Atlas Copco GA 75 VSD Instruction Book
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Atlas Copco GA 75 VSD Instruction Book

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Summary of Contents for Atlas Copco GA 75 VSD

  • Page 1 GA 75 VSD, GA 90 VSD Instruction book...
  • Page 3 Atlas Copco GA 75 VSD, GA 90 VSD Instruction book 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. 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.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................6 ...........................6 AFETY ICONS ...................6 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................9 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................11 ..........................11 NTRODUCTION ............................15 IR FLOW ............................17 IL SYSTEM ..........................18 OOLING SYSTEM ........................19 ONDENSATE SYSTEM ........................19...
  • Page 5 Instruction book 3.11 ..........................36 UDIT DATA MENU 3.12 ........................37 EASURED DATA MENU 3.13 ..........................38 OUNTERS MENU 3.14 .............................39 EST MENU 3.15 .......................39 ODIFY PARAMETERS MENU 3.16 ..................40 ODIFYING COMPRESSOR MOTOR SETTINGS 3.17 ........................41 ODIFYING PARAMETERS 3.18 ......................42 ODIFYING PROTECTION SETTINGS 3.19 ........................43 ODIFYING SERVICE PLANS...
  • Page 6 Instruction book ........................70 IMENSION DRAWINGS ........................72 NSTALLATION PROPOSAL .........................75 LECTRICAL CONNECTIONS ......................76 OOLING WATER REQUIREMENTS ..........................77 ICTOGRAPHS Operating instructions....................78 ........................78 EFORE INITIAL START ..........................78 NITIAL START ..........................81 EFORE STARTING ............................82 TARTING ..........................84 URING OPERATION ........................86 HECKING THE DISPLAY ............................87 TOPPING ........................87 AKING OUT OF OPERATION Maintenance........................89...
  • Page 7 Instruction book 10.1 ...........................98 ROBLEM SOLVING Technical data......................100 11.1 ........................100 EADINGS ON DISPLAY 11.2 ........................100 LECTRIC CABLE SIZE 11.3 ..................103 ETTINGS OF FAN MOTOR CIRCUIT BREAKER 11.4 ..................103 EFERENCE CONDITIONS AND LIMITATIONS 11.5 ........................104 OMPRESSOR DATA Instructions for use of air receiver................108 12.1 ......................108 IR RECEIVER INSTRUCTIONS...

  • Page 8: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions during installation 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 9: Safety Precautions During Operation

    Instruction book 4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working pressure. 5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead to internal fire or explosion.
  • Page 10 Instruction book General precautions 1. The operator must employ safe working practices and observe all related local work safety requirements and regulations. 2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply. 3.

  • Page 11: Safety Precautions During Maintenance Or Repair

    Instruction book Also consult following safety precautions: Safety precautions during installation Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein.
  • Page 12 Instruction book 11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels. 12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed;...

  • Page 13: General Description

    General description Introduction Introduction GA 75 VSD and GA 90 VSD are single-stage, oil-injected screw compressors driven by an electric motor. The compressors are air-cooled. Water-cooled GA 75 VSD and GA 90 VSD are single-stage, oil-injected screw compressors driven by an electric motor.
  • Page 14 Electric cabinet GA Workplace Full-Feature GA Workplace Full-Feature (FF) are enclosed in a sound-insulated bodywork. The compressors are controlled by the Atlas Copco Elektronikon® II regulator. The electronic control module is fitted to the door at the right 2920 1634 04...
  • Page 15 The compressors are provided with an air dryer which is integrated in the sound-insulated bodywork. The dryer removes condensate from the compressed air by cooling the air to near freezing point. Front view, GA 75 VSD and GA 90 VSD Workplace Full-Feature 2920 1634 04...
  • Page 16 Instruction book Rear view, GA 75 VSD and GA 90 VSD Workplace Full-Feature Reference Name Air filter Air receiver Air outlet valve Air cooler Oil cooler CV/Vs Check valve/oil stop valve Automatic condensate outlet Automatic condensate outlet, dryer Dryer Compressor element...

