Atlas Copco GA 18 VSD+ Instruction Book
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Atlas Copco GA 18 VSD+ Instruction Book

Oil-injected rotary screw compressors
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INSTRUCTION BOOK
OIL-INJECTED ROTARY SCREW COMPRESSORS
GA 18 VSD+, GA 22 VSD+, GA 26 VSD+, GA 30 VSD+, GA 37 VSD+

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Summary of Contents for Atlas Copco GA 18 VSD+

  • Page 1 INSTRUCTION BOOK OIL-INJECTED ROTARY SCREW COMPRESSORS GA 18 VSD+, GA 22 VSD+, GA 26 VSD+, GA 30 VSD+, GA 37 VSD+...
  • Page 3 Atlas Copco Oil-injected rotary screw compressors GA 18 VSD+, GA 22 VSD+, GA 26 VSD+, GA 30 VSD+, GA 37 VSD+ Instruction book Original instructions COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................5 ........................... 5 AFETY ICONS ......................5 AFETY PRECAUTIONS GENERAL ................... 6 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR .......................10 ISMANTLING AND DISPOSAL General description...................... 11 ..........................11 NTRODUCTION ..........................15...
  • Page 5 Instruction book 3.12 ......................47 ONTROLLER SETTINGS MENU 3.13 ..........................50 CCESS LEVEL Installation........................52 ........................52 IMENSION DRAWINGS ........................56 NSTALLATION PROPOSAL .........................59 LECTRICAL CONNECTIONS ..........................62 ICTOGRAPHS Options.......................... 63 .......................... 63 NERGY RECOVERY ..........................77 AIN SWITCH Operating instructions....................79 Maintenance........................85 ....................85 REVENTIVE MAINTENANCE SCHEDULE ..........................89...
  • Page 6 Instruction book ......................103 LECTRIC CABLE SIZE AND FUSES ..................110 EFERENCE CONDITIONS AND LIMITATIONS ........................110 OMPRESSOR DATA ......................114 ECHNICAL DATA CONTROLLER Instructions for use....................116 Guidelines for inspection...................117 Pressure equipment directives................. 118 Declaration of conformity..................119 2920 7110 05...

  • Page 7: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger to 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 8: Safety Precautions During Installation

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

  • Page 10: Safety Precautions During Maintenance Or Repair

    Instruction book • All guards are in place and securely fastened • All hoses and/or pipes inside the machine are in good condition, secure and not rubbing • No leaks occur • All fasteners are tight • All electrical leads are secure and in good order •...
  • Page 11 Instruction book 6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment. 7.

  • Page 12: Dismantling And Disposal

    Instruction book Also consult following safety precautions: Safety precautions during installation Safety precautions during operation. 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. Some precautions are general and cover several machine types and equipment;...

  • Page 13: General Description

    GA 18 VSD+ up to GA 37 VSD+ are single-stage, oil-injected screw compressors driven by an interior permanent magnet (English: Interior Permanent Magnet (IPM)) motor. The compressors are controlled by the Atlas Copco Elektronikon Touch controller (ER). The controller is fitted to the front panel. An electric cabinet (1) comprising fuses, transformers, relays, etc.
  • Page 14 Instruction book Open side view, GA VSD+ Workplace GA Workplace Full-Feature The Workplace Full-Feature compressors have 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.
  • Page 15 Instruction book Front view, GA VSD+ Workplace Full-Feature Open side view, GA VSD+ Workplace Full-Feature Reference Name Air filter Air receiver Air outlet Air cooler 2920 7110 05...
  • Page 16 Instruction book Reference Name Oil cooler Automatic condensate outlet Manual condensate outlet Refrigerant dryer Compressor element Electronic water drain Elektronikon Touch controller Cooling fan Drive motor Oil filter Oil separator Emergency stop button Electric cabinet 2920 7110 05...

  • Page 17: Flow Diagram

    Instruction book Flow diagram GA 18 VSD+ up to GA 37 VSD+ Workplace 2920 7110 05...
  • Page 18 Instruction book GA 18 VSD+ up to GA 37 VSD+ Workplace Full-Feature 2920 7110 05...
  • Page 19 Instruction book GA 18 VSD+ up to GA 37 VSD+ Workplace Full-Feature Reference Description Air inlet Air/oil mixture Wet compressed air Condensate 2920 7110 05...

