryer Minimum...
  • Page 118 Instruction book Minimum Factory Maximum setting setting setting Unloading pressure (100 psi compressors) psig 59.5 107.3 Unloading pressure (125 psi compressors) bar(e) Unloading pressure (125 psi compressors) psig 59.5 Unloading pressure (150 psi compressors) bar(e) 10.3 10.8 Unloading pressure (150 psi compressors) psig 59.5 156.6...
  • Page 119 Instruction book Minimum Factory Maximum setting setting setting Unloading pressure (125 psi compressors) psig Unloading pressure (150 psi compressors) bar(e) 10.3 10.6 Unloading pressure (150 psi compressors) psig 153.5 Unloading pressure (175 psi compressors) bar(e) 12.3 Unloading pressure (175 psi compressors) psig 178.4 Loading pressures...
  • Page 120 The built-in service timers will give a Service warning message after their respective preprogrammed time interval has elapsed. Also see section Preventive maintenance schedule. Consult Atlas Copco if a timer setting has to be changed. The intervals must not exceed the nominal intervals and must coincide logically. See section Modifying general settings.

  • Page 121: Energy Recovery (Optional)

    Instruction book Energy recovery (optional) Energy recovery unit Description A large part of the energy required for any compression process is transformed into heat. For oil-injected screw compressors, the major part of the compression heat is dissipated through the oil system. The energy recovery (ER) systems are designed to recover most of this heat by transforming it into warm or hot water without any adverse influence on the compressor performance.

  • Page 122: Energy Recovery Systems

    Instruction book Reference Designation Water inlet pipe Water outlet pipe Temperature sensor, water inlet pipe Temperature sensor, water outlet pipe Oil drain plug Oil flexible from compressor oil separator vessel to ER unit Oil flexible from ER unit to oil filter housing Pressure relief valve Location of heat exchanger by-pass valve (BV2) Heat exchanger...

  • Page 123: Operation

    To minimize these problems, the water should meet a number of requirements. See section Cooling water requirements. If in any doubt, consult Atlas Copco. Operation Description The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable compressor operation and optimal energy recovery.
  • Page 124 Instruction book Flow diagram of compressor with energy recovery system Reference Designation Reference Designation Thermostatic bypass valve of ER Oil filter unit Oil/water heat exchanger (ER Oil separator tank unit) Compressor element Thermostatic bypass valve in oil filter housing Oil cooler (compressor) Aftercooler (compressor) Water inlet Water outlet...

  • Page 125: Maintenance

    Instruction book Energy recovery system in use (see drawing) Compressor start-up When the compressor is started up from cold, the oil temperature will be low. Bypass valve (BV2) shuts off the oil supply through the heat exchanger (HE) and bypass valve (BV1) shuts off the oil supply through the oil cooler (C0) to prevent the compressor oil from being cooled.

  • Page 126: Energy Recovery Data

    Instruction book 2. Depressurize the compressor and drain the oil by opening the drain valve on the oil separator vessel. See section Oil and oil filter change. 3. Resume oil change as described in section Oil and Filter Change in this book. Units with the energy recovery option are factory filled with 8000 h oil.
  • Page 127 Instruction book Temperature input Minimum Nominal Maximum setting setting setting Water inlet temperature of energy recovery ˚C Water inlet temperature of energy recovery ˚F Energy recovery water outlet temperature ˚C Depends on application Energy recovery water outlet temperature ˚F Depends on application To modify a setting, consult the relevant section in the description of the controller.

  • Page 128: Cooling Water Requirements

    Instruction book Cooling water requirements General Cooling water needs to fulfill certain requirements in order to avoid problems of scaling, fouling, corrosion or bacterial growth. In open circuit cooling towers, protective measures must be taken to avoid the growth of harmful bacteria such as legionella pneumophila when there is a risk of inhalation of the water droplets.
  • Page 129 Instruction book 2. Total dissolved solids (TDS) and conductivity The conductivity is expressed in μS/cm, the TDS in ppm. Both parameters are related with each other. The conductivity is convenient for quick monitoring of general water quality, but the TDS is required for calculating the RSI. If only one of both parameters is measured, an estimation can be obtained by using a theoretical conversion factor (0.67): TDS = conductivity x 0.67 3.
  • Page 130 Instruction book Total Temperature Ca hardness dissolved (°C) (ppm CaCO Alkalinity solids (ppm (mg/l) CaCO 28 - 32 36 - 44 36 - 44 33 - 38 45 - 56 45 - 56 39 - 43 57 - 70 57 - 70 44 - 49 71 - 89 71 - 89...
  • Page 131 Instruction book Sulphate (ppm) Type of cooling system Standard Energy recovery Single pass < 1000 < 200 Recirculating (with tower) < 1000 not applicable Closed loop < 400 < 200 8. Iron and Manganese Dissolved iron (ppm) Dissolved manganese (ppm) Type of cooling Standard Energy recovery...
  • Page 132 Instruction book Biology (CFU/ml) Type of cooling system Standard Energy recovery Single pass < 10 / < 10 < 10 / < 10 Recirculating (with tower) not applicable < 10 / < 10 Closed loop < 10 / < 10 <...

