Atlas Copco GA 75+ Instruction Book
  1. Manuals
  2. Brands
  3. Atlas Copco Manuals
  4. Air Compressor
  5. GA 75+
  6. Instruction book

Atlas Copco GA 75+ Instruction Book

Oil-injected rotary screw compressors
Hide thumbs
Table of Contents

Advertisement

Quick Links

Atlas Copco
Oil-injected rotary screw compressors
GA 55+, GA 55, GA 75+, GA 75, GA 90
Instruction book

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GA 75+ and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Atlas Copco GA 75+

Summary of Contents for Atlas Copco GA 75+

  • Page 1 Atlas Copco Oil-injected rotary screw compressors GA 55+, GA 55, GA 75+, GA 75, GA 90 Instruction book...
  • Page 3 Atlas Copco Oil-injected rotary screw compressors GA 55+, GA 55, GA 75+, GA 75, GA 90 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................7 ...........................7 AFETY ICONS ......................7 AFETY PRECAUTIONS GENERAL ...................8 AFETY PRECAUTIONS DURING INSTALLATION ....................9 AFETY PRECAUTIONS DURING OPERATION .................10 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................12 ..........................12 NTRODUCTION ............................16 IR FLOW ............................18 IL SYSTEM ..........................19 OOLING SYSTEM ........................21...
  • Page 5 Instruction book 3.11 .......................40 ALLING UP MOTOR STARTS 3.12 .......................41 ALLING UP MODULE HOURS 3.13 ......................41 ALLING UP LOADING HOURS 3.14 ........................41 ALLING UP LOAD RELAY 3.15 ..................42 ALLING UP RESETTING THE SERVICE TIMER 3.16 ................43 ELECTION BETWEEN LOCAL REMOTE OR CONTROL 3.17 ..................43...
  • Page 6 Instruction book ...........................80 NPUTS MENU ..........................83 UTPUTS MENU ............................84 OUNTERS ........................86 ONTROL MODE SELECTION 4.10 ..........................88 ERVICE MENU 4.11 ..........................92 ETPOINT MENU 4.12 ........................94 VENT HISTORY MENU 4.13 ......................95 ODIFYING GENERAL SETTINGS 4.14 ............................97 NFO MENU 4.15 ...........................98 EEK TIMER MENU 4.16 ...........................107 EST MENU...
  • Page 7 Instruction book ...........................141 PERATION ..........................144 AINTENANCE ........................144 NERGY RECOVERY DATA Installation........................147 ........................147 IMENSION DRAWINGS .........................149 NSTALLATION PROPOSAL .......................152 LECTRICAL CONNECTIONS .......................154 OOLING WATER REQUIREMENTS ..........................158 ICTOGRAPHS Operating instructions....................160 ..........................160 NITIAL START ..........................163 EFORE STARTING ............................165 TARTING ........................166 URING OPERATION ........................169 HECKING THE DISPLAY ............................170 TOPPING...
  • Page 8 Instruction book 9.10 ......................181 TORAGE AFTER INSTALLATION 9.11 ......................182 ISPOSAL OF USED MATERIAL Problem solving......................183 Technical data......................187 11.1 ........................187 EADINGS ON DISPLAY 11.2 ......................188 LECTRIC CABLE SIZE AND FUSES 11.3 ........................192 ROTECTION SETTINGS 11.4 ...........................193 RYER SWITCHES 11.5 ..................193 EFERENCE CONDITIONS AND LIMITATIONS 11.6 ........................194 OMPRESSOR DATA...

  • Page 9: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions, general General precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.

  • Page 10: 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 11: Safety Precautions During Operation

    Instruction book 17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure. 18. If the ground is not level or can be subject to variable inclination, consult the manufacturer. Also consult following safety precautions: Safety precautions during operation Safety...

  • Page 12: Safety Precautions During Maintenance Or Repair

    Instruction book 11. Do not remove any of, or tamper with, the sound-damping material. 12. 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.
  • Page 13 Instruction book 15. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be put out of action. 16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures, temperatures and time settings are correct.