  • Page 20: Condensate System

    Instruction book Reference Description Dry compressed air (Workplace Full-Feature) Air flow Air comes in through filter (AF) and inlet valve (IV) and is compressed in the compressor element (E). A mixture of compressed air and oil flows into the air receiver/oil separator (AR), where oil and air are separated.
  • Page 21 Instruction book Location of the electronic water drain (Workplace) Location of the electronic water drain (Workplace Full-Feature) Alternative drain (Workplace Full-Feature) On Workplace Full-Feature units, the condensate formed in the dryer collects in the lower part of the heat exchanger/evaporator. 2920 7110 05...
  • Page 22 Instruction book When the condensate in the electronic drain reaches a certain level, it is drained via the automatic drain outlet (Da). Condensate drain connections, Workplace Full-Feature Reference Designation Automatic drain connection Manual drain connection Electronic water drain (ED), typical view 2920 7110 05...
  • Page 23 Instruction book Electronic water drain (ED), (alternative) The Test button (2) on top of the drain can be used in three different ways, according the situation: • When pressed during normal operation, it starts the manual drain test. • When pressed during an alarm, it resets the control logic. •...
  • Page 24 Instruction book Green LED fading on/off Water is not flowing in to the drain‘s tank. If the floater does not reach the upper level for 3 hours, the solenoid is energized for 2 seconds. This cycle is repeated for 5 times (so up to 15 hours).

  • Page 25: Regulating System

    Instruction book Regulating system Description When the compressor is started and the net pressure is below the setpoint, the motor speed increases until the net pressure reaches the setpoint or until the maximum motor speed is reached. If the air consumption is less than the air delivery of the compressor, the net pressure increases further.
  • Page 26 Instruction book Electric cabinet, typical example Reference Designation Transformer Circuit breaker Circuit breaker Contactor EMC filter Frequency converter Electrical diagrams The complete electrical diagram can be found in the electric cabinet as well as in the technical documentation, supplied with the unit. 2920 7110 05...

  • Page 27: Air Dryer

    Instruction book Air dryer Flow diagram Air dryer Reference Name Air inlet Air outlet Air/air heat exchanger Air/refrigerant heat exchanger/evaporator Condensate separator Automatic drain / condensate outlet Refrigerant compressor Refrigerant condenser Liquid refrigerant dryer/filter Capillary Bypass valve Condenser cooling fan Pressure switch, fan control Liquid separator Compressed air circuit...
  • Page 28 Instruction book The cold air flows through the separator (3) where all the condensate gets out of the air. The condensate is automatically drained through the outlet (4). The outgoing, cold, dried air flows through the heat exchanger (1) where it is warmed up by the incoming compressed air.

  • Page 29: Elektronikon™ Touch Controller

    Instruction book Elektronikon™ Touch controller Controller The Elektronikon™ Touch controller Introduction The controller has the following functions: • Controlling the unit • Protecting the unit • Monitoring components subject to service • Automatic Restart After Voltage Failure (ARAVF) Automatic control of the unit The controller maintains the net pressure between programmable limits by automatically loading and unloading the unit (fixed speed units) or by adapting the motor speed (units with frequency converter).
  • Page 30 Instruction book Protecting the unit Shutdown Several sensors are provided on the unit. If one of the measured signals exceeds the programmed shutdown level, the unit will be stopped. Example: If the element outlet temperature exceeds the programmed shutdown level, the unit will be stopped.

  • Page 31: Control Panel

    Instruction book Control panel Control panel Parts and functions Reference Designation Function Touch screen Shows the unit operating condition and several icons to navigate through the menu. The screen can be operated by touch. Warning sign Flashes in case of a shut-down and is lit in case of a warning condition.