  • Page 17: Air Flow

    Instruction book Coolers on water-cooled compressors Water-cooled air cooler and oil cooler Reference Name Air cooler Oil cooler Air flow Flow diagram GA 75 VSD and GA 90 VSD Workplace 2920 1634 04...
  • Page 18 Instruction book GA 75 VSD and GA 90 VSD Workplace Full-Feature Reference Description Air inlet Air/oil mixture Condensate Wet compressed air Dry air Note: The cooling fan is not provided on water-cooled compressors. Description Air drawn through filter (AF) and check valve (CV) into compressor element (E) is compressed.

  • Page 19: Oil System

    Instruction book Oil system Flow diagrams Reference Description Air inlet Air/oil mixture Wet compressed air Condensate In case of a Workplace unit to the air outlet valve. In case of a Full-Feature unit to the dryer Note: The cooling fan is not provided on water-cooled compressors. Description In air receiver (AR) most of the oil is removed from the air/oil mixture centrifugally.

  • Page 20: Cooling System

    Instruction book Cooling system Flow diagrams Reference Description Air inlet Air/oil mixture Wet compressed air Condensate In case of a Workplace unit to the water separator In case of a Full-Feature unit to the dryer Note: The cooling fan is not provided on water-cooled compressors. Description The cooling system comprises air cooler (Ca) and oil cooler (Co).

  • Page 21: Condensate System

    Instruction book Condensate system Electronic water drains Condensate drains, typical example Location of electronic condensate drains GA Workplace and Workplace Full-Feature compressors have an electronic water drain (EWD). The condensate from the air cooler accumulates in a collector. When the condensate reaches a certain level, it is discharged through drain outlet (Da).

  • Page 22: Electrical System

    Electrical system General Also consult sections Electrical diagrams Electrical connections. Electric cabinet The electrical system comprises the frequency converter and following components: Electric cabinet for GA 75 VSD and GA 90 VSD, typical example References Reference Designation F1/2 Fuses F4/5/6 Fuses...

  • Page 23: Electrical Diagrams

    Instruction book Electrical diagrams Diagrams Service diagram for GA 75 VSD and GA 90 VSD Reference Designation Emergency stop Remote start/stop Overload, fan motor Fault, EWD Dp of DD filter Dp of PD filter Remote pressure set selection Overload fan, motor (IT version)
  • Page 24 Instruction book Designations Reference Compressor Dryer Electronic Water Drain (EWD) Compressor motor Fan motor PDT01 Pressure sensor, pressure difference across oil separator PT20 Pressure sensor, delivery air TT01 Temperature sensor, ambient air TT11 Temperature sensor, element outlet TT51 Temperature sensor, cooling water inlet (water-cooled compressors) TT52 Temperature sensor, cooling water outlet (water-cooled compressors) TT53/54...

  • Page 25: Air Dryer

    Instruction book Reference Optional equipment AIE1 Analogue input expansion module Electronic Water Drain (EWD) (Full-Feature) PDS11 Dp switch for integrated DD filter PDS12 Dp switch for integrated PD filter R3/R4/R7 Freeze protection R8/R9 Heaters converter Anti-condensation heater Main power isolating switch TSLL91 Thermostat, cubicle freeze protection TSLL92...
  • Page 26 Instruction book Reference Name Refrigerant condenser Liquid refrigerant dryer/filter Thermostatic expansion valve Hot gas by-pass valve Condenser cooling fan Pressure switch, fan control Compressed air circuit Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the incoming air starts to condense.

