Related Manuals for Atlas Copco GA 37+
Summary of Contents for Atlas Copco GA 37+
- Page 1 Atlas Copco Oil-injected rotary screw compressors GA 37+, GA 45+, GA 55, GA 75 Instruction book...
- Page 3 Atlas Copco Oil-injected rotary screw compressors GA 37+, GA 45+, GA 55, GA 75 From serial No. PNA923150 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.
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Page 4: Table Of Contents
Instruction book Table of contents Safety precautions ....................8 ......................8 AFETY ICONS ..............8 AFETY PRECAUTIONS DURING INSTALLATION ..............10 AFETY PRECAUTIONS DURING OPERATION ............ 11 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description ..................... 13 ......................13 NTRODUCTION ........................ 17 IR FLOW ...................... - Page 5 Instruction book 3.12 ....................55 VENT HISTORY MENU 3.13 ................... 56 ODIFYING GENERAL SETTINGS 3.14 ......................58 NFO MENU 3.15 ....................59 EEK TIMER MENU 3.16 ......................63 EST MENU 3.17 ....................64 SER PASSWORD MENU 3.18 ..................65 ROGRAMMABLE SETTINGS OSCi (optional)....................
- Page 6 Instruction book ......................103 ICTOGRAPHS Operating instructions..................105 ..................105 EFORE INITIAL START ....................106 NITIAL START ....................109 EFORE STARTING ......................110 TARTING ....................112 URING OPERATION ..................114 HECKING THE DISPLAY ......................115 TOPPING ..................115 AKING OUT OF OPERATION Maintenance....................117 ................117 REVENTIVE MAINTENANCE SCHEDULE .....................119 RIVE MOTOR ....................120 IL SPECIFICATIONS ..................120...
- Page 7 Instruction book 11.8 .............144 ECHNICAL DATA LEKTRONIKON CONTROLLER Instructions for use of air receiver..............145 12.1 ..................145 NSTRUCTIONS FOR USE Guidelines for inspection.................146 13.1 ...................146 UIDELINES FOR INSPECTION 9096 3321 00...
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Page 8: Safety Precautions
Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note 1.2 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 Instruction book Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits.
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Page 10: Safety Precautions During Operation
Instruction book 1.3 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non- observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. General precautions 1. -
Page 11: Safety Precautions During Maintenance Or Repair
Instruction book 10. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure-relieving device or devices as required. Also consult following safety precautions: Safety precautions during installation Safety... - Page 12 Instruction book 8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. 9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours of cleaning liquids. 10.
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Page 13: General Description
GA Workplace are enclosed in a sound-insulated bodywork. The compressors are controlled by the Atlas Copco Elektronikon® regulator. The electronic control module is fitted to the door on the right side. An electric cabinet comprising the motor starter is located behind this panel. A condensate trap with Electronic Water Drain (EWD) is provided. - Page 14 GA Workplace Full-Feature are enclosed in a sound-insulated bodywork. The compressors are controlled by the Atlas Copco Elektronikon® regulator. The electronic control module is fitted to the door on the right side.An electric cabinet comprising the motor starter is located behind this panel. They are provided with an air dryer.
- Page 15 Instruction book Front view, GA 37+ up to GA 75 Full-Feature 9096 3321 00...
- Page 16 Instruction book Rear view, GA 37+ up to GA 75 Workplace Reference Name Electric cubicle Air filter Air receiver (oil separator vessel) Air outlet valve Air cooler Oil cooler CV/Vs Check valve/oil stop valve Automatic condensate outlet, aftercooler Automatic condensate outlet, dryer DD filter (optional) Dryer Compressor element...
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Page 17: Air Flow
Instruction book Coolers on water-cooled compressors Water-cooled air cooler and oil cooler Reference Name Air cooler Oil cooler 2.2 Air flow Flow diagrams Flow diagram, GA workplace 9096 3321 00... - Page 18 Instruction book Flow diagram, GA Workplace Full-Feature Reference Description Intake air Air/oil mixture Wet compressed air Condensate Dry compressed air Note: The cooling fan is not provided on water-cooled compressors. Description Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. A mix of compressed air and oil flows into the air receiver/oil separator (AR) via check valve (CV).
