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Atlas Copco GA 110 VSD Instruction Book

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GA 110 VSD, GA 132 VSD, GA 160 VSD
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Summary of Contents for Atlas Copco GA 110 VSD

  • Page 1 GA 110 VSD, GA 132 VSD, GA 160 VSD Instruction book...
  • Page 3 Atlas Copco GA 110 VSD, GA 132 VSD, GA 160 VSD Instruction book Original instructions Copyright Notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................6 ...........................6 AFETY ICONS ......................6 AFETY PRECAUTIONS GENERAL ...................6 AFETY PRECAUTIONS DURING INSTALLATION ....................8 AFETY PRECAUTIONS DURING OPERATION ................9 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................11 ..........................11 NTRODUCTION .........................13 IR AND OIL SYSTEM ....................17 OOLING AND CONDENSATE SYSTEM .......................18...
  • Page 5 Instruction book 3.15 ........................57 AN MOTOR SETTINGS 3.16 ....................58 ODIFYING DRYER MOTOR SETTINGS 3.17 ........................59 ODIFYING PARAMETERS 3.18 ......................60 ODIFYING PROTECTION SETTINGS 3.19 ........................61 ODIFYING SERVICE PLANS 3.20 ......................62 ROGRAMMING CLOCK FUNCTION 3.21 ....................67 ODIFYING CONFIGURATION SETTINGS 3.22 ..........................68 ERVICE MENU 3.23 ...........................70 AVED DATA MENU...
  • Page 6 Instruction book ......................123 AKING OUT OF OPERATION ........................123 SE OF AIR RECEIVER Maintenance........................125 ....................125 REVENTIVE MAINTENANCE SCHEDULE ............................126 OTORS ........................127 IL SPECIFICATIONS ..........................127 IL CHANGE ......................132 TORAGE AFTER INSTALLATION ..........................132 ERVICE KITS DD filter........................133 ..........................133 AINTENANCE ........................133 ILTER ELEMENT CHANGE ........................134 ERVICE INTERVALS ..........................134...
  • Page 7 Instruction book 10.1 .........................145 ROBLEM SOLVING Technical data......................147 11.1 ........................147 EADINGS ON DISPLAY 11.2 .........................148 EFERENCE CONDITIONS 11.3 ............................148 IMITS 11.4 ......................149 ETTINGS OF SAFETY VALVE 11.5 .......................150 ETTINGS OF CIRCUIT BREAKERS 11.6 ........................150 OMPRESSOR DATA Pressure equipment directives.................160 Documentation......................161 2920 1728 05...

  • Page 8: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions, general General 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 9 Instruction book Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits.

  • Page 10: Safety Precautions During Operation

    Instruction book 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.

  • Page 11: Safety Precautions During Maintenance Or Repair

    Instruction book 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, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
  • Page 12 Instruction book • Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid.

  • Page 13: General Description

    Instruction book General description Introduction General view General view of GA VSD Description of GA VSD compressors GA VSD (Variable Speed Drive) compressors are single-stage, oil-injected screw compressors directly driven by an electric motor. The compressors deliver pulsation-free air. By continuously matching the speed of the drive motor to the air net pressure, the compressor optimizes energy consumption and reduces the operating pressure band.
  • Page 14 By integrating a DD filter, the compressor delivers Quality Air according to ISO 8573-1, Class 2.4.2. Energy recovery The compressor is provided with an Atlas Copco energy recovery system to recover the major part of the compression heat in the form of hot water without any influence on the compressor performance.

  • Page 15: Air And Oil System

    Instruction book Air and oil system Flow diagrams Flow diagram for air-cooled GA VSD compressors 2920 1728 05...
  • Page 16 Instruction book Flow diagram for water-cooled GA VSD compressors Position of components Main components 2920 1728 05...
  • Page 17 Instruction book Rear view of air-cooled GA 2920 1728 05...

  • Page 18: Air Flow

    Instruction book Rear view of water-cooled GA Air flow Air drawn through filter (AF) is compressed in compressor element (E). Compressed air and oil are discharged through check valve (CV) to air receiver/oil separator (AR) where oil is separated from the compressed air. The air is blown through minimum pressure valve (Vp) to air cooler (Ca).

  • Page 19: Cooling And Condensate System

    Instruction book On air-cooled compressors with energy recovery or water-cooled compressors, the oil temperature is controlled by a thermostatic or electronic valve to avoid overcooling and consequently condensation in the air receiver (AR). In the air receiver (AR) most of the oil is removed from the air centrifugally. Almost all of the remaining oil is removed by the separator element.