  • Page 27: Elektronikon Ii Regulator

    Instruction book Elektronikon II regulator ® Elektronikon II regulator Control panel General The Elektronikon regulator controls the compressor: • By matching the compressor output to the air consumption • By stopping the compressor whenever necessary • By restarting the compressor when required In general, the Elektronikon regulator has following functions: •...
  • Page 28 The regulator has a built-in function to automatically restart the compressor when the voltage is restored after voltage failure. This function is deactivated in compressors leaving the factory. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. If 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 within a programmed time period.

  • Page 29: Control Panel

    Stop button Button to stop the compressor. LED (8) goes out. On GA 75 VSD and GA 90 VSD only: button to stop the compressor. LED (8) goes out. The compressor will slow down to minimum speed and then stop after a few seconds.

  • Page 30: Function Keys

    To cancel a programmed setting when programming parameters ‘Del.’ To delete compressor start/stop commands ‘Help’ To find the Atlas Copco Internet address ‘Lim.’ To show limits for a programmable setting ‘Main’ To return from a menu to the main screen ‘Menu’...

  • Page 31: Scroll Keys

    Instruction book Scroll keys Control panel The keys (1) allow the operator to scroll through the display. As long as a downwards pointing arrow is shown at the far 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 far right position of the display, the scroll key with the same symbol can be used to see the previous item.

  • Page 32: Control Programs

    Instruction book Control programs Description In order to facilitate programming and controlling, menu-driven control programs have been implemented in the regulator. Menu flow (simplified) 2920 1634 04...

  • Page 33: Main Screen Menu

    Instruction book Main screen menu Function Control panel The Main screen menu shows the status of the compressor operation and is the gateway to all functions implemented in the regulator. Procedure The Main screen is shown automatically when the voltage is switched on. If the function or arrow keys (1, 2 and 3) are not used for some minutes, the regulator will automatically return to the Main screen.

  • Page 34: Calling Up Menus

    Instruction book Calling up menus Description Control panel When the voltage is switched on, the Main screen is shown automatically. ‘Compr. Outlet’ 2500 ‘Menu’ The arrow down key (1) can be used for a quick look at the actual compressor status. After pressing the ‘Menu’...

  • Page 35: Status Data Menu

    Instruction book Starting from the Main screen (see section Main screen menu), press the arrow down key (3): A screen similar to the one below appears: Example of the compressor status screen ‘Auto Operation’ ‘Local Control’ ‘Timer Active’ ‘Main’ ‘Help’ ‘Xtra’...
  • Page 36 Instruction book Procedure Starting from the Main screen (see Main screen menu): • Press the key ‘Menu’ (F1): the option ‘Status data’ will be followed by a horizontal arrow. • Press the tabulator key (2). No message exists • General alarm LED (1) is out and the message on the display will indicate that all conditions are normal: ‘All Conditions are OK’...
  • Page 37 ‘Status data’ menu to ‘Inputs’ and press the ‘Rset’ key to reset the service message. • If the service message was referring to ‘Plans’: carry out the service actions related to the indicated plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See section Service menu.

  • Page 38: Audit Data Menu

    Instruction book A warning message exists • LED (1) is lit and a warning message will appear on the screen. • The indicators (**) are flashing. This warning indicates that: • On water-cooled compressors, the cooling water temperature exceeds the programmed warning level. •...

  • Page 39: Measured Data Menu

    Instruction book • ‘Energy saved’: percentage of energy saved compared to a compressor with load/no-load regulation (L/ NL) or compared to one with modulating control (MC) • ‘Energy saved’: amount of energy (kWh) saved compared to a compressor with load/no-load regulation (L/NL) or compared to one with modulating control (MC) •...

  • Page 40: Counters Menu

    • Consult the procedure above to select ‘Accumulated vol’. • In the example above, the display indicates that the compressor has delivered 230 x 1000 m If it should be required to modify the value of the indicated timer, consult Atlas Copco. 2920 1634 04...

  • Page 41: Test Menu

    Instruction book 3.14 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 key ‘Menu’ (F1). •...

  • Page 42: Modifying Compressor/Motor Settings

    Instruction book 3.16 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 section Main screen menu): • Press the key ‘Menu’ (F1). •...