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Page 19: Oil System
Instruction book Check valve (CV) prevents blow-back of compressed air when the compressor is stopped. Minimum pressure valve (Vp) prevents the receiver pressure (AR) from dropping below a minimum pressure during unloaded operation. 2.3 Oil system Flow diagram Oil system References Description For Workplace units, compressed air flow to the air outlet valve... -
Page 20: Cooling System
Instruction book Air pressure forces the oil from air receiver/oil separator (AR) through oil filter (OF) and oil stop valve (Vs)to compressor element (E). Bypass valve (BV) starts opening the supply from cooler (Co) when the oil temperature has increased to the set point. - Page 21 Instruction book Cooling system,water-cooled compressors References Description Intake air Air/oil mixture Wet compressed air Condensate Water flow Description The cooling system comprises air cooler (Ca) and oil cooler (Co). On air-cooled compressors, the cooling air flow is generated by fan (FN). Water-cooled compressors are connected to a cooling water circuit.
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Page 22: Condensate System
Instruction book 2.5 Condensate system Water drains Condensate drains, typical example Reference Designation Automatic drain connection Automatic drain connection of the dryer (only on Full-Feature units) Electronic condensate drains, typical example The compressors have an electronic water drain (EWD). The condensate from the air cooler accumulates in a collector. -
Page 23: Regulating System
Instruction book 2.6 Regulating system Flow diagram Regulating system (loaded condition) Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results: • The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank pressure (1) via the solenoid valve. -
Page 24: Electrical System
Instruction book Electrical system General Also consult sections Electrical diagrams Electrical connections. Electrical components The electrical system comprises following components: F16/17/18 F1/2/3 X103 X117 X108 X108A Electric cubicle Reference Designation Fuses (F3 is only provided in case a phase sequence relay is F1/2/3 provided) Overload relay fan motor... - Page 25 Instruction book Reference Designation Transformer Terminal strip (voltage supply) X103/X108/X108 Connectors A/X117 Earth terminal 9096 3321 00...
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Page 26: Electrical Diagrams
Instruction book Electrical diagrams Service diagram for GA37+ up to GA 75 9096 3321 00... - Page 27 Instruction book Reference Designation Emergency stop Overload, compressor motor, fan motor and Phase Sequence Relay (PSR) Remote start/stop Fault, EWD Remote pressure sensing Remote load/unload (closed = load) Pressure drop over DD filter Pressure drop over PD filter Remote pressure set selection (10) ES 100 (if installed) (11)
- Page 28 Instruction book Reference Motors Compressor motor Fan motor (on air-cooled compressors) Fan motor, cubicle (on water-cooled compressors) Reference Electric cabinet F1-18 Fuses Overload relay, drive motor Line contactor Star contactor Delta contactor Transformers 1X0-1X5 Terminal strips X101-133 Connectors Reference Compressor control module Start button Stop button Emergency stop button...
- Page 29 Instruction book Optional equipment Reference Designation Expansion module Electronic water drain (EWD) (Full-Feature) K04' Auxiliary relay, load/unload for ES100 Auxiliary contact, compressor running for ES100 Phase sequence relay PDS11 Delta p switch for integrated DD filter PDS12 Delta p switch for integrated PD filter R1, K34 Drive motor thermistor protection, shut-down R2, K35...
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Page 30: 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 Thermostatic expansion valve Hot gas by-pass valve Condenser cooling fan Pressure switch, fan control Compressed air circuit... - Page 31 Instruction book Refrigerant circuit Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most of the refrigerant condenses. The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to thermostatic expansion valve (8). The refrigerant leaves the thermostatic expansion valve at evaporating pressure. The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further evaporation at constant pressure.
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Page 32: Elektronikon Graphic Controller
Instruction book Elektronikon® Graphic controller 3.1 Elektronikon® Graphic regulator Control panel ® Display of the Elektronikon Graphic controller Introduction In general, the Elektronikon regulator has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service •... - Page 33 The regulator has a built-in function to automatically restart the compressor if the voltage is restored after voltage failure. For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. If 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.
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Page 34: Control Panel
Instruction book 3.2 Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Shows the compressor operating condition and a Display number of icons to navigate through the menu. Pictograph Automatic operation Pictograph General alarm General alarm LED Flashes if a shut-down warning condition exists. -
Page 35: Icon Used
Instruction book Icons used Status icons Name Icon Description When the compressor is stopped, the icon stands still. Stopped / Running When the compressor is running, the icon is rotating. Compressor status Motor stopped Running unloaded Running loaded Machine control mode Local start / stop Remote start / stop Network control... - Page 36 Instruction book Input icons Icon Description Pressure temperature Digital input Special protection System icons Icon Description Compressor element (LP, HP, ...) Dryer Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm 9096 3321 00...
- Page 37 Instruction book Menu icons Icon Description Inputs Outputs Alarms (Warnings, shutdowns) Counters Test Settings Service Saved data Access key / User password Network Setpoint Navigation arrows Icon Description Down 9096 3321 00...