  • Page 20: Energy Recovery System

    The energy required in any compression process is mainly transformed into heat. The major part of the compression heat is dissipated through the oil system. The Atlas Copco energy recovery systems are designed to recover most of the above-mentioned heat as warm or hot water without any adverse influence on the compressor performance.
  • Page 21 Instruction book Energy recovery system Pressure drop, water side Text on figure Pressure drop (kPa) Pressure drop (bar) Water flow (l/s) For GA 90-132: • pd = 6.96 F + 2.71 F For GA 160: • pd = 4.23 F + 1.62 F With: •...
  • Page 22 Instruction book Flow diagram The recovery water enters the unit at the heat exchanger inlet connection (Wi). In the heat exchanger the compression heat is transferred from the compressor to the water. The water leaves the heat exchanger via the outlet connection (Wo). Installation The compressor frame is prepared for the Energy Recovery system.
  • Page 23 Instruction book Air-cooled compressors 2920 1728 05...
  • Page 24 Instruction book Water-cooled compressors Operation The compressor oil flow is controlled by two by-pass valves (Y152 and Y151 ), ensuring reliable compressor operation and optimum energy recovery. Recoverable Energy The graphs of section Principal data below represent the performance for each power variant of GA90-160+ at reference working pressure.
  • Page 25 The compressor should never be running in “lowest dewpoint mode”. (See section Modifying fan motor settings). The vessel temperature setting has to be set by an Atlas Copco service technician. Regulation The element outlet temperature must always be higher than the condensation temperature. (see section Starting).
  • Page 26 Instruction book Calculation examples Example point X High temperature rise, low water flow application, e.g. pre-heating of boiler feed water in open circuit: • Compressor unit: GA160-50Hz • Working pressure: 14 bar / 200 psi • Water flow: 0.6 l/s / 1.27 cfm •...
  • Page 27 Instruction book • Toutlet = 55.8 + (141 / (4.2 x 4)) = 64.2°C Total pressure drop on waterside is (1): • pd = (4.23 x 4²) + (1.62 x 4) = 74 kPa = 0.74 bar Example point Y for a GA VSD working at 1500 RPM, when max RPM is 3000: dT = 90-36 = 54°C = 1500 = 3000...

  • Page 28: Additional Safety Precautions

    Instruction book • Compressor unit: GA 160 VSD • Working pressure: 8 bar / 116 psi • Water inlet temperature: 30 °C / 86 °F • Water outlet temperature: 60 °C / 140 °F The lowest curve is the maximum energy that can be recovered. If it is necessary to work in the area below the lowest curve, you have to calculate with the 140.5kW anyway.
  • Page 29 Principal data Performance curves The given curves show only indicative values. Some deviations may be possible, depending on the circumstances. The fine tuning of the installation must be done on site, by a service technician of Atlas Copco. 2920 1728 05...
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  • Page 37 Instruction book Spare parts list Air-cooled compressors Partnumber Name Extra info 1623 2823 00 Pipe 0147 1322 03 Bolt, M8 x 16 Pipe to frame 0147 1362 03 Bolt, M10 x 25 Pipe to block 0301 2344 00 Washer Pipe to block 0663 2107 77 O-ring Pipe to block...
  • Page 38 Instruction book Partnumber Name Extra info 1623 1347 00 or 1623 2780 00 Block 0663 2107 77 O-ring 1623 1245 00 Support 1619 2766 00 Bolt, M8 x 20 Support to frame 1623 1774 00 Bracket 0147 1326 03 Bolt, M8 x 30 Brackets to support, over cooler 0301 2335 00 Washer...
  • Page 39 Instruction book Partnumber Name Extra info 0663 2109 68 O-ring Valve to hose assembly 1623 1255 00 Hose assembly 0663 2109 68 O-ring Hose assembly to vessel 0147 1365 03 Bolt, M10 x 40 Hose assembly to vessel 0301 2344 00 Washer Hose assembly to vessel 2250 2528 00...
  • Page 40 Instruction book Partnumber Name Extra info 0147 1362 03 Bolt, M10 x 25 Pipe to block 0301 2344 00 Washer Pipe to block 0663 2107 77 O-ring Pipe to block 1623 2824 00 Pipe 0147 1322 03 Bolt, M8 x 16 Pipe to frame 0147 1362 03 Bolt, M10 x 25...
  • Page 41 Instruction book Partnumber Name Extra info 1623 1213 00 Valve 0663 2109 68 O-ring Hose assembly to valve 0147 1363 03 Bolt, M10 x 30 Valve to pipe 0301 2344 00 Washer Valve to pipe 0266 211 100 Nut, M10 Valve to pipe 1623 2065 00 Pipe...

  • Page 42: Elektronikon Regulator

    Instruction book Elektronikon regulator Elektronikon control system Main functions In general, the Elektronikon regulator has the following functions: • Controlling the motor speed (Variable Speed Drive), reducing the power consumption and pressure band. • Controlling the speed of the fans of the coolers, reducing the power consumption and noise level. •...

  • Page 43: Protecting The Compressor

    Instruction book Ref. Designation Minimum Time Load Indirect stop Start (10) Indirect stop offset If the motor is running at minimum speed and the net pressure rises to a value equal to the sum of the programmed pressure set-point and the programmed indirect stop offset, the compressor will stop. When the net pressure drops, the regulator will calculate the optimum moment to restart the compressor to avoid the net pressure decreasing below the pressure set-point (anticipated starting).

  • Page 44: Control Panel

    The regulator has a built-in function to automatically restart the compressor if the voltage is restored after voltage failure. This function is deactivated in compressors leaving the factory. If desired, the function can be activated. Consult Atlas Copco. If activated and provided the module was in the automatic operation mode, the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period.

  • Page 45: Function Keys

    Instruction book Parts and functions Reference Designation Function Start button Button to start the compressor. LED (8) lights up indicating that the Elektronikon regulator is operative. Display Shows messages about the compressor operating condition, a service need or a fault. Scroll keys Keys to scroll upwards or downwards through the display.

  • Page 46: Scroll Keys

    “Cancel” To cancel a programmed setting when programming parameters “Delete” To delete compressor start/stop commands “Help” To find the Atlas Copco internet address “Limits” To show limits for a programmable setting “Load” Not used on VSD (Variable Speed Drive) compressors To load the compressor manually “Mainscreen”...