  • Page 43: Modifying Parameters

    Instruction book 3.17 Modifying parameters 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 Params’ is followed by a horizontal arrow. •...

  • Page 44: Modifying Protection Settings

    Instruction book 3.18 Modifying protection settings Control panel Function To modify protection settings: • Shut-down (‘Shd’), e.g. for the compressor element outlet temperature • Shut-down warning (‘Shdw’), e.g. for the compressor element outlet temperature • Warning (‘Warn’), e.g. the cooling water temperature outlet for water-cooled compressors •...

  • Page 45: Modifying Service Plans

    Service plans are to be carried out. Always consult your Atlas Copco Customer Centre if any timer should be changed. The intervals must not exceed the intervals below and must coincide logically.
  • Page 46 Instruction book Resulting service actions to be carried out Service actions according to At Service plan A and B 4000 running hours Service plan A, B and C 8000 running hours Service plan A and B 12000 running hours Service plan A, B and C 16000 running hours Service plan A, B, C and D 24000 running hours...

  • Page 47: Programming Clock Function

    Instruction book 3.20 Programming clock function Control panel Function To program: • Time-based start/stop commands for the compressor • Time-based change-over commands for the setpoint Programming start, stop and setpoint commands In this example, the compressor will be programmed as follows: •...
  • Page 48 Instruction book --:-- ---------------------- --:-- ---------------------- --:-- ---------------------- ‘Menu’ ‘Mod.’ ‘Del.’ • Press the key ‘Mod.’ (F2). The first two dashes will flash. Use the scroll keys (1) to enter 06. Press the tabulator key (2) to jump to the following two dashes. Use the scroll keys to enter 15. Press the tabulator key to jump to the row of dashes.
  • Page 49 Instruction book It is necessary to program the start/stop commands in successive order time-wise. Program the commands from ‘Monday’ till ‘Sunday’, e.g.: • 07.30 Start Compressor • 07.30 Setpoint 1 • 08.30 Setpoint 2 • 18.00 Stop Compressor Make sure that the timer function is activated (‘Activated’). If not, the programmed start/stop commands will not be executed.
  • Page 50 Instruction book ‘Clock Function’ ‘Not Activated’ ‘Menu’ ‘Mod.’ ‘Del.’ Suppose the command to stop the compressor at 18:00 must be added to the list of Monday. • Press the tabulator key (2), the following screen appears: ‘Monday’ ‘Tuesday’ ‘Wednesday’ ‘Menu’ ‘Del.’...

  • Page 51: Modifying Configuration Settings

    Instruction book ‘Clock Function’ ‘Not Activated’ ‘Menu’ ‘Mod’ ‘Del’ Deleting all commands • Press the key ‘Del.’ in the screen above. A question to confirm the deleting operation will appear. Deleting all commands of a specific day • Scroll through the display until the desired day is followed by a horizontal arrow. Press the key ‘Del.’, a question to confirm the deleting operation will appear.

  • Page 52: Programming Compressor Control Modes

    Instruction book • Press the key ‘Prog’ (F1) to program the new value or the key ‘Canc’ (F3) to cancel the modification operation (the original value will be retained). • The procedure to modify other parameters is similar. 3.22 Programming compressor control modes Control panel Compressor control modes The compressor can be controlled locally, remotely or via a local area network (LAN).

  • Page 53: Service Menu

    Instruction book 3.23 Service menu Control panel Function • To reset the service plans which are carried out. • To check when the next service plans are to be carried out. • To find out which service plans were carried out previously. Service plans A number of service operations are grouped (called Level A, Level B, etc...).
  • Page 54 Instruction book • A screen similar to the one below appears: ‘Service Timer’ ‘Running Hours’ ‘hrs’ 7971 ‘Menu’ • The screen shows that the total compressor running time is 7971 hours. • Press the tabulator key (2), the following screen appears: ‘Next Timer’...