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Page 38: Main Screen Menu
Instruction book Main screen menu Control panel Function The Main screen menu shows the status of the compressor operation and is the gateway to all functions implemented in the regulator. The Main screen is shown automatically when the voltage is switched on. The display indicates: Main screen •... - Page 39 Instruction book Text on figures Reference Description Compressor Outlet Element Outlet Menu To call-up more information, select the icon using the scroll keys (1) and press the enter key (2). • Status bar (C) • Action buttons (D). These buttons are used: •...
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Page 40: Calling Up Menus
Instruction book 3.5 Calling up menus Control panel Control panel Description When the voltage is switched on, the main screen is shown automatically. • Highlight the menu button using the scroll keys (1) • Press the enter key (2) to select the menu, following screen appears: 9096 3321 00... -
Page 41: Inputs Menu
Instruction book • The screen shows a number of icons. Each icon indicates a menu item. As a standard, the pressure settings icon is selected. The status bar shows the name of the menu that corresponds with the selected icon. Use the scroll keys (1) to jump from one icon to another. •... - Page 42 Instruction book Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the inputs icon (see above, section Menu icon) •...
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Page 43: Outputs Menu
Instruction book Outputs menu Control panel Menu icon, outputs Function To call up information regarding the actually measured data and the status of some inputs such as the motor overload protection. Procedure Starting from the Main screen (see Main screen): •... - Page 44 Instruction book Text on figure Configuration Pressure Settings Main screen • Move the cursor to the outputs icon (see above, section Menu icon, using the scroll keys (1) • Press the enter key (2), a screen similar to the one below appears: Analog &...
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Page 45: Counters
Instruction book Counters Control panel Menu icon, counters Function To call up: • The running hours • The loaded hours • The number of motor starts • The number of hours that the regulator has been under tension • The number of load cycles 9096 3321 00... - Page 46 Instruction book Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings Main screen • Using the scroll keys (1), move the cursor to the counters icon (see above, section Menu icon) •...
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Page 47: Settings Menu
Instruction book Settings menu Control panel Menu icon, settings Function To modify a number of parameters. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Menu screen 9096 3321 00... -
Page 48: Service Menu
Instruction book Text on figure Configuration Pressure Settings Main screen • Using the scroll keys (1), move the cursor to the settings icon (see above, section Menu icon) • Press the enter key (2), a screen similar to the one below appears: 3.10 Service menu Control panel... - Page 49 Instruction book Text on figure Configuration Pressure Settings Main screen • Using the scroll keys (1), move the cursor to the service icon (see above, section Menu icon) • Press the enter key (2), following screen appears: • Scroll through the items to select the desired item and press the enter key (2). 9096 3321 00...
- Page 50 Instruction book Overview The overview screen shows all the running and Real Time hours Example for service level (A): The first row from shows the running hours when the first service is needed (light green), the value on the right side of the status bar is the remaining time left (dark green). The second row shows the Real Time hours Service plans A number of service operations are grouped (called Level A, Level B, etc...).
- Page 51 Instruction book Use the scroll keys (1) to select the value to be modified. Press the enter key (2), following screen appears: Modify the value as required using the up or down scroll key (1). Running hours can be modified in steps of 100 hours, real time hours can be modified in steps of 1 hour. Next Service 9096 3321 00...
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Page 52: Setpoint Menu
Instruction book The first row shows that service was done at 6223 Running hours and Real Time hours 7976. The following rows show the running hours and real time for the next service Levels (A, B, C) which need to be done at 7000 Running hours History The history screen shows a list of all service actions done in the past, these actions are sorted by date. - Page 53 Instruction book Function If necessary, the operator can program two different setpoints. This menu is also used to select the active setpoint. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings...
- Page 54 Instruction book Unloading pressure 2 Loading pressure 2 Back Modify • The screen shows the actual unloading and loading pressure settings for both pressure bands. To modify settings, move the cursor to the action button Modify and press the enter key, following screen appears: •...
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Page 55: Event History Menu
Instruction book 3.12 Event history menu Control panel Menu icon, event history Function To call up the last shut-down and last emergency stop data. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings... -
Page 56: Modifying General Settings
Instruction book • Using the scroll keys (1), move the cursor to the event history icon (see above, section Menu icon) • The list of last shut-down and emergency stop cases are shown. • Scroll through the items to select the desired shut-down or emergency stop item. •... - Page 57 Instruction book Text on figure Configuration Pressure Settings Main screen • Using the scroll keys (1), move the cursor to the settings icon (see above, section menu icon). • Press the enter key (2). • Navigate to the settings icon (see above) using the scroll keys (1) and press the enter key (2), following screen appears: •...