  • Page 47: Emergency Stop Button

    Instruction book As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll key with the same symbol can be used to see the next item. As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key with the same symbol can be used to see the previous item.

  • Page 48: Control Programs

    Instruction book Control programs Function In order to facilitate programming and controlling, menu-driven control programs have been implemented in the regulator. Menu flow for air-cooled GA 132/160 VSD compressors (simplified example) 2920 1728 05...
  • Page 49 Instruction book Menu flow for water-cooled GA 132 W/160 W VSD compressors (simplified example) Program Function Main screen Shows in brief the operational status of the compressor. Is the gateway to all functions. “Status Data” Calls up the status of the compressor protection functions (shut-down, shut-down warning and service warning).

  • Page 50: Calling Up Menus

    Instruction book Program Function “Counters” Calls up: • running hours • regulator (module) hours • number of motor starts “Test” Display test. “Modify Parameters” Modifying the settings for: • Parameters (e.g. loading and unloading pressures) • Protections (e.g. temperature shut-down level) •...

  • Page 51: Main Screen Menu

    Instruction book After pressing the “Menu” (F1) key, the option “Status Data” will be followed by a horizontal arrow: • Either press the tabulator key (2) to select this menu, • or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow and then press the tabulator key (2) to select this menu.

  • Page 52: Status Data Menu

    Instruction book • Messages regarding the compressor operating condition • Just above the function keys (3), the actual functions of these keys Status data menu Warning Before starting any maintenance or repairs, press the stop button (4), wait until the compressor has stopped, press the red emergency stop button and open the isolating switch (customer's installation) to switch off the voltage to the compressor.
  • Page 53 Instruction book “All Conditions Are OK” “Menu” “Help” A shut-down message exists • In case the compressor is shut down, LED (1) will blink. • In case of a shut-down due to too high a temperature at the outlet of the compressor element: “Element Outlet”...
  • Page 54 “Status Data” menu to “Inputs” and press the “Reset” key to reset the service message. • In case the service message was referring to “Plan”: carry out the service actions related to the indicated plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See Service menu.

  • Page 55: Measured Data Menu

    Instruction book 3.10 Measured data menu Control panel Function To call up information regarding the actually measured data and the status of some inputs such as the motor overload protection. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): •...

  • Page 56: Counters Menu

    Instruction book 3.11 Counters menu Control panel Function To call up: • The running hours • The loaded hours • The number of motor starts • The number of hours the regulator (module) has been under tension • The number of load cycles Procedure Starting from the Main screen (see Main screen...

  • Page 57: Test Menu

    Instruction book 3.12 Test menu Control panel Function To carry out a display test, i.e. to check whether the display and LEDs are still intact. Procedure • Starting from the Main screen (see Main screen menu), press the “Menu” (F1) key. •...

  • Page 58: Modifying Compressor/Motor Settings

    Instruction book 3.14 Modifying compressor/motor settings Control panel Function To modify a number of settings. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Modify parameters” is followed by an arrow pointing to the right. •...

  • Page 59: Fan Motor Settings

    Instruction book “Setpoint 1” 7.0 bar “Setpoint 2” 6.0 bar “Indirect Stop Level” 0.3 bar “Menu” “Modify” The regulator will not accept new values beyond the limitations. It is possible to check the limitations which are valid for the parameter to be modified by selecting “Limits”.

  • Page 60: Modifying Dryer Motor Settings

    Instruction book “Minimum Speed” 600 “rpm” “Maximum RPM Reduction” 100 “pct” “Fan Operation Mode” “Normal” “Menu” “Modify” • The screen shows that the current fan operation mode is “Normal”. To modify this setting, press the “Modify” key (F2); the operation mode will flash. •...

  • Page 61: Modifying Parameters

    Instruction book • The first option “Compressor Motor” will be followed by an arrow pointing to the right. • Press the arrow down key (1) to scroll until “Dryer Motor” is followed by a horizontal arrow. • Activate the menu by pressing tabulator key (2). Modifying the dryer operation mode It is possible to program three operation modes: •...

  • Page 62: Modifying Protection Settings

    Instruction book Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Modify parameters” is followed by a horizontal arrow. • Activate the menu by pressing the tabulator key (2). •...

  • Page 63: Modifying Service Plans

    Instruction book To check various compressor conditions, e.g. the status of the emergency stop button. Some parameters cannot be modified. Procedure Starting from the Main screen (see Main screen menu): • Press the “Menu” (F1) key. • Press the arrow down key (1) until “Modify parameters” is followed by a horizontal arrow. •...

  • Page 64: Programming Clock Function

    Instruction book Always consult your Atlas Copco Customer Centre in case any timer should be changed. The intervals must not exceed the programmed nominal values. 3.20 Programming clock function Control panel Function To program: • Time-based start/stop commands for the compressor •...
  • Page 65 Instruction book “Clock Function” “Not Activated” “Menu” “Modify” “Delete” • Press the tabulator key (2), following screen appears: “Monday” “Tuesday” “Wednesday” “Menu” “Delete” • Use the scroll keys (1) until the day on which a command must be programmed is followed by a horizontal arrow.
  • Page 66 Instruction book • Press the tabulator key (2) to activate the menu. • Use the arrow down key until the option “Clock Function” is followed by a horizontal arrow, press the tabulator key (2), following screen appears: “Clock Function” “Not Activated” “Menu”...
  • Page 67 Instruction book “Monday” “Tuesday” “Wednesday” “Menu” “Delete” • Scroll through the display until “Saturday” is followed by a horizontal arrow. Press the tabulator key (2). If necessary, scroll through the commands until the command to be modified is followed by a horizontal arrow.
  • Page 68 Instruction book • 06:00 Pressure Band 1 • 18:00 Stop Compressor The regulator does not allow to enter a new command which is situated before the last command in the list timewise. Scroll through the display until the command before which the new command must be entered is followed by a horizontal arrow (in the example above: “18:00 Stop Compressor”) and press the key “Modify”.