  • Page 133: Installation

    Instruction book Installation Dimension drawings The dimension drawing can be found on the CD-ROM, DVD or USB, supplied with the unit. Dimension drawing Model 9828 5102 34–01 GA 30 , GA 37, GA 45 Pack, metric units 9828 5102 34–02 GA 30 , GA 37, GA 45 Pack, imperial units 9828 5102 35–01...
  • Page 134 If frost might occur, the appropriate measures must be taken to avoid damage to the machine and its ancillary equipment. Consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Take care not to damage the bodywork during lifting or transport.

  • Page 135: Installation Guidelines

    Instruction book Compressor room example Text on drawing Reference Designation Ventilation proposals 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. 2920 7180 30...
  • Page 136 Instruction book 2. Position of the compressed air outlet valve. 3. The pressure drop over the air delivery pipe can be calculated from: 1.85 Δp = (L x 450 x Q ) / (d x P), with • Δp = pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi)) •...

  • Page 137: Electrical Connections

    Instruction book 10. To prevent feedback of exhaust air to the cooling inlet, sufficient space should be foreseen above the unit to evacuate the exhaust air. Electrical connections Important remark To preserve the protection degree of the electric cubicle and to protect its components from dust from the environment, it is mandatory to use a proper cable gland when connecting the supply cable to the compressor.
  • Page 138 Instruction book Compressor status indication On compressors equipped with an Elektronikon® controller, the controller is provided with an auxiliary relay (K05) for remote indication of a shutdown. This NO contact (NO = normally open) will be closed if all conditions are normal and will open in case of power failure or shutdown. Maximum contact load: 10 A / 250 V AC.

  • Page 139: Pictographs

    Instruction book Pictographs Description Pictographs 2920 7180 30...
  • Page 140 Instruction book Reference Designation Warning: Always read the manual, switch off the voltage, depressurise compressor and lock out/ tag out before repairing. Keep the doors closed during operation Switch off the voltage before removing protecting cover inside electric cubicle Warning, voltage Automatic condensate drain Stop the compressor before cleaning the coolers Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx.

  • Page 141: Operating Instructions

    Instruction book Operating instructions Initial start-up The operator must apply all applicable Safety precautions. For the location of the air outlet valve and the drain connections, see sections Introduction Condensate system. Preparations 1. Consult the sections Electrical cable size, Installation proposal Dimension drawings.
  • Page 142 Instruction book Electric cubicle 5. Check the setting of circuit breaker (Q15). Also check that the switch on the circuit breaker is in position I. 6. Fit air outlet valve (AV). See section Introduction for the location of the valve. Close the valve.
  • Page 143 Instruction book • The compressor is automatically controlled and may be restarted automatically. Initial start procedure If the compressor has not run for the past 6 months, it is strongly recommended to improve the lubrication of the compressor element before starting. To do so: 1.

  • Page 144: Before Starting

    Instruction book 2. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of drive motor (M1) while the motor is coasting to a stop. The correct rotation direction of the drive motor is indicated by an arrow shown on the motor fan cowl. If the rotation direction of the drive motor is incorrect, open the isolating switch and reverse two incoming electric lines.
  • Page 145 Instruction book Position of oil level sight glass 3. If necessary, empty the dust trap of the filter, see section 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.

  • Page 146: Starting

    Instruction book Starting For the position of the air outlet valve and the drain connections, see sections Introduction Condensate system. Control panel Elektronikon® Control panel Elektronikon® Graphic Procedure 1. Open the air outlet valve. 2. Switch on the voltage. Check that voltage on LED (6) lights up. 3.

  • Page 147: During Operation

    Instruction book During operation Warnings The operator must apply all relevant Safety precautions. Also consult section Problem solving. 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.
  • Page 148 Instruction book Regularly check the oil level. To do so: 1. Press stop button (9). 2. A few minutes after stopping, the oil level should be between the oil filler neck (FC) and the bottom of the sight glass (Gl). 3.

  • Page 149: Checking The Display

    Instruction book Air filter Position of the service indicator Regularly check the service indicator. If the colored part of service indicator (VI) shows full out, replace the air filter element. Reset the service indicator by pushing the knob in the extremity of the indicator body. Drains Regularly check that condensate is discharged during operation.

  • Page 150: Stopping

    Instruction book 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 pictographs. Remedy the trouble if alarm LED (7) is lit or flashes, see section Shutdown warning, Shutdown...