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Page 58: Info Menu
3.14 Info menu Control panel Menu icon, info Function To show the Atlas Copco internet address. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears:... -
Page 59: Week Timer Menu
Pressure Settings Main screen • Using the scroll keys (1), move the cursor to the info icon (see above, section Menu icon) • Press the enter key (2), the Atlas Copco internet address appears on the screen. 3.15 Week timer menu... - Page 60 Instruction book Text on figure Configuration Pressure Settings Main screen • Using the scroll keys (1), move the cursor to the timer icon (see above, section Menu icon) • Press the enter key (2), following screen appears: • The screen shows two items, week schemes and week cycle. Programming week schemes •...
- Page 61 Instruction book • Select the week to be programmed and press the enter key, following screen appears: • Select the day to be programmed and press the enter key, following screen appears: • Select the action to be programmed and press the enter key, a pop-up screen shows all possible actions: 9096 3321 00...
- Page 62 Instruction book • Use the scroll keys (1) to select the action to be programmed and press the enter key. • Select the corresponding time field for the action and press the enter key. Program the time using the up or down scroll key, use the right and left scroll keys to jump between hours and minutes. Programming the week cycle A week cycle is a sequence of 10 weeks.
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Page 63: Test Menu
Instruction book 3.16 Test menu Control panel Menu icon, test 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): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: 9096 3321 00... -
Page 64: User Password Menu
Instruction book Text on figure Configuration Pressure Settings Main screen • Using the scroll keys (1), move the cursor to the test icon (see above, section Menu icon) • Press the enter key (2), following screen appears: • The safety valve test can only be performed by authorized personnel and is protected by a security code. -
Page 65: Programmable Settings
Instruction book Function If the password option is activated, it is impossible for not authorized persons to modify any setting. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings... - Page 66 Instruction book Minimum Factory Maximu setting setting m setting Unloading pressure bar(e) Unloading pressure bar(e) Unloading pressure bar(e) 10.3 10.8 Unloading pressure bar(e) 12.5 Loading pressures Loading pressure (7.5 bar compressors) bar(e) Loading pressure (8 bar compressors) bar(e) Loading pressure (10 bar compressors) bar(e) Loading pressure (13 bar compressors) bar(e)
- Page 67 The built-in service timers will give a Service warning message after their respective preprogrammed time interval has elapsed. Also see section Preventive maintenance schedule. Consult Atlas Copco if a timer setting has to be changed. The intervals must not exceed the nominal intervals and must coincide logically. See section Modifying general settings. Terminology...
- Page 68 Instruction book Term Explanation Use only Atlas Copco oil separators. The recommended maximum pressure drop over the Oil separator oil separator element is 1 bar . Once the compressor has automatically stopped, it will remain stopped for the minimum Minimum stop stop time (approx.
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Page 69: Osci (Optional)
Instruction book OSCi (optional) 4.1 Introduction Compressed air produced by oil-injected compressors contains a small quantity of oil. During the cooling of the air in the aftercooler and in the refrigeration dryer (on compressors with built-in refrigeration dryer), oil- containing condensate is formed. The OSCi is a condensate treatment device, designed to separate the major part of this oil from the condensate and to sorb it in its replaceable filters, thus preventing contamination of the environment. -
Page 70: Operation
Instruction book 4.2 Operation General Condensate flow scheme Condensate inlet Foam cover Oleophilic filter Service drains with valve Air injection connection OGC filter Activated carbon filter Condensate test outlet Condensate outlet The OSCi 3790 housing consists of 3 interconnected vessels. The oil-containing condensate is injected (1) in discontinuous bursts at a downward angle into the first vessel which acts as expansion chamber. - Page 71 Instruction book A level switch (7 - View of OSCi), connected to the Elektronikon® regulator of the compressor monitors the condensate level in the second vessel. During normal operation this switch is in the closed position, so that any abnormality (a too high condensate level) opens the electric circuit and triggers the alarm, which is made visible on the Elektronikon®...
- Page 72 Instruction book View of OSCi Clamping ring Foam cover Location of sample bottles and connection material (during shipping only) Service drains with valve Fixation bolts Wire and tube clamp Overflow switch Filter position sensor and visual indication of the filter position 9096 3321 00...
- Page 73 Instruction book Detail views View of OSCi inlet Filter position sensor Condensate inlet connections View of OSCi outlet 9096 3321 00...
- Page 74 Instruction book Condensate outlet Condensate test outlet Condensate outlet connection of the OSCi Condensate sample valve Manual drain connections of the EWD's 9096 3321 00...