  • Page 14: General Description

    Instruction book General description Introduction GA 55 up to GA 90 are single-stage, oil-injected screw compressors driven by an electric motor. The compressors are available in air-cooled and water-cooled version. ® The compressors are controlled by an Elektronikon controller. GA Workplace GA Workplace compressors are enclosed in a sound-insulated bodywork.
  • Page 15 Instruction book Rear view, GA 55 up to GA 90 Reference Name Air outlet valve Air cooler Oil cooler CV/Vs Check valve/oil stop valve Compressor element Elektronikon®/Elektronikon® Graphic controller Cooling fan Drive motor Emergency stop button Unloader Da (Dm) Condensate outlets GA Workplace Full-Feature GA Workplace Full-Feature compressors are enclosed in a sound-insulated bodywork.
  • Page 16 Instruction book The dryer is integrated in the sound-insulated bodywork. The dryer removes water from the compressed air by cooling the air to near freezing point. The condensate is automatically drained. Front view, GA 55 up to GA 90 Full-Feature 2920 7109 60...
  • Page 17 Instruction book Rear view, GA 55 up to GA 90 Full-Feature 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 outlets Manual condensate outlets Dryer Compressor element Elektronikon®/Elektronikon®...

  • Page 18: Air Flow

    Instruction book Reference Name Unloader Air flow Flow diagrams Flow diagram, GA Workplace 2920 7109 60...
  • Page 19 Instruction book Flow diagram, GA Workplace Full-Feature Reference Description Intake air Air/oil mixture Wet compressed air Condensate Dried compressed air Note: The cooling fan is not provided on water-cooled compressors. Description Air drawn through filter (AF) and open inlet valve (IV) of unloader is compressed in compressor element (E). A mixture of compressed air and oil flows into the air receiver/oil separator (AR) via check valve (CV).

  • Page 20: Oil System

    Instruction book In all circumstances, minimum pressure valve (Vp) keeps the pressure in the separator tank (AR) above a minimum value, required for lubrication. An integrated check valve prevents the compressed air downstream the valve from being vented to atmosphere during unloaded operation. When the compressor is stopped, check valve (CV) and inlet valve (IV) close, preventing compressed air (and oil) to be vented into the air filter.

  • Page 21: 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 22 Instruction book Water-cooled compressors References Description Intake air Air/oil mixture Wet compressed air Water flow Description The cooling system on water-cooled compressors comprises air cooler (Cwa) and oil cooler (Cwo). They are connected to a cooling water circuit. The water flows through the inlet pipe, the coolers and the outlet pipe.

  • Page 23: Condensate System

    Instruction book Condensate system Drain connections The compressors have an centrifugal water separator WSD25 (1). The condensate formed in the air cooler accumulates in the collector. When the condensate reaches a certain level, it is discharged through the automatic drain outlet (Da). Also, the condensate water can be discharged manually through the manual drain outlet (Dm).

  • Page 24: Regulating System

    Instruction book Reference Designation Automatic drain connection Manual drain connection Automatic drain connection of the dryer (only on Full-Feature units) Manual drain connection of the dryer (only on Full-Feature units) Regulating system Load/unload regulating system Regulating system (loaded condition) Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised.

  • Page 25: Electrical System

    Instruction book • Unloading valve/blow-off valve (UV) moves upwards, connecting the oil separator tank pressure (1) with channels (2) and (3). • The pressure in channel (2) causes the loading plunger (LP) to move upwards, causing inlet valve (IV) to close, while the pressure is gradually released to atmosphere.

  • Page 26: Air Dryer

    Instruction book Reference Designation Transformer Earth terminal Electrical diagram The complete electrical diagram can be found in the electric cubicle. 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...
  • Page 27 Instruction book Reference Name Liquid separator Compressed air circuit Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the incoming air starts to condense. The air then flows through heat exchanger/evaporator (2), where the refrigerant evaporates, causing the air to be cooled further to close to the evaporating temperature of the refrigerant.