  • Page 151: Taking Out Of Operation

    Instruction book Control panel Elektronikon® Graphic Procedure Step Action Press stop button (9). Automatic operation LED (8) goes out and the compressor stops after 30 seconds of unloaded operation. To stop the compressor in the event of an emergency, press emergency stop button (10). Alarm LED flashes (7).
  • Page 152 Instruction book Step Action Press the test button on top of the electronic water drain(s) until the air system between air receiver and outlet valve is fully depressurized. Consult section Condensate system to locate the drain valve. Switch off the voltage and disconnect the compressor from the mains. Open the condensate drain valve(s) (Dm).

  • Page 153: Maintenance

    For overhauling or carrying out preventive maintenance, service kits are available. Consult the Spare Parts list for part numbers. Service contracts Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work. Consult your Atlas Copco Customer Centre. General When servicing, replace all removed O-rings and washers.
  • Page 154 Instruction book Maintenance checklist Period Operation Daily Check oil level. Check readings on the controller display. Check the air filter service indicator. Check that condensate is discharged during operation of the compressor. Drain condensate. Check the pressure dew point temperature (on compressors with integrated dryer). 3-monthly (1) Check coolers.

  • Page 155: Oil Specifications

    Roto-Inject Fluid Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specific composition keeps the compressor in excellent condition. See the table below for oil exchange intervals:...

  • Page 156: Drive Motor

    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...

  • Page 157: Air Filter

    Instruction book Air filter Location of air filter Recommendations 1. Never remove the element while the compressor is running. 2. For minimum downtime, replace the dirty element by a new one. 3. Discard the element when damaged. Procedure 1. Stop the compressor. Switch off the voltage. 2.

  • Page 158: Oil And Oil Filter Change

    Instruction book Oil and oil filter change Warning The operator must apply all relevant Safety precautions. Always drain the compressor oil at all drain points. Used oil left in the compressor can contaminate the oil system and can shorten the lifetime of the new oil. Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties.

  • Page 159: Coolers

    Instruction book Step Description Run the compressor until warm. Stop the compressor after 3 minutes of unloaded operation. Close the air outlet valve and switch off the voltage. Wait a few minutes and depressurise by unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape. Air cooled units: loosen the vent plug (VP) of the oil cooler and wait for 5 minutes.
  • Page 160 Instruction book • Remove any dirt from the coolers with a fibre brush. Brush in the direction of the cooling fins. Also remove any dirt from the fan with a fibre 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).

  • Page 161: Safety Valves

    Instruction book Safety valves Location of safety valve Position of safety valve Operating Operate the safety valve from time to time by unscrewing the cap one or two turns. Retighten it afterwards. Testing Before removing the valve, depressurize the compressor. See also section Problem solving. The safety valve (SV) can be tested on a separate air line.

  • Page 162: Service Kits

    Instruction book • Fluid refrigerant will also cause freezing of the eyes; always wear safety glasses. • Refrigerant is harmful. Do not inhale refrigerant vapours. Check that the working area is adequately ventilated. Be aware that certain components such as the refrigerant compressor and the discharge pipe can become quite hot (up to 110 °C - 230 °F).

  • Page 163: Disposal Of Used Material

    Instruction book If the compressor is going to be stored without running from time to time, protective measures must be taken. Consult your supplier. 8.11 Disposal of used material Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation.

  • Page 164: Problem Solving

    Instruction book Problem solving Warning Always apply all relevant Safety precautions. Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped and close the air outlet valve. Open the manual drain valve(s). Press the emergency stop button and switch off the voltage.
  • Page 165 Instruction book Condition Fault Remedy Too high temperature in oil Find cause and remedy. Replace separator vessel or temperature if necessary. switch (TSHH1) defective Phase sequence relay (K25) open Find cause and remedy. Replace if necessary. Wiring interrupted Find cause and remedy. Replace if necessary.
  • Page 166 Instruction book Condition Fault Remedy Minimum pressure valve Have valve checked malfunctioning Safety valve out of order Have valve replaced Oil separator element clogged Have oil separator element replaced Compressor element out of order Consult your supplier Compressor element outlet Oil level too low Check and correct temperature or delivery air...
  • Page 167 Instruction book Condition Fault Remedy Compressor stops or does not Electric power supply to Check and correct as necessary start compressor is interrupted Thermal protection of Motor will restart when motor windings have refrigerant compressor motor cooled down has tripped Condensate drain remains Drain system clogged Have system inspected...

  • Page 168: Technical Data

    Instruction book Technical data 10.1 Readings on display Elektronikon® Controller Elektronikon® Graphic Controller Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limitations). Reference Reading Air outlet pressure Modulates between programmed unloading and loading pressures. Compressor element Approx.