  • Page 32: Icons Used

    Instruction book Icons used Menu icons Menu Icon Menu Icon Menu Icon Data Status Inputs Outputs Counters Aux. Equipment Converters Parameters Service Service Overview Service Plan Service History Service functions Clean Screen Week Timer Week Remaining Running Time Event History Saved Data 2920 7110 05...
  • Page 33 Instruction book Menu Icon Menu Icon Menu Icon Machine Alarms Settings Regulation Control Parameters Aux. Equipment Converter(s) Parameters Internal SmartBox Auto Restart Controller Network Ethernet Settings Settings Settings CAN Settings Localisation Language Date/Time Units User Password Help Information Status icons Icon Description Motor Stopped...
  • Page 34 Instruction book Motor Stopped Wait Running Unloaded Manual Unload Running Unloaded Wait Running Loaded Failed to Load Running Loaded Wait Manual Stop Machine Control Mode, Local Machine Control Mode, Remote Machine Control Mode, LAN Automatic Restart After Voltage Failure Week Timer Active System icons Icon Description...
  • Page 35 Instruction book Antenna 50% Antenna 75% Antenna 100% Change between screens (indication) Energy recovery Dryer Element Drain(s) Analogue Output Menu Reset Auto Restart Filter(s) Cooler Valve(s) Power Meter Input icons Icon Description Pressure 2920 7110 05...

  • Page 36: Main Screen

    Instruction book Temperature Special Protection Open Closed This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to every machine. Main screen Function The Main screen is the screen that is shown automatically when the voltage is switched on. It is switched off automatically after a few minutes when there is no touch input.

  • Page 37: Quick Access Screen

    Instruction book Reference Designation Function Alarm button The alarm button can be tapped to show the current alarms. If an alarm occurs, the icon on the button will be red. Service button The service button can be tapped to show the service information.

  • Page 38: Menu Screen

    Instruction book Function Description Setpoints Several setpoints can be modified by tapping this icon. Control mode The control mode can be changed by tapping this icon. • Local control via start/stop buttons • Remote control via digital input(s) • LAN control via the network. When in Remote or LAN control, the start/stop buttons on the controller will not work.
  • Page 39 Instruction book Reference Designation Function Service The service menu contains the Service information. The ‘Clean screen’ function can be used to clean the touchscreen. Week timer Multiple Week timers and a Remaining running time can be set through this menu. Event history In case of an alarm, the Status information of the unit is saved and can be viewed through this menu.

  • Page 40: Data Menu

    Instruction book Data menu Function This screen is used to display the following submenus: • Status • Inputs • Outputs • Counters • Aux. Equipment These submenus can be entered by tapping the icons. Procedure To enter the Data menu screen: 1.
  • Page 41 Instruction book If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the reset button (1). Before remedying, consult the Safety precautions. Before resetting a warning or shutdown message, always solve the problem. Frequently resetting these messages without remedying may damage the unit.

  • Page 42: Service Menu

    Instruction book This menu shows an overview of all actual hours and counters of the unit and controller. Auxiliary equipment menu Tap the Aux. Equipment icon to enter the Aux. equipment menu. This menu shows an overview of all auxiliary equipment fitted. Service menu Function This screen is used to display the following submenus:...
  • Page 43 Instruction book Description Reference Designation Service Service functions (Only visible as advanced user) Clean screen Service menu Tap the Service icon to enter the Service menu. This menu shows the remaining Running Hours and the remaining Real Time Hours until the next service.

  • Page 44: Week Timer Menu

    Instruction book Depending on the machine, this menu can have a different set of functions. Many of them are password protected, as they are only accessible for authorized personnel. Clean screen Tap the Clean Screen icon to start the 15 seconds countdown to perform cleaning of the touchscreen.

  • Page 45: 3.10 Event History Menu

    Instruction book Description Reference Designation Function Add or select week If less than 4 weeks are programmed, tap the ‘+’ button to add a week. Remove week Tap to remove a programmed week timer. Activate week timer A selection screen pops up. The user can choose the correct week by tapping ‘–’...