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Page 75: Putting Into Operation (Commissioning)
Instruction book 4.3 Putting into operation (commissioning) 1. Verify that the OSCi drain valves (4) are closed. 2. Unscrew the clamping ring (1) of the cover of the first vessel of the OSCi and take off the cover (2). 3. Take out the CDROM and the box (3) with the test bottle and the reference bottle and keep them in a safe place nearby the compressor. -
Page 76: Pictographs
Instruction book 5. Connect an outlet tube leading to the sewage system (19 mm inner diameter). Since the OSCi functions at atmospheric pressure, the outlet piping must always be positioned below the outlet connection on the OSCi vessel 3, unless a pump (able to run dry) is installed (not provided). 6. -
Page 77: Data Displayed During Normal Operation
Instruction book 4.6 Data displayed during normal operation The normal starting display on the Elektronikon® Graphic will look like indicated on the following Picture.Press the enter arrow to reach the following display. Reference Description Reference Description Compressor outlet Unload Element outlet Menu Load Regulation... -
Page 78: Warning
Instruction book Reference Description OSCi overflow Warnings Service required This warning indicates that the remaining filter lifetime has dropped below 10%. In this case a service kit with new filters needs to be ordered. The “service” LED will light up at the right side of the Elektronikon® Graphic. - Page 79 Instruction book Reference Description Reference Description Protections Service Reset Level Once the filter has reached a lifetime below 10%, this warning will remain active until new filters are inserted correctly (sensor arm in tower 1 should rest on the filter edge!). When the new filters are installed correctly and the percentage is above 10% (normally between 90% and 100%), press enter to reset the status.
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Page 80: Maintenance
Instruction book In this display you can see that an overflow warning is issued (blinking “Yes”), indicating that the water level in the OSCi is too high. By fixing the problem (see section Problem solving, fault 2 or 3), this warning will disappear automatically. - Page 81 Instruction book 3. Compare the turbidity of the sample with the reference 15 ppm turbidity bottle. 4. If the turbidity of the test sample is more intense than the reference turbidity, a request for servicing should be initiated, to be carried out within 2 weeks time. The vertical position of the test outlet ensures that there is enough clean activated carbon left above this position to keep the condensate under 15 ppm for at least 2 weeks (valid for a GA 90 with dryer which runs 24 h/day at reference conditions).
- Page 82 Instruction book 11. Pour clean water along the inner edge of vessel 1 until water flows out of the outlet tube (1-View of OSCi outlet), or until the water reaches the bottom of the sensor chamber (visible through the sight- glass).
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Page 83: Services Kits
Instruction book Service kits Your Atlas Copco Customer Centre will be glad to provide you with a wide range of service kits. Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. - Page 84 Instruction book Condition Fault Remedy Water is present on the floor A connection is leaking. A Stop the compressor. Open the side around the compressor (and on push-in coupling is leaking. panel and inspect the OSCi (remove the compressor frame). the covers from the vessels).
- Page 85 Instruction book Condition Fault Remedy No enough airflow during Disconnect the strainer (4-View of OSCi the test. inlet) and take out the strainer. Clean the strainer and the nozzle with compressed air and dry tissue. Check that the air tube does not touch any other components and is not hindered in any way.
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Page 86: Energy Recovery (Optional)
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 87: 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 88: Operation
To minimize these problems, the water should meet a number of requirements. See section Cooling water requirements. If in any doubt, consult Atlas Copco. Operation General The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable compressor operation and optimum energy recovery. - Page 89 Instruction book Re fe re nce De s ignation Re fe re nce De s ignation Thermostatic bypass valve of ER unit OF Oil filter Oil/water heat exchanger (ER unit) Oil separator vessel Compressor element Thermostatic bypass valve in oil filter housing Oil cooler (compressor) Aftercooler (compressor)
- Page 90 Instruction book ER label 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.
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Page 91: 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. 9096 3321 00... -
Page 92: Energy Recovery Data
Instruction book Energy recovery data Reference conditions See section Reference conditions and limitations. Effective working pressure Consult section Compressor data for the normal working pressure. Maximum allowed pressure of the heat exchanger Oil side 15bar Water side 10bar Reading settings In addition to other data, the following temperatures can be read on the Elektronikon display: For air-cooled units: •... - Page 93 Instruction book Data for low temperature rise/high water flow systems Parameter Unit GA37+ GA45+ GA55 GA75 Recoverable energy 32.5 39.6 48.4 Water flow l/min 46.6 56.7 69.3 94.5 Temperature at inlet °C Temperature at outlet °C Data for high temperature rise/low water flow systems Parameter Unit GA37+...
