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No. 2920 1449 00
Registration code: APC G³90/'99 / 38 / 965
2001-09
Atlas Copco Stationary Air Compressors
GR110 - GR132 - GR160 - GR200
GR110 W - GR132 W - GR160 W - GR200 W
Instruction Book
Important
1. This book applies to the compressors from serial number AIF-
073 956 onwards.
2. This book must be used together with the "User manual for
®
Elektronikon
regulator for GA-GR-ZA-ZE-ZR-ZT compressors",
printed matter no. 2920 1291 0x.
· Copyright 2001, Atlas Copco Airpower n.v., Antwerp, Belgium.
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.
· This instruction book meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines.
www.atlascopco.com
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Summary of Contents for Atlas Copco GR110
- Page 1 Atlas Copco Stationary Air Compressors GR110 - GR132 - GR160 - GR200 GR110 W - GR132 W - GR160 W - GR200 W Instruction Book Important 1. This book applies to the compressors from serial number AIF- 073 956 onwards.
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Page 2: Table Of Contents
Follow all relevant safety precautions, including those mentioned on the cover of this book. Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further information. In all correspondence mention the type and the serial number, shown on the data plate. -
Page 3: Leading Particulars
A refrigerant dryer is fully integrated into the bodywork of the compressor. This “all-in-one” feature reduces the required GR110 up to GR200 and GR110 W up to GR200 W are two- space for installation and provides savings on piping installation stage, oil-injected screw compressors, driven by an electric cost. - Page 4 Instruction book By-pass valve By-pass valve By-pass valve Oil coolers Vent plug Air cooler Cooling fan Minimum pressure valve Oil drain plug, air receiver Air receiver Oil filters Condensate trap Air dryer Condensate outlets Compressed air outlet Air filter M25 Fan motor Fig.
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Page 5: Air Flow / Regulating System
BSP or NPT connections The OSD (Oil Separating Device) separates the oil-residues For GR110 up to -200 a BSP or NPT connection can be chosen. from the condensate water. The clean water can be drained in the sewer without any further treatment. The separated oil is... - Page 6 Instruction book Fig. 1.4 GR Full-feature during unloading 2920 1449 00...
- Page 7 Instruction book Fig. 1.5 GR Full-feature during loading 2920 1449 00...
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Page 8: Oil System
Instruction book Air filter 20 Check valve 38 Fan control switch Unloader 21 Oil scavenging line 39 High pressure switch Unloading valve 22 Safety valve 40 Fan Air cooler 23 Oil filler plug 41 Fan motor Cooling fan 24 Oil level indicator 42 Condenser Oil coolers 25 Oil drain plug... -
Page 9: Elektronikon Control System
If desired, the function can be activated. Consult number of motor starts are taken into account. Atlas Copco. The regulator stops the compressor whenever possible to reduce Warning If activated and provided the regulator was in the... -
Page 10: Control Panel
Instruction book 1.3.2 Control panel (.ig. 1.6) Ref. Designation Function Ref. Designation Function Automatic Indicates that the regulator is Start button Push button start operation LED automatically controlling the compressor. LED (1) lights up compressor: the compressor is indicating that the regulator is loaded, unloaded, stopped and operative (in automatic operation). -
Page 11: Menu-Driven Control Programs
Instruction book Designation Function Program/ Description (4-Fig. 1.6) Function Menu Starting from the main display (Fig. 1.7), to Timer Programming automatic compressor start/ initiate the main menu (Fig. 1.8) which gives stop commands. access to submenus Configuration Programming the time, date, display Starting from a submenu, to return to the main language, units, motor start mode and date menu (Fig. -
Page 12: External Compressor Status Indication
3 A / 230 V AC Motor running 19-20 6 A / 230 V AC 1) GR110 are provided with one fan. GR132 up to GR200 are Control mode provided with two fans. 2) This function is called the Timer function. See "User manual for... -
Page 13: Installation
Instruction book 2 INSTALLATION 2.1 Dimension drawings Fig. 2.1 Dimension drawing GR110 up to GR200 2920 1449 00... - Page 14 Instruction book Fig. 2.2 Dimension drawing GR110 W up to GR200 W 2920 1449 00...