  • Page 46: 3.11 Machine Settings Menu

    Instruction book Reference Designation Saved Data Saved data Tap the Saved Data icon to enter the Saved Data menu. Scroll through the items swiping up and down in this list. The event date and time is shown at the right side of the screen. Press on one of the items in the list for more information reflecting the status of the unit when the shutdown occurred.
  • Page 47 Instruction book Description Reference Designation Alarms menu Regulation menu Control Parameters menu Aux. Equipment Parameters menu Auto Restart menu Alarms menu Tap the Alarms icon to enter the Alarms menu. A list of all alarms is shown. When pressing on one of the items in this list, the warning and/or shutdown levels are shown for this alarm.
  • Page 48 Instruction book When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’. Change a selection When tapping a list item, a selection screen pops up. The user can change the selection by swiping up or down and confirm by tapping ‘V’...

  • Page 49: 3.12 Controller Settings Menu

    Instruction book Through this menu, the automatic restart can be activated. The activation is password protected. The automatic restart settings can also be changed. Enter a password When tapping a password protected item, a selection screen pops up. The user can enter the password by swiping up or down to select the desired number.
  • Page 50 Instruction book Reference Designation Network Settings menu Localisation menu User Password menu Help menu Information menu Network settings menu Tap the Network Settings icon to enter the Network Settings menu. Ethernet Settings The list of Ethernet Settings is shown. When ethernet is turned off, the settings can be modified. CAN Settings The list of CAN Settings is shown.
  • Page 51 Instruction book The date and time settings of the controller can be modified through this menu. Units The units displayed can be modified through this menu. Modify a setting When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’...

  • Page 52: 3.13 Access Level

    Instruction book This menu shows information about the controller. 3.13 Access level Function Through this pop-up screen the access level settings can be viewed or changed. Procedure The Access Level screen can be viewed or changed by tapping the Access Level button at the upper right corner of the screen.
  • Page 53 Instruction book Service access level Tap the Service access level icon (1) and confirm (2). The screen information bar (1) now shows the current status of the unit instead of the machine serial number. The Received Signal Strength Indicator (RSSI) value is now shown in the Internal SmartBox menu.

  • Page 54: Installation

    Instruction book Installation Dimension drawings Center of gravity and weight Type Weight (mm) (mm) (mm) (kg) GA 18 VSD+ 380-460V GA 22 VSD+ 380-460V GA 26 VSD+ 380-460V GA 30 VSD+ 380-460V GA 37 VSD+ 380-460V 2920 7110 05...
  • Page 55 Instruction book 2920 7110 05...
  • Page 56 Instruction book Center of gravity and weight Type Weight (mm) (mm) (mm) (kg) GA 18 VSD+ FF 380-460V GA 18 VSD+ FF with transformer 200-230V GA 18 VSD+ FF with transformer 500-575V GA 18 VSD+ with transformer 200-230V GA 18 VSD+ with transformer 500-575V GA 22 VSD+ FF 380-460V GA 22 VSD+ FF with transformer...
  • Page 57 Instruction book Reference Designation Electric cable entry for 380 V - 460 V (use the cable tray inside the bottom of the frame) Cooling air outlet Compressor air outlet Compressor cooling air inlet Manual drain compressor Automatic drain compressor Cubicle and converter cooling air inlet Oil level indicator Dryer cooling air inlet Electric cable entry for 200 - 230 V and 500 - 575 V...

  • Page 58: Installation Proposal

    Instruction book Installation proposal Compressor room example Text on image Ventilation proposals Minimum free area to be reserved for the compressor installation Description Compressor unit: Install the compressor unit on a solid, level floor suitable for taking the weight. Position of the compressed air outlet valve. 2920 7110 05...
  • Page 59 Atlas Copco has oil/water separators (type OSD or OSCi) to separate the major part of the oil from the condensate to ensure that the condensate meets the requirements of the environmental codes.
  • Page 60 In this case, consult Atlas Copco. 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. Take care not to damage the bodywork during lifting or transport.