  • Page 28: Elektronikon® Regulator

    Instruction book Elektronikon® regulator ® Elektronikon regulator Control panel Introduction ® In general, the Elektronikon regulator has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) Automatic control of the compressor The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor.

  • Page 29: Control Panel

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

  • Page 30: Icons Used On The Display

    Instruction book Reference Designation Function LED, Service Is lit when service is needed. Start button This button starts the compressor. Automatic operation LED (3) lights up. The Elektronikon is operative. Stop button This button is used to stop the compressor. Automatic operation LED (3) goes out.
  • Page 31 Instruction book Function Icon Description Units Pressure unit (Mega Pascal) Pressure unit (pounds per square inch) Pressure unit (bar) Temperature unit Temperature unit Hours (always shown together with seconds) Percent The value shown must be multiplied by 10 to get the actual value The value shown must be multiplied by 100 to get the actual value...

  • Page 32: Main Screen

    The Main screen shows: • The compressor status by means of pictographs • The air outlet pressure Always consult Atlas Copco if the pressure on the display is preceded by a "t". Shut-down warning Description A shut-down warning will appear in the event of: •...
  • Page 33 Instruction book • Press Scroll down button (12). The screen shows the temperature at the compressor element outlet: It remains possible to scroll through other screens, using the Scroll buttons up and down (12) to check the actual status of other parameters. Press button (11) to stop the compressor and wait until the compressor has stopped.

  • Page 34: Shut-Down

    Instruction book Warning screen, dewpoint temperature The screen shows that the dewpoint temperature is 9˚C. • It remains possible to scroll through other screens (using Scroll buttons 12) to check the actual status of other parameters. • Press button (11) to stop the compressor and wait until the compressor has stopped. •...

  • Page 35: Service Warning

    Instruction book • Press Scroll buttons (12) until the actual compressor element temperature appears. Shut-down screen, element outlet temperature The screen shows that the temperature at the outlet of the compressor element is 120 ˚C. • Switch off the voltage and remedy the trouble. •...
  • Page 36 Instruction book • If the service timer exceeds the programmed time interval, alarm LED (5) will light up. • Press Scroll buttons (12) to scroll to <d.6> and the service symbol is shown. Press button (13): the actual reading of the service timer appears and is shown in <hrs> or <x1000 hrs> (if the service timer value is higher than 9999).

  • Page 37: Scrolling Through All Screens

    Instruction book • After servicing, reset the service timer. See section Calling up/resetting the service timer Scrolling through all screens Control panel Control panel Scroll buttons (12) can be used to scroll through all screens. The screens are divided into register screens, measured data screens, digital input screens (numbered as <d.in>, <d.1>, ...), parameter screens (numbered as <P.1>, <P.2>, ...), protections screens (numbered as <Pr.1>,...) and test screens (numbered as <t.1>,...).
  • Page 38 Instruction book Digital input Designation Related topic screens <d.4> Loading hours (hrs or x1000 hrs) See section Calling up loading hours <d.5> Load relay (x1 or x 1000) See section Calling up Calling up load relay <d.6> Service timer reading (hrs or x 1000 hrs) See section Calling up/resetting the service timer...
  • Page 39 Instruction book Test screens Designation Related topic <t.1> Display test See sections Test screens <t.2> Safety valve test See sections Test screens <t.3> Production test See sections Test screens Menu flow Simplified menu flow 2920 7109 60...

  • Page 40: Calling Up Outlet And Dewpoint Temperatures

    Instruction book Ref. Description Ref. Description Compressor outlet pressure (16) Pressure band setting Compressor outlet temperature (17) Service timer settings Dewpoint temperature (18) Temperature unit Digital input status (19) Unit pressure Running hours (20) Auto restart Motor starts (21) Selection Y-D/DOL Module hours (22) Load delay time...

  • Page 41: Calling Up Running Hours

    Instruction book The screen shows that the outlet temperature is 82 ˚C. • For Full-Feature compressors: Press Scroll button (12). The dewpoint temperature will be shown: The screen shows that the dewpoint temperature is 3 ˚C. • Press Scroll button (12) to scroll downwards or upwards through the screens. 3.10 Calling up running hours Control panel Starting from the Main screen:...