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Page 94: Installation
Instruction book Installation Dimension drawings DRYER COMPRESSOR COOLING AIR ELECTRICAL CABLE COOLING AIR OUTLET OUTLET PASSAGE Ø65(2X) COMPRESSED AIR OUTLET Watercooler G 1 1/2" F Water outlet DRYER G1 1/2" M COOLING AIR INLET Watercooler Water inlet VIEW"X" G 1 1/2" M Energy Recovery Water outlet G 1"... - Page 95 Instruction book Reference Designation Electric cable passage Cooling water outlet Cooling water inlet Dryer cooling air outlet Compressor cooling air outlet Compressed air outlet Dryer Cooling air inlet Compressor cooling air inlet Cubicle cooling air inlet Energy recovery inlet Energy recovery outlet Compressed air, dryer bypass outlet Automatic drain, aftercooler Automatic drain, dryer (On Workplace Full-Feature units)
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Page 96: Installation Proposal
Instruction book 6.2 Installation proposal Compressor room example VENTILATION PROPOSALS Minimum free area to be reserved for the compressor installation. 1000 ALT. 1 ALT. 2 1000 ALT. 4 ALT. 3 COOLING SYSTEMS ALT. 1 ALT. 4 ALT. 2 ALT. 3 9820 3539 01 9820 3539 00 56537D... - Page 97 Max. allowable pressure drop in ducting before or after the compressor = 30 Pa 5 The drain pipes to the drain collector must not dip into the water of the drain collector. 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 requiremen 6 Control module with monitoring panel.
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Page 98: Electrical Connections
Instruction book 11 By-pass system to by-pass the dryer during service operations (available as an option, consult Atlas Copco). On water-cooled compressors: Water flow and pressure to be adjusted depending upon local conditions. For cooling water quality see section Cooling water requirements. - Page 99 Instruction book Electrical connections All voltages (50 and 60Hz) All other voltages 9820 3549 11-00 Reference Designation Customer's installation Contactors type 3RT106 with 6 fuses type 1 All other variants with 3 fuses type1 Option dryer All voltages (50 and 60 Hz) Star connection: all other voltages 9096 3321 00...
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Page 100: Cooling Water Requirements
Instruction book Re fe re nce De s ignation Delta connection: 200/220/230 V - 50/60 Hz Instructions 1. Provide an isolating switch. 2. Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals. 3. - Page 101 Instruction book • B : depends on the highest cooling water temperature (°C),For GA/GR units take T = 75 °C • C : depends on the calcium hardness (ppm CaCO3) • D : depends on the HCO3- concentration or M-alkalinity (mval/l) •...
- Page 102 Instruction book Tendency of the water Action 7.6 < RSI < 9.0 Strong corrosion Regular control necessary, use of corrosion inhibitor recommended 9.1 <RSI<11 Very strong corrosion Regular control necessary, use of corrosion inhibitor required RSI > 11 Very strong corrosion in the Water should not be used complete water circuit This table indicates that distilled or demineralised water should never be used, as their RSI is...
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Page 103: Pictographs
Instruction book 14. Additives If it should be necessary to use additives in the cooling water, take into account that the cooling capacity will change. Remarks: • Chloride and sulphate are interactive. In pass-through systems the sum of the squares must not exceed 85000. - Page 104 Instruction book Reference Designation Torques for steel (Fe) or brass (CuZn) bolts Lightly oil gasket of oil filter, screw it on and tighten by hand (approx. half a turn) Warning: stop the compressor before repairing fans Warning: switch off the voltage before removing protecting cover inside electric Consult the instruction book before carrying out maintenance Cooling water outlet Cooling water inlet...
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Page 105: Operating Instructions
Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below 0 °C , precautions must be taken. In this case, and also if operating above 1000 m , 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 106: Initial Start-Up
This results in loading and unloading of the compressor at the closing and opening pressures of the external pressure switch respectively. See section Electrical system to locate the connectors. • LAN control: The compressor is controlled via a local network. Consult Atlas Copco. 7.2 Initial start-up Safety The operator must apply all relevant Safety precautions. Procedure... - Page 107 Instruction book Air receiver transport fixtures Motor and gear casing transport fixtures 9096 3321 00...
- Page 108 Instruction book F16/17/18 F1/2/3 X103 X117 X108 X108A Electric cubicle ,GA 37 up to GA 75 Consult the sections Electric cable size, Installation proposal Dimension drawings The following transport fixtures, painted red, must be removed: Bolts (1) Bushes (2) Supports (3) Check that the electrical connections correspond to the applicable codes and that all wires are clamped tight to their terminals.