  • Page 61: Electrical Connections

    These safety precautions depend on the kind of network used (TN, TT, IT system). Consult Atlas Copco. Most compressors are designed for use in TT/TN networks and are intended for industrial environments where the electrical supply is separated from the residential/ commercial supply network.
  • Page 62 Instruction book Electrical connections for GA 37 VSD+ Electrical connections diagram, typical example Reference Designation Customer’s installation Power circuit Motor Dryer Note The complete electrical diagram can be found in the electrical cubicle. Description You can find the correct position for the electrical connections in the section Dimension drawings.
  • Page 63 Have the modifications checked by Atlas Copco. Stop the compressor and switch off the voltage before connecting external equipment. Only potential free contacts are allowed. • LAN control: The compressor is controlled via a local network. Consult Atlas Copco. Compressor status indication The Elektronikon...

  • Page 64: Pictographs

    Instruction book Pictographs Pictographs Reference Designation Lock out/ tag out the compressor before starting maintenance or repairs Automatic condensate drain Manual condensate drain Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx. half a turn) Warning, hot surface Stop the compressor before cleaning the coolers Warning, voltage...

  • Page 65: Options

    Instruction book Options Energy recovery 5.1.1 Energy recovery unit Description A large part of the energy required for any compression process is transformed into heat. The major part of the compression heat is dissipated through the oil system. Energy Recovery (ER) systems are designed to recover most of this heat by transforming it into warm or hot water without any adverse effects on compressor performance.
  • Page 66 Instruction book Energy Recovery (ER) unit Main components of the ER unit (typical installation) Reference Designation Water inlet pipe Water outlet pipe Temperature sensor, water inlet pipe Temperature sensor, water outlet pipe Oil drain valve Oil line from compressor oil separator vessel to ER unit Oil line from ER unit to oil filter housing Location of heat exchanger by-pass valve (BV2) Heat exchanger...
  • Page 67 Instruction book Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor. Consult your supplier for installing and connecting the energy recovery unit. 5.1.2 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 68 Instruction book 5.1.3 Operation Description The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable compressor operation and optimum energy recovery. Bypass valve (BV1) is integrated in the oil filter housing of the compressor and controls the oil flow to the heat exchanger (HE) and the main oil cooler (Co) of the compressor.
  • Page 69 Instruction book Flow diagram of compressor with energy recovery system 2920 7110 05...
  • Page 70 Instruction book Reference Designation Reference Designation Thermostatic bypass valve of ER Oil filter unit Oil/water heat exchanger (ER Oil separator vessel unit) Compressor element Thermostatic bypass valve in oil filter housing Oil cooler (compressor) Aftercooler (compressor) Water inlet Water outlet BV1 starts closing the bypass line over the oil cooling circuit at the lower limit of its temperature range.
  • Page 71 Instruction book Position of bypass ball valves ER label Attention: It is NOT allowed to use the ball valves at an in-between position! Energy recovery system in use (see drawing) Bypass valves in position (A): the heat exchanger (HE) is integrated in the water side of the ER. 2920 7110 05...
  • Page 72 Instruction book • Compressor start-up When the compressor is started up from cold, the oil temperature will be low. Bypass valve (BV1) shuts off the oil supply to the oil cooling system to prevent the compressor oil from being cooled. The oil flows from the oil separator vessel (AR) through the oil filter(s) (OF) back to compressor element (E).
  • Page 73 Instruction book 2. Depressurize the compressor and drain the oil by opening the drain valve. Also drain the oil from the heat exchanger by opening the drain valve on the heat exchanger (HE). Close the valve after draining. 3. Resume oil change as described in section Oil and Filter Change in this book. Thermostatic bypass valves Change the thermostat of the ER system at the same interval as the thermostat of the unit.
  • Page 74 Instruction book Type of cooling system Materials Standard Energy recovery Single pass Containing copper 6.8 - 9.3 6.8 - 9.3 Stainless steel with carbon 6.8 - 9.3 6.8 - 9.3 steel and / or cast iron Stainless steel only 6 - 9.3 6 - 9.3 Recirculating (with tower) Containing copper...
  • Page 75 Instruction book is calculated from: = (9.3 + A + B) - (C + D), in which • A : depends on the total solids concentration • B : depends on the water temperature at the outlet of the heat exchanger •...
  • Page 76 Instruction book A continuous level of 0.5 ppm should not be exceeded. For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies. 6. Chlorides (Cl Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited, depending from the RSI value.
  • Page 77 Instruction book Suspended solids (ppm) Type of cooling system Standard Energy recovery Single pass < 10 < 1 Recirculating (with tower) < 10 not applicable Closed loop < 10 < 1 12. Oil or grease < 1 ppm (rejection value) 13.
  • Page 78 Instruction book • The water inlet temperature of the energy recovery system • The water outlet temperature of the energy recovery system Modifying settings If the programmed warning settings for the water temperatures are exceeded, a warning indication is shown on the controller: Temperature input Minimum Nominal...