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Page 15: Installation Proposals
Instruction book 2.2 Installation proposals (.ig. 2.3) Fig. 2.3 Installation proposal 2920 1449 00... - Page 16 Consult Atlas Copco. in bar(a) Qc = free air delivery of the compressor in l/s Remove the plastic plugs (if provided) from the condensate outlets (Fig.
- Page 17 Compressor motor, air dryer motor of air dryer (Full-feature (GR110/200) (Full-feature only) only) Contactor, fan motor M26 Fan motor, air dryer (GR110/ Circuit breaker, fan motor(s) of (GR132/200) 200 Full-feature) air dryer (Full-feature only) Phase sequence relay (option) Fan motor, air dryer (GR200...
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Page 18: Electric Cable Size
Instruction book 2.3 Electric cable size 50 Hz compressors 3) Type 230 V 400 V 500 V GR110 2x (3x150mm²+95mm²) 3x120mm²+70mm² 3x95mm²+50mm² GR132 2x (3x185mm²+95mm²) 2x (3x95mm²+50mm²) 3x120mm²+70mm² GR160 2x (3x240mm²+120mm²) 2x (3x120mm²+70mm²) 2x (3x70mm²+35mm²) GR200 2x (3x150mm²+70mm²) 2x (3x120mm²+70mm²) -
Page 19: Cooling Water Requirements
Instruction book Fig. 2.6 Pictographs, other locations (typical examples) 13 Automatic condensate drain 21 Torques for steel (Fe) or brass (CuZn) bolts 14 Automatic condensate drain for optional oil/water 22 Consult the Instruction book before greasing separator (type OSD) 23 Switch off the voltage before removing the protecting 15 Manual condensate drain cover inside the electric cabinet 16 Stop the compressor before maintenance or repair... -
Page 20: Cooling Water Parameters
Instruction book 2.5.2 Cooling water parameters The Rysnar stability index (RSI) The Rysnar Index (RSI) is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate. The adhesion of scaling depositions and their effect are different on different materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by the saturation pH value (pH The saturation pH value is determined by the relationship between the calcium hardness, the total alkalinity, the total solids concentration and the temperature. - Page 21 Instruction book The interpretation of the values obtained is : RSI < 6 boiler scale formation RSI 6 - 7 neutral water RSI > 7 corrosive water A more detailed interpretation follows below : Tendency of the water Action RSI < 3.9 Very high scale formation Water cannot be used 4.0 <...
- Page 22 Instruction book Free chlorine (CI Continuously, a level of 0.5 ppm should not be exceeded. For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies. Sulphates (SO4 Closed cooling system : Sulphates < 400 ppm Open cooling system : Sulphates <...
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Page 23: Operating Instructions
Instruction book 3 OPERATING INSTRUCTIONS the frame. Make sure that the forks protrude from the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Make sure that the beams cannot 3.1 Initial start-up slide and that they protrude from the frame equally. - Page 24 (S2) remains active. 51442F Remote control mode 2. The compressor can be controlled by an ES-type controller or by computer. Consult Atlas Copco. Voltage supply inlet Data plate Location of air outlet valve Fig. 3.3 Air outlet GR 200 FF...