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Page 109: Before Starting
Instruction book Check the oil level. See section Oil and oil filter change. Provide labels, warning the operator that: The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco). On water-cooled compressors, close the cooling water drain valves. Open the cooling water inlet valve and the regulation valve. -
Page 110: Starting
Instruction book Procedure 56756F Location of Unloader 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. If the pointer registers in the LOW range, depressurize the oil system (see section Problem solving). - Page 111 Instruction book Control panel Elektronikon Graphic c t i a t l a t l g i l . l e c i t g i l c t i a t l n i l a t i ° °...
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Page 112: 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) in an ambient temperature of 20 °C and at a relative air humidity of 100%, the minimum temperature to prevent condensate from forming is 68 °C . - Page 113 Instruction book Position of the oil level gauge Regularly check the oil level during loaded operation. The pointer of level gauge (Gl) must register in the green range. If the oil level is too low, press stop button (9). Wait until the compressor has stopped and depressurised and push the emergency stop button (10) to avoid the compressor to start unexpectedly.
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Page 114: Checking The Display
Instruction book Air filter Position of the service indicator Regularly check the service indicator. If the coloured part of service indicator (VI) shows full out, replace the air filter element. Reset the service indicator by pushing the knob in the extremity of the indicator body. Drains Regularly check that condensate is discharged during operation. -
Page 115: Stopping
Instruction book service plan interval has been exceeded or if a service level for a monitored component has been exceeded. Carry out the service actions of the indicated plans or replace the component and reset the relevant timer, see section Service menu. - Page 116 Instruction book Procedure Step Action Stop the compressor and close the air outlet valve. Press the test button on top of the electronic water drain(s) until the air system between air receiver and outlet valve is fully depressurized. Consult section Condensate system to locate the drain valve.
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Page 117: Maintenance
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 118 Instruction book Intervals The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor. The longer interval checks must also include the shorter interval checks. Service plans for compressors with an Elektronikon® Graphic controller Besides the daily and 3-monthly checks, preventive service operations are specified in the schedule below.
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Page 119: Drive Motor
(2): or every 2 years, whichever comes first Important Always consult Atlas Copco if a timer setting has to be changed. For the change interval of oil and oil filter in extreme conditions of temperature, humidity or cooling air, consult your Atlas Copco Customer Centre. -
Page 120: Oil Specifications
It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of field experience and research in our labs. See section Preventive maintenance schedule for replacement intervals and section Service Kits for part number information. - Page 121 Instruction book Procedure Oil system components Oil drain plugs 9096 3321 00...
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Page 122: Disposal Of Used Material
Instruction book Run the compressor until w arm. Stop the compressor after 3 minutes of unloaded operation. Close the air outlet valve and switch off the voltage. W ait a few minutes and depressurise by unscrewing oil filler plug (FC) just one turn to permit any pressure in Loosen the vent plug of the oil cooler and w ait for 5 minutes. -
Page 123: Service Kits
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 124: Adjustments And Servicing Procedures
Instruction book Adjustments and servicing procedures Air filter Location of air filter Air filter Service indicator Recommendations 1. Never remove the element while the compressor is running. 2. For minimum downtime, replace the dirty element by a new one. 3. Discard the element when damaged. 9096 3321 00... -
Page 125: Coolers
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) . • If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco. • Remove the cover used during cleaning. -
Page 126: Safety Valves
Instruction book Safety valves Location of safety valve Operating Operate the safety valve by unscrewing the cap one or two turns and retighten it. Testing Before removing the valve, depressurise the compressor. See section Problem solving. Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure stamped on the valve, it needs to be replaced. -
Page 127: Problem Solving
Instruction book Problem solving 10.1 Problem solving Warning Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped (approx. 30 seconds) and close the air outlet valve. P ress the test button on top of the electronic water drain unit the air system between the air receiver and outlet valve is fully depressurized. - Page 128 Oil separator clogged Have element replaced Air leakage Have leaks repaired Safety valve leaking Have valve replaced Compressor element out of Consult Atlas Copco order Condition Fault Remedy Excessive oil flow through air Check valve leaking or oil Replace defective parts.
- Page 129 If installed, check capacity of compressor room On water-cooled Increase flow compressors, cooling water flow too low On water-cooled Consult Atlas Copco compressors, restriction in Customer Centre cooling water system Oil cooler clogged Clean cooler By-pass valve malfunctioning Have valve tested...