  • Page 55: Saved Data Menu

    Instruction book 3.24 Saved data menu Control panel Function To call up some compressor data saved by the regulator. These data are: • Last shut-down data • Last emergency stop data Procedure Starting from the Main screen: • Press the key ‘Menu’ (F1). •...
  • Page 56 380 V, 400 V and 460 V units 2560 2100 Parameters Minimum Factory Maximum setting setting setting Minimum stop time: GA 75 VSD GA 90 VSD Power recovery time 3600 Restart delay 1200 Communication time-out On air-cooled compressors also: Fan motor starts per day Protections Minimum...
  • Page 57 Delay at start Service plan Also see section Preventive maintenance schedule. Consult Atlas Copco in case any timer setting should be changed. The intervals must not exceed the nominal intervals and must coincide logically. See section Modifying service plans. Minimum Factory...
  • Page 58 (approx. 20 seconds), whatever happens with the net air pressure. Consult Atlas Copco if a setting lower than 20 seconds should be required Oil separator Use Atlas Copco oil separators. The recommended maximum pressure difference is 1 bar (15 psi). Power recovery Is the period within which the voltage must be restored to have an automatic restart.

  • Page 59: Osd Oil/Condensate Separator (Optional)

    Instruction book OSD oil/condensate separator (optional) OSD unit Oil-condensate separators Compressed air leaving oil-injected compressors contains oil. During cooling of this air, oil-containing condensate is formed. OSD are designed to separate the major part of this oil from the condensate and to catch the oil in a collector.

  • Page 60: Instructions For Field Installation

    (7), which is led outside the bodywork, and one for the separated oil (8), which is caught in collector (4). Instructions for Field installation Location of OSD GA 55 up to GA 90, GA 75 VSD and GA 90 VSD Condensate drains GA Workplace 2920 1634 04...

  • Page 61: Operating And Maintenance Instructions

    Instruction book GA Full-Feature Procedure 1. Stop the compressor and close the air outlet valve. Depressurize the air outlet system by pressing the test button on top of the Electronic Water Drain(s). Switch off the voltage. • Install one OSD unit for Workplace compressors. •...
  • Page 62 Instruction book Operating instructions Inside of OSD • Before starting, check that vessel (1) is filled. If necessary, gently pour water into filler pipe (2) until it flows through tube (3). Reinstall the cover. • During operation of the compressor, an oil layer is built up above the water level in vessel (1). Depending on the capacity of the compressor and its operation cycle, the humidity of the inlet air and the oil content of the compressed air, it may take several weeks or months before an oil level is observed in collector (4).

  • Page 63: Pictographs

    Instruction book Interval Running hours Operation Weekly Check pressure gauge (2). If the pressure reaches 2 bar(e) (29 psig) or every 6000 operating hours, replace filter (3): Unscrew the filter. Fill the new filter with water, lightly oil its gasket, screw it on and tighten by hand (approx.

  • Page 64: 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 GA oil-injected screw compressors, the major part of the compression heat is dissipated through the oil system. The Atlas Copco energy recovery (ER) systems are designed to recover most of the above-mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance.

  • Page 65: Energy Recovery Systems

    Location of oil cooler bypass valve (BV1) Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor. Consult Atlas Copco for installing and connecting the energy recovery unit. Energy recovery systems General The energy recovery systems can be applied as low temperature rise/high water flow systems or as high temperature rise/low water flow systems.

  • Page 66: Operation

    Although the heat exchanger is made of stainless steel, the water circuit connected to the compressor may require corrosion inhibitors. Consult the table below to minimise problems due to bad water quality. If in any doubt, consult Atlas Copco. Add an anti-freeze product such as ethylene-glycol to the water in proportion to the expected temperature to avoid freezing.
  • Page 67 Instruction book BV2 starts closing the bypass line and opening the oil supply line from the ER heat exchanger (HE) at the lower limit of its temperature range. At the upper limit of its temperature range, the bypass line is completely closed and all the oil flows through the ER heat exchanger.
  • Page 68 Instruction book Attention: It is only allowed to turn the handle completely in or out. No in-between position is allowed! The oil cooler bypass valve (BV1) starts closing the bypass line and opening the oil supply line from the main oil cooler (Co) at the lower limit of its temperature range.