  • Page 169: Electric Cable Size And Fuses

    Instruction book 10.2 Electric cable size and fuses Important • The voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1).
  • Page 170 Instruction book UL/cUL approval Compressor type I (1) Max. fuse (1) I (2) Max. fuse (2) HRC form II HRC form II 121,8 129,8 GA 30 61,2 65,3 GA 30 49,3 53,4 GA 30 IEC approval Compressor type I (1) Max.
  • Page 171 Instruction book UL/cUL approval Compressor type I (1) Max. fuse (1) I (2) Max. fuse (2) HRC form II HRC form II GA 45 181,4 GA 45 86,4 92,7 GA 45 68,6 I: current in the supply lines at maximum load and nominal voltage (1): compressors without integrated dryer (2): compressors with integrated dryer Fuse calculations for IEC are done according to 60364-4-43 Low-voltage electrical installations - Part...
  • Page 172 Instruction book Installation method B2 according table B.52.1. Multi-core cable in conduit on a wooden wall Maximum allowed current in function of the ambient temperature for installation method B2 Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm²...
  • Page 173 Instruction book Installation method F according table B.52.1. Single-core cables, touching in free air Clearance to wall not less than one cable diameter Maximum allowed current in function of the ambient temperature for installation method F conductor temperature 70°C Ambient temperature Cable section 30 °C 40 °C...
  • Page 174 Instruction book • Add 10 % to the total compressor current (I Pack or I FF from the tables) and divide by 2 • Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1)) • Install fuses of half the size of the recommended maximum fuse size on each cable. •...

  • Page 175: Protection Settings

    Instruction book • Add 25 % to the total current from the tables (see UL 508A 28.3.2: "Ampacity shall have 125 % of the full load current") • Install the prescribed maximum fuse on each cable • Parallel supply cable (2 x 3 phases + 2 PE - configuration (2)): •...

  • Page 176: Dryer Switches

    Instruction book Frequency (Hz) Voltage (V) 30kW F21 (A) 37kW F21 (A) 45kW F21 (A) 67,9 96,3 33,9 39,8 48,5 27,4 31,9 38,5 Settings for fan motor overload protection (Q15) Frequency (Hz) Voltage (V) 30kW Q15 (A) 37kW Q15 (A) 45kW Q15 (A) UL/cUL 10.4 Dryer switches General...

  • Page 177: Compressor Data

    Instruction book Minimum working pressure bar(e) Minimum working pressure psig Maximum air inlet temperature ˚C Maximum air inlet temperature ˚F Minimum ambient temperature ˚C Minimum ambient temperature ˚F 10.6 Compressor data Reference conditions All data specified below apply under reference conditions, see section Reference conditions and limitations.
  • Page 178 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Temperature of air ˚C leaving outlet valve Temperature of air ˚F leaving outlet valve Pressure dew point, ˚C units with integrated dryer Pressure dew point, ˚F 37.4...
  • Page 179 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Maximum (unloading) psig pressure Maximum (unloading) bar(e) 12.8 10.6 12.3 pressure, units with integrated dryer Maximum (unloading) psig pressure, units with integrated dryer Reference working bar(e) 12.5...
  • Page 180 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Dryer power at no load, units with integrated dryer Dryer power at no load, units with integrated dryer Refrigerant type, units R410A R410A R410A R410A R410A R410A R410A R410A with integrated dryer Refrigerant quantity, units with integrated...
  • Page 181 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Motor shaft speed r/min 2956 2956 2956 2956 3565 3565 3565 3565 Nominal motor power Nominal motor power 60.4 60.4 60.4 60.4 60.4 60.4 60.4...

  • Page 182: Technical Data Controller

    Instruction book 10.7 Technical data controller General Supply voltage 24 V AC /16 VA 50/60Hz (+40%/-30%) 24 V DC/0.7 A Type of protection IP54 (front) IP21 (back) Ambient and temperature IEC60068-2 conditions • Operating temperature • -10°C…..+60°C (14 °F ..140 °F) range •...

  • Page 183: Instructions For Use

    Instruction book Instructions for use Oil separator vessel This vessel can contain pressurized air. This can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator tank and must be operated within the limits specified on the data plate.

  • Page 184: Guidelines For Inspection

    Instruction book Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.

  • Page 185: Pressure Equipment Directives

    Instruction book Pressure equipment directives Components subject to 2014/68/EU Pressure Equipment Directive The following table contains the necessary information for the inspection of all pressure equipment of category II and higher according to the Pressure Equipment Directive 2014/68/EU and all pressure equipment according to the Simple Pressure Vessel Directive 2014/29/EU.

  • Page 186: Declaration Of Conformity

    Instruction book Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium (2): Applicable directives (3): Standards used 2920 7180 30...
  • Page 187 Instruction book On the Declaration of Conformity / Declaration by the Manufacturer, 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.
  • Page 190 Atlas Copco delivers 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.

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