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Page 130: Technical Data
Instruction book Technical data 11.1 Readings on display Display of the Elektronikon® Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limitations). Type Approval FF (1) Recommended Recommended Main fuses P (1) wire section wire section (A) (4) GA 37+... -
Page 131: Electric Cable Size And Main Fuses
Instruction book 11.2 Electric cable size and main 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 132: Settings Of Fan Motor Circuit Breaker
Instruction book Recommended cable size (Pack and Full-Feature) Type Approval I FF (1) Recommended Recommended Main fuses P (1) wire section (2) wire section (A) (4) GA 37+ 100 (50) 4 X 35 mm 4 X 70 mm GA 45+ 125 (63) 4 X 50 mm 7 X 25 mm... -
Page 133: Dryer Switches
Instruction book Maximum allowed fuse ratings 11.5 Dryer switches General The regulating and safety devices are factory-adjusted to give optimum performance of the dryer. Do not alter the setting of any of the devices. 11.6 Reference conditions and limitations Reference conditions Air inlet pressure (absolute) Air inlet temperature °C... -
Page 134: Compressor Data
Instruction book On water-cooled units also: Maximum cooling water outlet temperature °C Maximum cooling water inlet pressure bar(e) 11.7 Compressor data Reference conditions All data specified below apply under reference conditions, see section Reference conditions and limitations. GA 37+ Units 7.5 bar 8 bar 10 bar... - Page 135 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar Temperature of air leaving outlet valve (approx.),water-cooled Units without dryer Temperature of air leaving outlet valve (approx.),Full-Feature units Pressure dewpoint, Full-Feature units Drive motor, 1LA5 1LA5 1LA5 1LA5 SIEMENS 209-2 209-2 209-2...
- Page 136 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar Refrigerant type, R410A R410A R410A Full-Feature units Refrigerant quantity, Full-Feature units Refrigerant quantity, 1.00 0.97 0.97 0.97 Full-Feature units l/min Cooling water consumpation ( at water inlet temperature below 35 temperature rise of 15 C ), water cooled units...
- Page 137 Instruction book GA 45+ Un its 7 .5 ba r 8 b ar 10 b ar 1 3 ba r F requency M axim u m (un lo ading) bar(e ) 7 .5 P ressure,units without d ryer M axim u m (un lo ading) bar(e ) 7 .25 7.75...
- Page 138 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar Drive motor, 1LA9 1LA9 1LA9 1LA9 SIEMENS 209-2 209-2 209-2 209-2 Motor shaft speed r/min 2965 2965 2965 2965 Nominal motor rating Power consumpation dryer at full load, Full-Feature units Power consumption dryer at full load, Full-Feature units...
- Page 139 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar l/min Cooling water consumpation ( at water inlet temperature between 35 and 40 temperature rise of 10 C ), water cooled units Oil capacity, air-cooled units Oil capacity, water-cooled units Sound pressure level, dB(A)
- Page 140 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar Set point,thermostatic valve Temperature of air leaving outlet valve (approx),air- cooled units without dryer Temperature of air leaving outlet valve (approx),water- cooled units without dryer Temperature of air leaving outlet valve (approx.),Full- Feature units Pressure dewpoint,Full-...
- Page 141 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar Refrigerant type,Full-Feature R404a R404a R404a R404a units Refrigerant type,Full-Feature R410A R410A R410A R410A units (1) Refrigerant quantity, Full- Feature units Refrigerant quantity, Full- 0.97 0.97 1.00 0.97 Feature units (1) l/min 54.5 54.5...
- Page 142 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar Reference working bar(e) 12.5 pressure, units without dryer Reference working bar(e) 7.75 12.5 pressure, Workplace Full- Feature units Pressure drop over bar(e) 0.23 0.23 0.14 0.08 dryer, Full-Feature units Set point,thermostatic valve Temperature of air leaving...
- Page 143 Instruction book Units 7.5 bar 8 bar 10 bar 13 bar Power consumption dryer at full load,Full-Feature units Power consumpation Dryer at no load, Full- Feature units Power consumpation Dryer at no load, Full- Feature units (1) Refrigerant type,Full-Feature R404a R404a R404a R404a...
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Page 144: Technical Data Elektronikon Controller
Instruction book 11.8 Technical data Elektronikon® controller General Parameter Value Supply voltage 24 V AC /16 VA 50/60Hz (+40%/-30%) 24 V DC/0.7 A Type of protection IP54 (front) IP21 (back) Ambient and temperature IEC60068-2 conditions Temperature range Operating -10°C…..+60°C Storage -30°C…..+70°C Permissible humidity Relative humidity 90% No condensation... -
Page 145: Instructions For Use Of Air Receiver
Instruction book Instructions for use of air receiver 12.1 Instructions for use 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 146: Guidelines For Inspection
Instruction book Guidelines for inspection 13.1 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 147 Instruction book Notes: .....................
- Page 150 In order to be First in Mind-First in Choice ® for all your quality compressed air needs, Atlas Copco delivers the products and services that help to increase your business’ efficiency and profitability. Atlas Copco's pursuit of innovation never ceases, driven by our need for reliability and effeciency.