  • Page 69: Modifying Configuration Settings

    Instruction book 3.21 Modifying configuration settings Control panel Function To modify a number of parameters. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to the right. •...

  • Page 70: Service Menu

    Instruction book “C.C.M.” “Local Control” “Program” “Cancel” • “Local Control” is blinking, use the scroll keys (1) to select the desired control mode. • Press the key “Program” to program the new control mode or “Cancel” to quit without reprogramming. 3.22 Service menu Control panel Function...
  • Page 71 Instruction book Service actions according to Intervals Service plan A 4000 running hours Service plan A and B 8000 running hours Service plan A 12000 running hours Service plan A, B and C 16000 running hours Procedure Starting from the Main screen (see Main screen menu): •...

  • Page 72: Saved Data Menu

    Instruction book The “Reset” button only appears when the “Next Timer” level is almost reached. After pressing the arrow down key in the “Service Timer” screen, the “Life Time” hours are shown, i.e. the number of hours elapsed since initial programming ex-factory. This timer is not taken into account.

  • Page 73: Programmable Settings

    Instruction book 3.24 Programmable settings Compressor/motor Minimum Factory Maximum setting setting setting Set-point 1/2 GA VSD 8.5 bar Pack compressor bar(e) GA VSD 8.5 bar (123 psi) Pack compressor psig GA VSD 8.5 bar Full-Feature compressor bar(e) GA VSD 8.5 bar (123 psi) Full-Feature psig compressor GA VSD 8.5 bar Full-Feature compressor...
  • Page 74 Instruction book Minimum Factory Maximum setting setting setting GA VSD 200 psi (13.8 bar) Full-Feature bar(e) 13.5 13.8 compressor GA VSD 200 psi Full-Feature compressor psig GA VSD 200 psi (13.8 bar) Full-Feature bar(e) 10.4 13.6 compressor with DD filter GA VSD 14 bar (203 psi) Full-Feature psig compressor with DD filter...
  • Page 75 Instruction book Minimum Factory Maximum setting setting setting Shut-down level ˚C Shut-down level ˚F Compressor element outlet temperature: Shut-down warning level ˚C Shut-down warning level ˚F Shut-down level ˚C Shut-down level ˚F Cooling medium temperature: Air-cooled compressors (shut-down warning ˚C level) Air-cooled compressors (shut-down warning ˚F...
  • Page 76 Instruction book Minimum Factory Maximum setting setting setting Shut-down warning level ˚C Shut-down warning level ˚F Shut-down level ˚C Shut-down level ˚F Delay at signal dp oil separator (shut-down warning level) mbar 1000 dp oil separator (shut-down warning level) in WC dp oil separator (shut-down level) mbar 1000...
  • Page 77 Delay at signal Remark A number of service operations are grouped (Level A, Level B, ...). Each level stands for a number of service operations to be carried out at the programmed intervals. Consult your Atlas Copco Service Centre. Terminology Term...

  • Page 78: Installation

    Instruction book Installation Dimension drawing Compressor dimensions Dimension drawing of air-cooled Pack VSD compressors 2920 1728 05...
  • Page 79 Instruction book Dimension drawing of air-cooled Full-Feature VSD compressors 2920 1728 05...
  • Page 80 Instruction book Dimension drawing of water-cooled VSD compressors Text on drawing Reference Designation Compressed air outlet Cooling air outlet Compressor air inlet Cooling air inlet 2920 1728 05...
  • Page 81 Instruction book Reference Designation Right hand side view Left hand side view Electric cable entry Automatic drain, dryer Rear side view (10) Manual drain (11) Automatic drain (12) Detail X (13) Energy recovery, water in (14) Energy recovery, water out (15) Front view (16)

  • Page 82: Installation Proposal

    Instruction book Installation proposal Compressor room example Compressor room example of GA VSD air-cooled compressor 2920 1728 05...
  • Page 83 Instruction book Compressor room example of air-cooled GA VSD Full-Feature compressor 2920 1728 05...
  • Page 84 Instruction book Compressor room example of GA VSD water-cooled compressor Text on drawing Reference Designation Minimum free area to be reserved for compressor installation Ventilation proposals Cooling systems 2920 1728 05...
  • Page 85 Instruction book Reference Designation Compressor air outlet, if dryer is by-passed Compressor air outlet, Full-Feature compressors Motor ventilation, air outlet Motor ventilation, air inlet Compressor air inlet Cooling air outlet (10) Dryer cooling air outlet (11) Dryer and motor cooling air inlet (12) Compressor air inlet (13)
  • Page 86 Instruction book Phase Description Install the compressor on a level floor suitable for taking its weight. For ventilation alternative 1 (indicated as Alt. 1), the minimum distance between the top of the bodywork and the ceiling is 1200 mm (47.2 in). Remove the plastic plug (if provided) from the compressor air outlet pipe and fit the air outlet valve (to be provided by the customer) to the pipe.
  • Page 87 The fan capacity should match the compressor fan capacity at a pressure head equal to the pressure drop caused by the cooling air outlet ducts. Consult Atlas Copco. Remove the plastic plugs (if provided) from the condensate outlets and fit the manual condensate drain valve.