  • Page 69: Maintenance

    To clean the oil side, soak the heat exchanger in a degreasing solution. To remove scale formation in the water compartment, a proper descaling process should be applied. Consult Atlas Copco. Energy recovery data...
  • Page 70 RECOVERED ENERGY (kW) = 4.2 x water flow (l/s) x water temperature rise (˚C) In the tables below, typical examples are given, except for the recovered energy. Consult Atlas Copco for specifications. Data for low temperature rise/high water flow (at maximum speed)
  • Page 71 Instruction book Data for high temperature rise/low water flow (at maximum speed) Parameter Unit GA75 VSD GA90 VSD Recoverable energy 56.3 67.5 Recoverable energy 75.5 90.5 Water flow l/min 11.3 13.6 Water flow 0.40 0.48 Temperature at inlet ˚C Temperature at inlet ˚F Temperature at outlet ˚C...

  • Page 72: Installation

    Instruction book Installation Dimension drawings GA 75 VSD and GA 90 VSD GA 75 VSD and GA 90 VSD 2920 1634 04...
  • Page 73 Instruction book Centre of gravity Unit With dryer With dryer With dryer Without Without Without dryer dryer dryer Type GA 75 VSD and 1100 1090 GA 90 VSD GA 75 VSD and 42.9 19.7 29.9 42.5 19.1 27.3 GA 90 VSD Dimensions in mm: +/- 50 mm (1.95 in)

  • Page 74: Installation Proposal

    Instruction book Installation proposal Compressor room example Compressor room example Text on drawing 2920 1634 04...
  • Page 75 Control module with monitoring panel. Power supply cable to be sized and installed by an electrician. In case of an IT network consult Atlas Copco. Provision for energy recovery system. Filter, type DD for general purposes. The filter traps solid particles down to 1 micron with a max.
  • Page 76 Cooling air grating, dryer Attention Working with machinery controlled by a frequency converter requires special safety precautions. These safety precautions depend on the kind of network used (TN, TT, IT system). Consult Atlas Copco. 2920 1634 04...

  • Page 77: Electrical Connections

    Instruction book Electrical connections Electrical connections for GA 75 VSD and GA 90 VSD 2920 1634 04...

  • Page 78: Cooling Water Requirements

    5. Connect the earth conductor to the earth bolt (PE). Cooling water requirements General Following requirements are given as a general rule to prevent cooling water problems. If in any doubt, consult Atlas Copco. Recommended maxima Recirculating system Pass-through system...

  • Page 79: Pictographs

    Instruction book Additives If it should be necessary to use additives in the cooling water, take into account that the cooling capacity will change. Pictographs GA 37 VSD up to GA 90 VSD Pictographs, GA 37 VSD up to GA 90 VSD Reference Designation Switch off the voltage and depressurize the compressor before starting maintenance or...

  • Page 80: Operating Instructions

    Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below 0 ˚C/32 ˚F, precautions must be taken. In this case, and also if operating above 1000 m (3300 ft), consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame.
  • Page 81 Instruction book Air receiver transport fixtures of GA 75 VSD and GA 90 VSD Motor and gear casing transport fixtures of GA 75 VSD and GA 90 VSD 2920 1634 04...
  • Page 82 For Full-Feature units: also connect the condensate drain outlet of the dryer to a drain collector. The drain pipes to the drain collector must not dip into the water. For draining of pure condensate water, install an oil/water separator which is available from Atlas Copco as an option; see section unit.