  • Page 42: Calling Up Motor Starts

    Instruction book The screen shows the unit used (x1000 hrs) and the value (11.25): the running hours of the compressor are 11250 hours. 3.11 Calling up motor starts Control panel Starting from the Main screen, press Scroll button (12) until <d. 2> is shown and then press Enter button (13). A screen similar to the following appears: This screen shows the number of motor starts (x 1 or - if <x1000>...

  • Page 43: Calling Up Module Hours

    Instruction book 3.12 Calling up module hours Control panel Starting from the Main screen, press Scroll button (12) until <d. 3> is shown and then press Enter button (13). A screen similar to the following appears: In the example shown, the screen shows the unit used (hrs) and the value (5000): the regulator module has been in service during 5000 hours.

  • Page 44: Calling Up/Resetting The Service Timer

    Instruction book • Press Scroll button (12) until <d.5> is shown and then press Enter button (13): This screen shows the number of unload to load actions (x 1 or - if <x1000> lights up - x 1000). In the above example, the number of unload to load actions is 10100.

  • Page 45: Selection Between Local, Remote Or Lan Control

    Instruction book This screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1191>. In the example shown, the compressor has run 1191 hours since the previous service. Resetting the service timer After servicing, see section Service warning, the timer has to be reset: •...
  • Page 46 Instruction book If necessary enter the password. The next screen shows that the function is ON or OFF. Press the Enter button (13) to change this mode. Use the Scroll buttons (12) to select <On> or <OFF> and press Enter to program. When this function is ON, use the Scroll buttons up or down (12) to see the node ID.

  • Page 47: Calling Up/Modifying Ip, Gateway And Subnetmask

    Instruction book Press the Enter button (13) to modify the setting. The utmost left value will blink. Change this value by using the Scroll buttons (12). Press the Enter button (13) to confirm. Change the other values in the same way, as required.
  • Page 48 Instruction book Modification Press the Enter button (13) and if necessary enter the password. The first digits are blinking. Use the Scroll buttons Up or Down (12) to modify the settings and press Enter (13) to confirm. Modify the next digits the same way.

  • Page 49: Calling Up/Modifying Pressure Band Settings

    Instruction book 3.19 Calling up/modifying pressure band settings Calling up the settings Starting from the Main screen: • Press Scroll button (12) until <P.04> is shown and then press Enter button (13). Pressure band 1 (<Pb.1>) is shown on the display. Button (12) can be used to scroll to pressure band 2 (<Pb.2>). •...

  • Page 50: Modifying The Pressure Band Selection

    Instruction book Unloading pressure • Press Enter button (13) to modify the load level (value starts blinking). A password may be required. Use Scroll buttons (12) to change the loading pressure. • Press Enter button (13) to program the new values or press the Escape button (14) to cancel. 3.20 Modifying the pressure band selection Control panel Starting from the Main screen:...

  • Page 51: Calling Up/Modifying Service Timer Settings

    Instruction book 3.21 Calling up/modifying service timer settings Control panel Starting from the Main screen: • Press Scroll button (12) until <P. 6> is shown and then press Enter button (13): the setting of the service timer is shown in <hrs> (hours) or <x1000 hrs> (hours x 1000). Example: <4000 hrs> means the timer is set at 4000 running hours.

  • Page 52: Calling Up/Modifying Unit Of Pressure

    Instruction book 3.23 Calling up/modifying unit of pressure Control panel Starting from the Main screen: • Press Scroll button (12) until <P.08> and the possible settings are shown (<Mpa>, <psi>, and <bar>). Press Enter button (13) and the actually used unit is shown. •...

  • Page 53: Calling Up Modifying Load Delay Time

    Instruction book • This parameter can only be modified after entering a code. Consult Atlas Copco if the parameter is to be changed. 3.26 Calling up modifying load delay time Control panel Starting from the Main screen: • Press Scroll button (12) until <P.11> and the compressor load pictograph is shown and press the Enter button (13): •...