  • Page 88: Electric Cable Size And Fuses

    The cable size is stated for a maximum ambient temperature of 46 ˚C (115 ˚F). For IEC compressors, use 90 °C XLPE cables. IEC 50 Hz compressors Compressor type Voltage Cable size Remark GA 110 VSD 2 cables, spacing required 2x(3x70mm +35mm GA 110 VSD 2 cables, spacing required 2x(3x70mm...
  • Page 89 Instruction book Compressor type Voltage Cable size Remark GA 110 VSD 2x(3x AWG4/0+AWG3) 90 ˚C insulation cable at 46 ˚C ambient GA 110 VSD 2x(3x AWG2/0+AWG4) 90 ˚C insulation cable at 46 ˚C ambient GA 132 - 160 VSD 2x(MCM250+AWG2) 90 ˚C insulation cable at 46...
  • Page 90 Approval Cooled Air-Cooled 3x315 A 3x315 A DIN 43 620 size 3; high speed fuse. Fuse type: GA 110 VSD 3x315 A 3x315 A DIN 43 620 size 3; high speed fuse. Fuse type: GA 110 VSD DIN 43 620 size 3;...
  • Page 91 Frequency Water- Type Compressor type Approval Cooled Air-Cooled 3x315 A 3x315 A Class T fuse; very fast acting GA 110 VSD CSA/UL fuse 3x250 A 3x250 A Class T fuse; very fast acting GA 110 VSD CSA/UL fuse Class T fuse;...
  • Page 92 Approval Cooled Air-Cooled 3x355 A 3x355 A DIN 43 620 size 3; high speed fuse. Fuse type: GA 110 VSD 3x315 A 3x315 A DIN 43 620 size 3; high speed fuse. Fuse type: GA 110 VSD DIN 43 620 size 3;...

  • Page 93: Electric Connections

    Electric connections General instruction for the electrical installation of VSD compressors • Electrical equipment from Atlas Copco Compressor is designed in accordance with the safety regulations described in IEC60204-1 and CENELEC EN60204. • It is the responsibility of the customer to install the compressor unit according to the safety regulations in order to protect people from electric shocks from direct or indirect contact.
  • Page 94 BENDER IRDH 275/435 http://www.bender.org/prod.html. Atlas Copco strongly recommends that customers do not connect the neutral conductor from the power supply to the compressor unit. The exposed conductive parts of the installation must be earthed locally. (EN 60204-1 par.: 7.2.3)
  • Page 95 Instruction book Power system earth Exposed conductive parts Network type TN-C (Terra Neutral-Combined) : In the TN-C power distribution system, the neutral and the protective earth functions are combined in a single conductor. Power system earth Exposed conductive parts Network type TN-C-S (Terra Neutral-Combined-Separate) : In the TN-C-S power distribution system, the neutral and the protective earth functions are combined to some degree in a single conductor, a direct earth to the exposed conductive parts of the installation exists in part.
  • Page 96 Instruction book Power system earth Exposed conductive parts Network type TT (Terra Terra) : The TT power distribution system has one point that is directly earthed. In addition, the exposed conductive parts of the installation are connected to earth electrodes that are independent from the power system's earth. Power system earth Exposed conductive parts Network type IT (Impedance Terra) :...
  • Page 97 Instruction book Operation Installed for stationary use Air temperature No frost allowed Relative humidity 5 to 95 % No condensation allowed. Maximum allowed relative humidity is 60 % in the presence of corrosive gases. Contamination levels No conducting dust allowed •...
  • Page 98 Instruction book Electric diagram of GA 132/160 VSD Ref. Designation RFI filter Frequency converter, drive motor Frequency converter, fan motors of air/oil cooler block Frequency converter, compressor motor of dryer F3/5 Circuit breakers, control circuit F17/47 Circuit breakers, condensate circuit Auxiliary relay, motor running indication Contactor, emergency stop Contactor, compressor motor of air dryer...
  • Page 99 Drive motor of dryer Fan motor of dryer, air-cooled Cable connection for GA 110 VSD, GA 132 VSD and GA 160 VSD Always use cable glands. A plate (1) has to be made by the customer to cover up the hole in the cubicle and to install cable glands.
  • Page 100 Instruction book 2920 1728 05...
  • Page 101 Instruction book 2920 1728 05...

  • Page 102: Installation Instructions For Cubicle Fan

    Instruction book Cable section Cable diameter Cable gland size AC number 0698 5140 71 0698 5140 71 11.0 0698 5140 72 12.4 0698 5140 73 13.8 0698 5140 73 Installation instructions for cubicle fan Description The fan must be installed on the cubicle roof with 8 bolts 0147 1963 08 as follows: •...
  • Page 103 Instruction book Figure A 2920 1728 05...
  • Page 104 Instruction book Figure B 2920 1728 05...

  • Page 105: Installation Instructions For Heavy Duty Filter For Vsd Cubicle

    Instruction book Completed assembly of the cubicle fan Installation instructions for heavy duty filter for VSD cubicle Description 1. Remove the original filters (1). Remove the red plates (2). 2920 1728 05...
  • Page 106 Instruction book 2. Place the seals (3) on the back side of the box, then install the box to the cubicle door using rivets. The ordering number for the seals is 1619 5188 00. 3. Install the heavy duty filters as shown below. 2920 1728 05...
  • Page 107 Instruction book Text on figure: 2920 1728 05...