  • Page 83: Before Starting

    • Loosen the hose clip (3) and disconnect inlet hose (2). • On GA 75 VSD and GA 90 VSD, lift inlet hose (2), open check valve (CV) and pour 0.75 l (0.20 US gal, 0.17 Imp gal) of oil into the compressor element.

  • Page 84: Starting

    Instruction book Position of unloader on GA 75 VSD and GA 90 VSD Procedure See section Initial start-up for location of the oil system components. Check oil level (Gl), top up if necessary. The pointer should be in the upper field of the green range or in the orange range.
  • Page 85 For optimum operation, the cooling water outlet temperature must never exceed the value specified in section Compressor data. Consult Atlas Copco if condensate should be formed during frequent unloading periods. Minimum compressor element temperature for water-cooled units 2920 1634 04...

  • Page 86: During Operation

    Instruction book • (A): Air inlet temperature • (B): Condensation temperature • (C): Working pressure • (D): Relative air humidity Example: If operating at a pressure of 10 bar(e) (145 psig) in an ambient temperature of 20 ˚C (68 ˚F) and at a relative air humidity of 100%, the minimum temperature to prevent condensate from forming is 68 ˚C (154 ˚F).
  • Page 87 Instruction book Position of oil level sight-glass on GA 75 VSD and GA 90 VSD Position of the service indicator on GA 75 VSD and GA 90 VSD Check the oil level during operation: the pointer of level gauge (Gl) must register in the green range; if not, press stop button (9).

  • Page 88: Checking The Display

    Instruction book For GA 37 VSD up to GA 90 VSD Full-Feature also press the test button on top of the electronic water drain of the dryer until the air system between the air receiver and outlet valve is fully depressurised. Press the emergency stop button (10).

  • Page 89: Stopping

    Instruction book Stopping Elektronikon regulator Control panel Procedure Press stop button (9). Automatic operation LED (8) goes out. The compressor stops. To stop the compressor in case of emergency, press emergency stop button (10). Alarm LED blinks (7). After remedying the fault, unlock the button by pulling it out and press ‘Rset’ key (5) before restarting.
  • Page 90 Instruction book Press the emergency stop button, switch off the voltage and disconnect the compressor from the mains. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net. On water-cooled compressors: •...

  • Page 91: Maintenance

    Instruction book Maintenance Preventive maintenance schedule Control panel Control panel Warning Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Close the air outlet valve and press the test button on top of the electronic water drain(s) until the air system between the air receiver and outlet valve is fully depressurised.
  • Page 92 For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits). 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 gaskets, O-rings and washers.

  • Page 93: Drive Motor

    Replace oil separator if the pressure drop exceeds 1 bar during loaded running with a stable working pressure. 8000 If Atlas Copco Roto-Xtend Duty Fluid is used, change oil and oil filter. Important • Always consult Atlas Copco if a timer setting has to be changed.

  • Page 94: Oil Specifications

    It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of extensive field experience and research in our labs. See section Preventive maintenance schedule for replacement intervals and section Service Kits for part number information.
  • Page 95 Instruction book Procedure Oil system components of GA 75 VSD and GA 90 VSD Oil drain plug of GA 75 VSD and GA 90 VSD Run the compressor until warm, close the air outlet valve and let the compressor run for 3 minutes at minimum speed.

  • Page 96: Disposal Of Used Material

    Service kits For overhauling and for preventive maintenance, a wide range of service kits is available. Service kits comprise all parts required for servicing the component and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low.
  • Page 97 Instruction book Also a full range of extensively tested lubricants, suitable for your specific needs is available to keep the compressor in excellent condition. Consult the Spare Parts List for part numbers. 2920 1634 04...

  • Page 98: Adjustments And Servicing Procedures

    Adjustments and servicing procedures Air filter Location of air filter Air filter, GA 75 VSD and GA 90 VSD Recommendations 1. Never remove the element while the compressor is running. 2. For minimum down-time, replace the dirty element by a new one.