  • Page 54: Activating Password Protection

    Instruction book • Press the Scroll button (12) until <P.12> and the motor pictograph is shown and press the Enter button (13): • This screen shows the minimum stop time (20) and the unit <s> (seconds). • To modify this value press the Enter button (13). The value starts blinking and Scroll buttons (12) can be used to modify this value.

  • Page 55: Calling Up/Modifying Protection Settings

    Instruction book • The function of this screen is to activate the remote load/unload relay. To be able to activate this remote Load/Unload functionality, a physical digital input with function Load/Unload is required. Once this parameter is activated, the physical digital input can be used to switch the compressor between Load and Unload.
  • Page 56 Instruction book • A low shut-down level, shown on the display as <Sd-L>. • A high shut-down level, shown on the display as <Sd-H>. • Service level shown on the display as <SE-L>. • Service level shown on the display as <SE-H>. Example of protection screens Changing the settings Starting from the Main screen (the example given describes the protection of the element outlet temperatures):...

  • Page 57: Test Screens

    Safety valve test In the test screen <t. 2>, a safety valve test is provided. The safety valves can only be tested after entering a code. Consult Atlas Copco if the safety valves are to be tested. Production test Test screen <t. 3> is only intended for production test. If the Main screen shows following screen, the controller...

  • Page 58: Web Server

    Instruction book Press the Enter button (13): the text starts blinking. Press enter again and the menu disappears. 3.32 Web server All Elektronikon controllers have a built-in web server that allows direct connection to the company network or to a dedicated PC via a local area network (LAN). This allows to consult certain data and settings via a PC instead of via the display of the controller.
  • Page 59 Instruction book Configuration of the network card • Go to My Network places (1). • Click on View Network connections (1). • Select the Local Area connection (1), which is connected to the controller. • Click with the right button and select properties (1). 2920 7109 60...
  • Page 60 Instruction book • Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked. After selecting TCP/IP, click on the Properties button (2) to change the settings. • Use the following settings: •...
  • Page 61 Instruction book • Click on the Connections tab (1) and then click on the LAN settings button (2). • In the Proxy server Group box, click on the Advanced button (1). 2920 7109 60...
  • Page 62 Instruction book • In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given but they must be separated with semicolons (;). Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture).
  • Page 63 Instruction book All screen shots are indicative. The number of displayed fields depends on the selected options. • Open your browser and type the IP address of the controller you want to view in your browser (in this example http://192.168.100.100). The interface opens: Navigation and options •...
  • Page 64 Instruction book Compressor settings All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen. Analog inputs Lists all current analog input values.
  • Page 65 Instruction book Digital outputs Lists all Digital outputs and their status. Special protections Lists all special protections of the compressor. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours.

  • Page 66: Programmable Settings

    Instruction book A possible ESi screen 3.33 Programmable settings Parameters: unloading/loading pressures for compressors without built-in refrigeration dryer Minimum Factory Maximum setting setting setting Unloading pressures Unloading pressure (7.5 bar compressors) bar(e) Unloading pressure (7.5 bar compressors) psig 59.5 101.5 108.8 Unloading pressure (8.5 bar compressors) bar(e)
  • Page 67 Instruction book Minimum Factory Maximum setting setting setting Loading pressure (13 bar compressors) psig 172.6 187.1 Loading pressure (100 psi compressors) bar(e) Loading pressure (100 psi compressors) psig 91.4 105.9 Loading pressure (125 psi compressors) bar(e) Loading pressure (125 psi compressors) psig 130.5 Loading pressure (150 psi compressors)
  • Page 68 Instruction book Minimum Factory Maximum setting setting setting Loading pressure (100 psi compressors) psig 91.4 Loading pressure (125 psi compressors) bar(e) Loading pressure (125 psi compressors) psig 127.5 Loading pressure (150 psi compressors) bar(e) 10.5 Loading pressure (150 psi compressors) psig 140.7 152.5...
  • Page 69 Minimum stop Once the compressor has automatically stopped, it will remain stopped for the minimum time stop time, whatever happens with the net air pressure. Consult Atlas Copco if a setting lower than 20 seconds is required. Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is Loading pressure programmed at 7.0 bar(e) (101 psi(g)), the maximum limit for the loading pressure changes...