  • Page 108: Installation Instructions For Dryer By-Pass

    Instruction book Cooling air flow Compressor side Outside Installation instructions for dryer by-pass Description It is not required to connect a bypass, a blind flange is foreseen ex factory. If by-passing of the dryer is required, connect the compressor to the air net as shown below. The compressed air outlet temperature sensor (G3/8”) and the pressure transducer (1/4”...
  • Page 109 Instruction book Shut-off valve, air net By-pass valve, compressor By-pass valve, dryer New location for temperature sensor and pressure transducer Pipe towards air net Nipple 2920 1728 05...

  • Page 110: Installation Instructions Gsm Alarm

    Instruction book Installation instructions GSM alarm Hardware installation Fix the Air contact module (1) to the rail as shown below. Assemble the power supply cable, using: • connector X150.3 (ordering number 1088 0037 64) • two power wires (ordering number 0017 2010 40) •...
  • Page 111 Instruction book The antenna must be led to the outside of the cubicle. The antenna cable can be led through a present conduit gland (preferably the gland which contains the Electronic drain cables) or a grommet can be used in a closed hole.
  • Page 112 Instruction book Software installation For software installation please contact your local Atlas Copco service center. 2920 1728 05...

  • Page 113: Pictographs

    Instruction book Pictographs Explanation of Pictographs Pictographs at other locations Ref. Designation Start Scroll keys Tabulator key Function keys Voltage on Alarm Automatic operation Stop Automatic condensate drain Manual condensate drain Stop the compressor before maintenance or repair Warning: under tension Read Instruction book before starting the compressor Switch off the voltage and depressurise the compressor before maintenance or repair Before connecting the compressor electrically, consult the instruction manual for the motor...

  • Page 114: Cooling Water Requirements

    Instruction book Ref. Designation Arrow, rotation direction Disconnect from electrical supply before opening Do not mix oil brands 4.10 Cooling water requirements Recommendations The cooling water quality must meet certain minimum requirements. No general recommendation can encompass the effects of all combinations of the various compounds, solids and gases typically found in cooling water in interaction with different materials.
  • Page 115 Instruction book Symbol Explanation Depends on the total solids concentration (mg/l) Depends on the highest cooling water temperature (˚C/˚F), (T=75 ˚C/167 ˚F) Depends on the calcium hardness (ppm CaCO Depends on the HCO concentration or M-alkalinity (mval/l) The values of A, B, C and D can be found in the following table. Total dissolved Temperature Ca-hardness (ppm...
  • Page 116 Instruction book Water condition Action 7.6<RSI<9.0 Strong corrosion Regular inspection necessary, use of corrosion inhibitor recommended. 9.1<RSI<11 Very strong corrosion Regular inspection necessary, use of corrosion inhibitor required. RSI>11 Very strong corrosion in Water should not be used. complete water system The table indicates that distilled or demineralised water should never be used, as their RSI is >...
  • Page 117 Instruction book / SO should be > 1 Ammonia < 0.5 ppm Copper < 1 ppm Iron and manganese < 1 ppm Organics No algae No oil Suspended solids Non-soluble particles, size < 1 mm. < 10 ppm 2920 1728 05...

  • Page 118: Operating Instructions

    Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below freezing point, precautions must be taken. In this case, and also if operating at high altitude, consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude from the other side of the frame.
  • Page 119 Instruction book Protection during transport Transport fixtures of GA VSD compressors Step Action The gear casing supports, motor support and air receiver supports are secured to the frame, immobilizing the vibration dampers during transport. Remove the bolts (1) from the gear casing supports and the motor support. Remove the brackets fitted next to the air receiver supports.

  • Page 120: Before Starting

    If the rotation direction is wrong, press the emergency stop button, switch off the voltage and reverse two incoming electric lines. If the rotation direction of the fan motor is wrong, consult your Atlas Copco customer centre. Run the compressor for a few minutes and check that it is operating normally.

  • Page 121: Starting

    Instruction book Starting Procedure Step Action • When the compressor is stopped and the automatic operation LED (3) is lit, the compressor may start automatically. • If the start/stop timer is active, the compressor may start automatically, even if it was stopped manually.

  • Page 122: During Operation

    Instruction book Cooling water temperature Minimum allowable air temperature at compressor element outlet of water-cooled compressors • (A): Air inlet temperature • (B): Condensation temperature • (C): Working pressure • (D): Relative air humidity During operation Description When automatic operation LED (3) is lit, the Elektronikon regulator is automatically controlling the compressor: the speed will continuously vary to match the air delivery to the air consumption, and the compressor will start and stop whenever necessary.

  • Page 123: Checking The Display

    Instruction book Keep all doors closed during operation. Example of the main screen “Compressor Outlet” 6.6 bar “Compressor Speed” 2100 rpm “Menu” Checking the display Warning Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the emergency stop button and switch off the voltage. Close the air outlet valve and open the manual condensate drain valve.

  • Page 124: Stopping

    Action Press stop button (1): the compressor will stop and LED (2) will go out. To stop the GA 110 VSD up to GA 160 VSD compressor in the event of an emergency, press the emergency stop button (S2). Close air outlet valve.