  • Page 79: Main Switch

    Instruction book Parameter Unit GA 37 GA 18 VSD GA 22 VSD GA 26 VSD GA 30 VSD Pressure drop in WC Temperature at inlet ˚C Temperature at inlet ˚F Temperature at outlet ˚C Temperature at outlet ˚F Main switch A built-in main switch can be ordered as a sales option.
  • Page 80 Instruction book The complete electrical diagram can be found in the electrical cubicle 2920 7110 05...

  • Page 81: Operating Instructions

    Instruction book Operating instructions Initial start-up The operator must apply all relevant Safety precautions. Also consult section Problem solving. For the location of the air outlet valve and the drain connections, see sections Introduction Condensate system. Step Action Remove the canopy panel(s) in order to get access to the internal components. Remove the red transport spacers (1) and the related bolts under the motor.
  • Page 82 Instruction book Step Action Check the oil level. The oil level should reach the bottom of the oil filler neck (FC). Minimum level should reach the oil sight glass (GI) when the compressor is stopped. If needed, top up the oil. Take care that no dirt drops into the oil system.
  • Page 83 Instruction book Step Action Open the air outlet valve. Start and run the compressor for a few minutes. Check that the compressor operates normally. Starting Control panel Elektronikon Touch Step Action Open the air outlet valve. Switch on the voltage. Check that voltage on LED (5) lights up. Press start button (7) on the control panel.
  • Page 84 Instruction book A few minutes after stopping, the oil level should reach the bottom of the oil filler neck (FC). If the oil level is too low, wait until the compressor has depressurized. Push the emergency stop button (10) to avoid the compressor to start unexpectedly. Next, close the air outlet valve and open the manual drain valve (Dm) until the air system between oil separator/air receiver vessel and outlet valve is fully depressurized.
  • Page 85 Instruction book Control panel Elektronikon Touch controller Check the display (1) regularly for readings and messages. The display normally shows the compressor outlet pressure, while the status of the compressor is indicated by means of a number of icons. Remedy the trouble if alarm LED (2) is lit or flashes, see section Icons used.
  • Page 86 Instruction book Taking out of operation Step Action Disconnect the compressor from the mains. Unscrew the oil filler plug only one turn to permit any pressure in the system to escape. 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.

  • Page 87: Maintenance

    For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits). Service agreements Contact Atlas Copco to set up a tailor-made service agreement. It will ensure optimum operational efficiency, minimize downtime and reduce the total life cycle cost. General When servicing, replace all removed O-rings and washers.
  • Page 88 Instruction book which service plans are to be carried out. After servicing, the intervals must be reset, see section Service menu. Preventive maintenance schedule Daily and 3-monthly check list Period Action Daily Check oil level. If needed, top up the oil (see section Operating instructions —...
  • Page 89 In order to achieve the best machine performance and guarantee the reliability, it is required to use genuine Atlas Copco Lubricants. Their tailor made formulation is the result of years of field experience, research and in-house development. Consult the Spare Parts list for part number information.
  • Page 90 40°C (104°F) above 105°C (221°F) use Roto Synthetic Fluid Xtend Duty Note: the presence of dust and/or high humidity may require a shorter exchange interval. Consult Atlas Copco. Exchange interval for Roto Synthetic Fluid Ultra Ambient temperature Element outlet...

  • Page 91: Oil Specifications

    • For change of oil contact Atlas Copco for the correct procedure. • For changing of one type of oil to another type of oil consult Atlas Copco for the correct procedure as this is not allowed in some conditions.