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Page 25: Initial Start-Up
Instruction book 3.2 Before starting Important The regulator will only react to a new control mode if the new position of the control mode switch is maintained for 3 seconds. Attention To avoid unauthorized switching over to another control mode, The operator must apply all relevant safety precautions, take out the key after selecting the required mode. -
Page 26: Starting
7.5. including the temperatures and pressures, the status of Consult Atlas Copco if condensate should be formed during controlling the compressor (automatic or manual, local or frequent unloading periods. -
Page 27: Stopping
Instruction book 3.7 Stopping system by opening the drain valves in the water inlet and outlet pipes (customer's installation). 7. Switch off the voltage. 1. Press stop button (9-Fig. 3.5). LED (1) goes out. The message <<Programmed stop>> appears. The compressor Important runs unloaded for 30 seconds and then stops. -
Page 28: Taking Out Of Operation
Instruction book 51477F 51444F Water inlet Water outlet Combined oil and air coolers Oil separator element Oil drain plug Regulating valve, water flow Air receiver Oil level sight-glass Oil filler plug Oil filters Fig. 3.7 Water system of GR W (typical example) Fig. -
Page 29: Maintenance
Check for possible leaks " Check coolers; clean if necessary " Remove air filters and inspect Yearly 2000 4.3/4.4/4.7 When Atlas Copco HD Roto-injectfluid is used, change oil " 4000 4.5/4.7 Replace oil filters " Carry out a LED/display test "... -
Page 30: Motors
Instruction book Notes 1. In very dusty surroundings it may be necessary to check and replace the air filters more frequently. Consult Atlas Copco. 2. Use Atlas Copco filters. 3. The separator element must be replaced two-yearly or each 8000 running hours or when the pressure difference over the element exceeds 0.8 bar. -
Page 31: Oil Change
Service kits comprise all parts needed for servicing components by unscrewing plug (3-Fig. 3.8) only one turn to permit any and offer the benefits of genuine Atlas Copco parts while pressure in the system to escape. keeping the maintenance budget low. All service kits are 2. -
Page 32: Adjustments And Servicing Procedures
Note If it should be necessary to wash the coolers with a cleansing agent, consult Atlas Copco. On GR W, consult Atlas Copco for cleaning. 5.3 Safety valve (2-.ig. 1.3) Operating Operate the safety valve by unscrewing the cap one or two turns and retightening it. -
Page 33: Problem Solving
Instruction book 6 PROBLEM SOLVING d Oil coolers clogged d Consult Atlas Copco e Air cooler clogged Warning Before carrying out any maintenance, repair or e Consult Atlas Copco adjustment, stop the compressor, press emergency On GR W, restriction in cooling water system due to dirt or stop button (S2-Fig. -
Page 34: Principal Data
15 bar(e) for 13 bar version 22 bar(e) for 20 bar version Important Some compressors with a specific approval may have valves with other settings. Always consult the data stamped on the valve or consult Atlas Copco. 2920 1449 00... -
Page 35: Settings Of Overload Relay, Circuit Breakers
Instruction book 7.4 Settings of overload relay, circuit breakers and fuses 7.4.1 Motor overload relay and fuses for 50 Hz compressors GR / GR W Motor type, ABB Supply Max. setting of Max. fuse ratings Class gL/gG voltage overload relay F21 Type 2 2) Type 1 3) M2CA 280MLB-4... -
Page 36: Fan Motor Circuit Breakers
Supply Circuit Max. setting of voltage breaker circuit breaker (Hz) Cooling fan for air- and oil coolers (GR110/160) Q25/26 12.4 Cooling fan for air- and oil coolers (GR110/160) Q25/26 Cooling fan for air- and oil coolers (GR110/160) Q25/26 Cooling fan for air- and oil coolers (GR200) Q25/26 17.1... -
Page 37: Circuit Breakers For Dryer Cooling
Type Frequency Supply voltage Max. setting of circuit breaker Q41 (Hz) GR110/160 dryer cooling fan motor GR110/160 dryer cooling fan motor GR110/160 dryer cooling fan motor GR200 dryer cooling fan motor GR200 dryer cooling fan motor GR110/160 dryer cooling fan motor... -
Page 38: Compressor Specifications
Instruction book 7.5 Compressor specifications 7.5.1 Reference conditions Absolute inlet pressure ..........bar(a) Relative air humidity . -
Page 39: Specific Data Of 20 Bar - 50 Hz Compressors
Instruction book 7.5.4 Specific data of 20 bar - 50 Hz compressors 4) Compressor type Maximum working pressure ..........bar(e) Maximum working pressure, Full-feature . -
Page 40: Specific Data Of 290 Psi - 60 Hz Compressors
Instruction book 7.5.6 Specific data of 290 psi - 60 Hz compressors 4) Compressor type Maximum working pressure ..........bar(e) Maximum working pressure, Full-feature .
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Checking Oil Level on GR110