  • Page 125: Taking Out Of Operation

    Instruction book Step Action Switch off the voltage. Taking out of operation Disconnecting the compressor At the end of the service life of the compressor, proceed as follows: Step Action Stop the compressor and close the air outlet valve. Switch off the voltage and disconnect the compressor from the mains. Depressurize the compressor by opening the drain valve and loosening the oil filler plug one turn.
  • Page 126 Instruction book Step Action This vessel and other parts under pressure have been designed and built to guarantee an operational lifetime in excess of 20 years and an infinite number of pressure load cycles. A visual inspection (for damage, non-authorised alterations,...) of the vessel (at the outside and inside) is recommended every 5 years.

  • Page 127: Maintenance

    Instruction book Maintenance Preventive maintenance schedule Warning Before carrying out any maintenance, repair work or adjustment, proceed as follows: • Stop the compressor. Press emergency stop button (S2). • • Close the air outlet valve and open the manual condensate drain valves. •...

  • Page 128: Motors

    Elektronikon regulator. When a level is reached, a message will appear on the screen. After carrying out all service actions, the interval timers must be reset using the “Reset” key in the “Service” menu. Consult your Atlas Copco Service Centre. Motors Warning Stop the compressor and switch off the voltage.

  • Page 129: Oil Specifications

    Service kits. Atlas Copco Roto-Xtend Duty Fluid Atlas Copco Roto-Xtend Duty Fluid is a high-quality synthetic lubricant for oil-injected scroll and screw compressors which keeps the compressor in excellent condition. Roto-Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F) (see section Service kits).
  • Page 130 Instruction book Control panel Control panel of MkIV regulator Procedure 1. Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. Wait a few minutes and depressurize by unscrewing the vent plug on top of the air receiver to permit any pressure in the system to escape.
  • Page 131 Instruction book 1. Take off the side panels of the compressor and remove the stays. 2. Open the cooler compartment and disconnect the cooler inlet pipe (1). 2920 1728 05...
  • Page 132 Instruction book 3. Disconnect the cooler outlet pipe (4) and roll out the oil cooler (2). 4. Remove the three bolts at the left side of the cooler. 5. Lift the oil cooler and fix the safety support. Remove the vent plug at the left side of the cooler. The oil is drained via the cooler drain plug at the inlet connection.
  • Page 133 Instruction book 1. Remove the drain plug (3) to drain the oil stop valve. 2. Remove the drain plug of the flexible to drain the oil from the gearbox. 3. Reinstall the drain plugs after draining. 4. Disconnect the flexible from the bypass valve (5) to drain the oil from the oil filter housing. 5.

  • Page 134: Storage After Installation

    Service kits General Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. All service kits are indicated in the relevant Parts Lists. Atlas Copco Roto-Inject Fluid Roto-Inject Fluid can be ordered in the following quantities: •...

  • Page 135: Dd Filter

    Instruction book DD filter Maintenance When maintaining the filter, keep in mind the following: • On filters with manual drain valve, open the latter at regular intervals to evacuate collected dust or liquid • Change the filter element yearly or when the pressure drop reaches approx. 0.35 bar •...

  • Page 136: Service Intervals

    Instruction book 9. Remove the plastic bag and reposition the bowl. A small amount of paint compatible lubricant ( e.g . FOODLUBE EXTREME) may be applied to screw threads and O-rings to facilitate the assembly. Service intervals The following service intervals should be observed: •...

  • Page 137: Integrated Dryer

    Instruction book Integrated dryer Condensate drain system Description The condensate enters the Electronic Water Drain (EWD) via inlet (1) and accumulates in the water separator of the heat exchanger and in collector (2). A capacitive sensor (3) continuously measures the liquid level. As soon as the collector is filled up to a certain level, a drain delay timer is started.

  • Page 138: Maintenance Instructions

    Instruction book Testing the Electronic water drain Control panel, EWD Briefly press the TEST button and check that the valve opens for condensate discharge. Checking the alarm signal • Press and hold the test button for at least 1 minute. •...

  • Page 139: Problem Solving

    Instruction book Warranty and product liability Use only Atlas Copco authorised genuine parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability. General The following remarks should be kept in mind: •...
  • Page 140 Instruction book Condition Fault Remedy Shortage of refrigerant Have circuit checked for leaks and recharged 2920 1728 05...

  • Page 141: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filters Warning Stop the compressor, close the air outlet valve, press the emergency stop button and switch off the voltage. The operator must apply all relevant Safety precautions. Control panel of MkIV regulator Control panel of MkIV regulator 2920 1728 05...
  • Page 142 Instruction book Position of air filter Procedure Step Action Remove panel (4) from the compressor. Remove the filter element. Fit the new filter element. Reinstall panel (4) Reset the message and service timer: Press the “Menu” key (3). • Press key (1) until “Service” is followed by an arrow pointing to the right. Activate the •...

  • Page 143: Coolers

    Instruction book Coolers Checking the coolers for cleanliness on air-cooled compressors Activate the "Cleanlinesstest" option in the Elektronikon regulator as follows: • Starting from the main screen, press the "Menu" key. • Press the arrow down key (1) until "Test" is followed by a horizontal arrow. •...
  • Page 144 Instruction book Maximum fan No action Cleaning Cleaning speed (rpm) advised necessary GA 110 VSD Pack and Full- 1500 Feature GA 132 VSD Pack 1200 GA 132 VSD Full-Feature 1500 GA 160 VSD Pack and Full- 1500 Feature Cleaning the coolers Stop the compressor, press the emergency stop button and switch off the voltage.