  • Page 92: Drive Motor

    Roto Synthetic Fluid XTEND DUTY. Roto Synthetic Fluid XTEND DUTY Atlas Copco's Roto Synthetic Fluid XTEND DUTY is a high quality synthetic 8000 hours lubricant for oil injected screw compressors which keeps the compressor in excellent condition. Because of its excellent oxidation stability, Roto Synthetic Fluid XTEND DUTY can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F).

  • Page 93: Air Filter

    Instruction book Air filter Location of air filter Procedure 1. Stop the compressor. Switch off the voltage. 2. Remove the cover of the air filter (AF) by turning it anti clockwise. Remove the filter element. 3. Fit the new element and the cover. 4.
  • Page 94 Instruction book Vent plug, oil cooler 3. Open the oil drain valve (Do). • Hold the oil drain hose (1) downward to drain the oil. • Disconnect the air hose (2) at the top on the vessel. • Move the hose downward to drain the oil from the element. •...

  • Page 95: Coolers

    Instruction book Take care that no dirt drops into the system. Refit and tighten filler plug (FC). 8. Run the compressor loaded for a few minutes. Stop the compressor. 9. Close the air outlet valve and switch off the voltage. •...

  • Page 96: Dryer Maintenance Instructions

    Remove dirt from the fan with a fibre brush. • Clean with an air jet in the reverse direction to normal flow. • If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco. After maintenance on the fan and on the coolers: Remove the material that was used as cover.

  • Page 97: Safety Valves

    Instruction book • Refrigerant is harmful. Do not inhale refrigerant vapours. Check that the working area is adequately ventilated. Be aware that certain components such as the refrigerant compressor and the discharge pipe can become quite hot (up to 110 °C - 230 °F). Therefore, wait until the dryer has cooled down before removing the panels.

  • Page 98: Service Kits

    Atlas Copco parts while keeping the maintenance budget low. Also a full range of extensively tested lubricants, suitable for your specific needs is available to keep the compressor in excellent condition.

  • Page 99: Problem Solving

    Instruction book Problem solving Warning Before carrying out any maintenance, repair work or adjustment, stop compressor, wait 3 minutes and close the air outlet valve. Press the test button on top of the electronic water drain until the air system between the air receiver and outlet valve is fully depressurized.
  • Page 100 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. Condition Fault Remedy Safety valve blows Minimum pressure valve Check and have defective parts malfunctioning replaced.
  • Page 101 If a problem is detected by the converter, a specific code will appear on the Elektronikon display. Below table lists the most important error codes. If another code appears, please contact Atlas Copco. Tap the Alarm button to enter the status of the alarm.
  • Page 102 Instruction book Fault code Cause Actions Overcurrent Contact Atlas Copco. Ground fault Contact Atlas Copco. Too high voltage. The voltage on the Check the supply voltage. converter is above the specifications. Contact Atlas Copco. Too low voltage. The voltage on the Check the supply voltage.
  • Page 103 Instruction book Condition Fault Remedy Shortage of refrigerant Have circuit checked for leaks and recharged. Refrigerant compressor does See below. not run Evaporator pressure too high See below. Condenser pressure too high See below. Condenser pressure too high Fan control switch out of Replace.

  • Page 104: Technical Data

    Instruction book Technical data Readings on display Elektronikon Touch controller Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limtations). Reference Reading Air outlet pressure Depends on the setpoint (desired net pressure). Compressor element Approx.