  • Page 99: Safety Valve

    • Then clean with an air jet in the reverse direction to normal flow. Use low pressure air, if necessary the pressure may be increased up to 6 bar(e) (87 psig). • If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco. • Remove the cover used during cleaning.

  • Page 100: Problem Solving

    Instruction book Problem solving 10.1 Problem solving Warning Before carrying out any maintenance, repair work or adjustment, press the stop button and wait until the compressor has stopped. Close the air outlet valve and 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.
  • Page 101 Replace valve Oil separator clogged Have element replaced Air leakage Have leaks repaired Safety valve leaking Have valve replaced Compressor element out of order Consult Atlas Copco Customer Centre Condition Fault Remedy Safety valve blows Minimum pressure valve Check and have defective...

  • Page 102: Technical Data

    Instruction book Technical data 11.1 Readings on display Display of Elektronikon regulator Elektronikon II regulator Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limitations). Reference Reading Air outlet pressure Depends on the setpoint (desired net pressure). Compressor element Approx.
  • Page 103 Instruction book IECversions For IEC designed control panels, the below suggested cable sections are calculated according to 60364-5-52 electrical installations of buildings, part 5: selection and erection equipment, section 52: current-carrying capacities in wiring systems. Standard conditions refer to loose copper conductors or multicore cable with 70˚C PVC insulation in free air or on open cable trays (installation method C) at 30˚C ambient temperature and operating at nominal voltage.
  • Page 104 Approval I Recommended Recommended Main fuses wire section (2) wire section (3) (A) (4) F (1) GA 75 VSD (200) 7 x 95 mm 7 x 185 mm GA 75 VSD (160) 7 x 70 mm 7 x 120 mm...

  • Page 105: Settings Of Fan Motor Circuit Breaker

    Instruction book Fuse specifications IEC: gL/gG Fuse specifications CSA: HRC Form II - UL: Class 5 11.3 Settings of fan motor circuit breaker Circuit breaker GA 75 VSD GA 90 VSD Frequency (Hz) Voltage (V) Fan motor circuit Fan motor circuit...

  • Page 106: Compressor Data

    Maximum cooling water inlet pressure psig 72.52 11.5 Compressor data Note All data specified below are valid at reference conditions; see section Reference conditions limitations. GA 75 VSD Unit 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi...
  • Page 107 Instruction book Unit 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi Total amount (refrigerant), Workplace Full- Feature Total amount (refrigerant), Workplace Full- 5.73 5.73 5.73 Feature Cooling water consumption (at water inlet l/min temperature below 35 ˚C and temperature rise of 15 ˚C), water-cooled units Cooling water consumption (at water inlet 192.7...
  • Page 108 Instruction book Unit 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi Maximum effective working pressure, psig Workplace Maximum effective working pressure, bar(e) 7.25 9.75 12.75 Workplace Full-Feature Maximum effective working pressure, psig Workplace Full-Feature Maximum motor shaft speed 3480 2970 2510...
  • Page 109 Instruction book Unit 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi Sound pressure level, 50 Hz variants dB(A) (according to ISO 2151 (2004)) Sound pressure level, 60 Hz variants dB(A) (according to ISO 2151 (2004)) 2920 1634 04...

  • Page 110: Instructions For Use Of Air Receiver

    Instruction book Instructions for use of air receiver 12.1 Air receiver instructions Instructions This vessel can contain pressurised air; this can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator and must be operated within the limits specified on the data plate.

  • Page 111: Guidelines For Inspection

    The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor. Local legal requirements and/or use outside the limits and/or conditions as specified by Atlas Copco may require other inspection periods as mentioned below.

  • Page 112: Ped

    Instruction book 14.1 Pressure equipment directives Components subject to 97/23/EC 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 97/23/EC and all pressure equipment according to the Simple Pressure Vessel Directive 87/404/EEC.
  • Page 114 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.

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Ga 90 vsd

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