  • Page 145: Safety Valve

    If it is necessary to clean the coolers with a cleaning agent, consult Atlas Copco. Close the inside doors. Reinstall the stays and side panels of the compressor. On water-cooled compressors, consult the Atlas Copco Customer Centre if it is necessary to clean the coolers. Safety valve Warning Stop the compressor and switch off the voltage.
  • Page 146 Instruction book Consult the Atlas Copco Customer Centre if the valve does not open at the correct pressure (see the section Settings of safety valve). 2920 1728 05...

  • Page 147: Problem Solving

    Instruction book Problem solving 10.1 Problem solving Warning Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the emergency stop button and switch off the voltage. Close the air outlet valve and open the manual condensate drain valves. Open and lock the isolating switch.
  • Page 148 Remedy the problem. It may be necessary to reset the display after remedying the fault: press the “Reset” key (2), the message “All protection functions are OK” will appear, after which the compressor can be restarted. Excessive oil consumption Have the compressor inspected by the Atlas Copco Customer Centre. Condition Fault Remedy...

  • Page 149: Technical Data

    Instruction book Technical data 11.1 Readings on display General Control panel Reference Units Reading Outlet pressure bar(e) Depends on pressure set-point Speed Varies (controlled by regulator) Maximum working pressure bar(e) Compressor data. At pressure set-point Reference Units 4 bar(e) 7 bar(e) 9.5 bar(e) 13.5 bar(e) 60 psig...

  • Page 150: Reference Conditions

    ˚C temperature version Maximum air inlet/ambient temperature, GA Pack, high ambient ˚F temperature version Maximum air inlet/ambient temperature, GA 110 VSD up to GA ˚C 160 VSD Maximum air inlet/ambient temperature, GA 110 VSD up to GA ˚F 160 VSD Maximum air inlet/ambient temperature, GA 110 VSD up to GA ˚C...

  • Page 151: Settings Of Safety Valve

    Maximum cooling air temperature, GA Full-Feature and Full- ˚F Feature with DD filter, high ambient temperature variant Maximum cooling air temperature, GA 110 VSD up to GA 160 ˚C Maximum cooling air temperature, GA 110 VSD up to GA 160 ˚F...

  • Page 152: Settings Of Circuit Breakers

    2.,5 CSA/UL 11.6 Compressor data Data for GA 8.5 bar (123.3 psi) 50 Hz compressors Units GA 110 VSD GA 132 VSD GA 160 VSD Maximum working pressure, GA Pack bar(e) Maximum working pressure, GA Pack psig Maximum working pressure, GA Full-...
  • Page 153 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Maximum working pressure, GA Full- bar(e) Feature with DD filter Maximum working pressure, GA Full- psig Feature with DD filter Nominal working pressure bar(e) Nominal working pressure psig...
  • Page 154 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Oil capacity, GA cu.ft 3.07 3.07 3.07 Oil capacity, GA W Oil capacity, GA W US gal 19.6 19.6 19.6 Oil capacity, GA W Imp gal 16.3 16.3 16.3...
  • Page 155 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Power input, air-cooled compressors designed for high ambient temperature Power input, air-cooled compressors designed for high ambient temperature Power input, GA W Pack Power input, GA W Pack...
  • Page 156 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Maximum working pressure, GA Full- bar(e) 13.6 13.6 Feature with DD filter Maximum working pressure, GA Full- psig Feature with DD filter Nominal working pressure bar(e) 13.5 13.5 13.5...
  • Page 157 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Oil capacity, GA cu.ft 3.07 3.07 3.07 Oil capacity, GA W Oil capacity, GA W US gal 19.6 19.6 19.6 Oil capacity, GA W Imp gal 16.3 16.3 16.3...
  • Page 158 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Power input, air-cooled compressors designed for high ambient temperature Power input, air-cooled compressors designed for high ambient temperature Power input, GA W Pack Power input, GA W Pack...
  • Page 159 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Maximum working pressure, GA Full- bar(e) 10.5 10.5 Feature with DD filter 10.5 Maximum working pressure, GA Full- psig Feature with DD filter Nominal working pressure bar(e) 10.4 10.4...
  • Page 160 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Oil capacity, GA cu.ft 3.07 3.07 3.07 Oil capacity, GA W Oil capacity, GA W US gal 19.6 19.6 19.6 Oil capacity, GA W Imp gal 16.3 16.3 16.3...
  • Page 161 Instruction book Units GA 110 VSD GA 132 VSD GA 160 VSD Power input, air-cooled compressors designed for high ambient temperature Power input, air-cooled compressors designed for high ambient temperature Power input, GA W Pack Power input, GA W Pack...

  • Page 162: Pressure Equipment Directives

    Instruction book Pressure equipment directives Category IV Product: • GA 110 VSD • GA 132 VSD • GA 160 VSD This machine is a pressure assembly of cat. IV according to 97/23/EC. Parts of article 3.3 of 97/23/EC are subject to good engineering practice.

  • Page 163: Documentation

    Instruction book Documentation Declaration of conformity Typical example of a Declaration of Conformity document 2920 1728 05...
  • Page 166 Not for the sake of technology, but for the sake of our customer’s bottom line and peace-of-mind. That is how Atlas Copco will strive to remain the first choice, to succeed in attracting new business and to maintain our position as the industry leader.

This manual is also suitable for:

Ga 132 vsdGa 160 vsd

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