  • Page 105: Electric Cable Size And Fuses

    Instruction book Electric cable size and fuses Important • The voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1). •...
  • Page 106 Instruction book Compressor type Maximum fuse (1) I Maximum fuse (2) gL/gG gL/gG GA 22 VSD+ 59.0 63.7 GA 22 VSD+ 400+N 59.0 63.7 GA 22 VSD+ 59.4 64.1 GA 22 VSD+ 47.2 49.7 Compressor type Maximum fuse (1) I Maximum fuse (2) gL/gG gL/gG...
  • Page 107 Instruction book UL/cUL approval Compressor type Maximum fuse (1) I Maximum fuse (2) Class T Class T form II form II GA 18 VSD+ 88.1 94.2 GA 18 VSD+ 88.8 94.9 GA 18 VSD+ 44.4 49.0 GA 18 VSD+ 35.5 37.9 Compressor type fuse (1)
  • Page 108 Instruction book Compressor type fuse (1) fuse (2) Class T Class T form II form II GA 37 VSD+ 175.4 183.1 GA 37 VSD+ 175.4 183.1 GA 37 VSD+ 87.7 93.4 GA 37 VSD+ 70.2 73.2 : current in the supply lines at maximum load and nominal voltage (1): compressors without integrated dryer (2): compressors with integrated dryer Compressors without built-in transformer require quick fuses to protect the frequency converter.
  • Page 109 Instruction book Installation method B2 according table B.52.1. Multi-core cable in conduit on a wooden wall Maximum allowed current in function of the ambient temperature for installation method B2 Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm²...
  • Page 110 Instruction book Installation method F according table B.52.1. Single-core cables, touching in free air Clearance to wall not less than one cable diameter Maximum allowed current in function of the ambient temperature for installation method F Ambient temperature Cable section 30 °C 40 °C 45 °C...
  • Page 111 Instruction book • Install 50 A fuses on each cable instead of 100 A. Cable sizing according UL/cUL Calculation method according UL 508A, table 28.1 column 5: allowable ampacities of insulated copper conductors (75 °C (167 °F)). Maximum allowed current in function of the wire size AWG or kcmil Maximum current <...

  • Page 112: Reference Conditions And Limitations

    Instruction book • I = 128 A + 25 % = 128 x 1.25 = 160 A • For AWG2/0, the maximum current is 175 A, which is sufficient => use AWG2/0 • Install the prescribed maximum fuse (150 A) on each cable •...
  • Page 113 Instruction book Temperature of the air leaving the outlet valve (approx.), Workplace ˚C Temperature of the air leaving the outlet valve (approx.), Workplace ˚F Temperature of the air leaving the outlet valve (approx.), Workplace Full- ˚C Feature Temperature of the air leaving the outlet valve (approx.), Workplace Full- ˚F Feature Refrigerant type, Workplace Full-Feature...
  • Page 114 Instruction book Maximum effective working pressure, psig Workplace Full-Feature Maximum motor shaft speed 5700 5700 5000 4200 Minimum motor shaft speed 1300 1300 1400 1500 Nominal motor power Nominal motor power 29.5 Total amount of refrigerant, Workplace Full-Feature 0.95 Total amount of refrigerant, Workplace Full-Feature 2.09 Oil capacity 14.7...
  • Page 115 Instruction book Normal effective working pressure psig Maximum effective working pressure, bar(e) Workplace Maximum effective working pressure, psig Workplace Maximum effective working pressure, bar(e) 12.75 12.75 12.75 12.75 Workplace Full-Feature Maximum effective working pressure, psig Workplace Full-Feature Maximum motor shaft speed 7400 7400 6500...

  • Page 116: Technical Data Controller

    Instruction book Oil capacity cu. ft. 0.57 Sound pressure level (according to ISO 2151:2004) dB(A) Fan data Model Static pressure head Flow Maximum absorbed power GA 18 VSD+, GA 22 VSD+ 125 Pa (0.50 in WC) 5500 m³/h (3250 cfm) 450 W GA 26 VSD+, GA 30 VSD+ 130 Pa (0.52 in WC)
  • Page 117 Instruction book Analog inputs Number of pressure inputs Number of temperature inputs 2920 7110 05...

  • Page 118: Instructions For Use

    Instruction book Instructions for use Air/oil separator vessel 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. No alterations must be made to this vessel by welding, drilling or any other mechanical methods without the written permission of the manufacturer.

  • Page 119: Guidelines For Inspection

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

  • Page 120: Pressure Equipment Directives

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

  • Page 121: Declaration Of Conformity

    Instruction book Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium (2): Applicable directives (3): Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
  • Page 124 COMMITTED TO SUSTAINABLE PRODUCTIVITY We stand by our responsibilities towards our customers, towards the environment and the people around us. We make performance stand the test of time. This is what we call — Sustainable Productivity. www.atlascopco.com...

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