  • Page 70: Elektronikon® Graphic Controller

    Instruction book Elektronikon® Graphic controller ® Elektronikon Graphic controller Control panel ® Display of the Elektronikon Graphic controller Introduction The Elektronikon controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) Automatic control of the compressor operation The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor (on compressors running at a fixed speed) or by adapting the motor speed...
  • Page 71 For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. If the function is 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.

  • Page 72: Control Panel

    Instruction book Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Display Shows the compressor operating condition and a number of icons to navigate through the menu. Pictograph Automatic operation Pictograph General alarm Alarm LED Flashes in case of a shut-down, is lit in case of a warning condition.

  • Page 73: Icons Used

    Instruction book Icons used Status icons Name Icon Description Stopped / Running When the compressor is stopped, the icon stands still. 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 74 Instruction book Name Icon Description Active protection functions Emergency stop Shutdown Warning Service Service required Main screen display Value lines display icon Chart display icon General icons No communication / network problem Not valid Input icons Icon Description Pressure Temperature Digital input Special protection 2920 7109 60...
  • Page 75 Instruction book System icons Icon Description Compressor element (LP, HP, ...) Dryer Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Menu icons Icon Description Inputs Outputs Alarms (Warnings, shutdowns) Counters Test 2920 7109 60...
  • Page 76 Instruction book Icon Description Settings Service Event history (saved data) Access key / User password Network Setpoint Info Navigation arrows Icon Description Down 2920 7109 60...

  • Page 77: Main Screen

    Instruction book Main screen Control panel Scroll keys Enter key Escape key Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed. Typically, 5 different main screen views can be chosen: 1.
  • Page 78 Instruction book Text on figures Compressor Outlet Element Outlet (fixed speed compressors) Load, shutdown, ... (text varies upon the compressors actual condition) Menu Unload, ES,...(text varies upon the compressors actual condition) Typical Main screen (4 value lines), fixed speed compressors Text on figures Compressor Outlet Load relay (one of the input signals of fixed speed compressors)
  • Page 79 Instruction book • Section D shows the Action buttons. These buttons are used: • To call up or program settings • To reset a motor overload, service message or emergency stop • To have access to all data collected by the regulator The function of the buttons depends on the displayed menu.
  • Page 80 Instruction book When the Chart (Low Resolution) is selected, the chart shows the variation of the selected input per day. The screen shows the evolution over the last 10 days. Selection of a main screen view To change between the different screen layouts, select the far right icon in the control icons line (see value lines display icon or chart display icon in section Icons used) and press the Enter key.

  • Page 81: Calling Up Menus

    Instruction book Calling up menus Control panel Control panel Scroll keys Enter key Escape key Description When the voltage is switched on, the main screen is shown automatically (see section Main screen): Typical Main screen (2 value lines) • To go to the Menu screen, highlight <Menu>(3), using the Scroll keys. •...

  • Page 82: Inputs Menu

    Instruction book • The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings (Regulation) icon is selected. The status bar shows the name of the menu that corresponds with the selected icon. •...
  • Page 83 Instruction book Procedure Starting from the main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on image Menu Regulation • Using the Scroll keys, move the cursor to the Inputs icon (see above, section Menu icon). •...
  • Page 84 Instruction book The first item in the list is highlighted. In this example, the Net Pressure is selected (chart icon). To change, press the Enter button again: a pop-up window opens: Press Enter again to remove this input from the chart. Another confirmation pop-up opens: Select Yes to remove or No to quit the current action.

  • Page 85: Outputs Menu

    Instruction book (1): Set as main chart signal Outputs menu Control panel Scroll keys Enter key Escape key Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact (on air cooled compressors), the Emergency stop contact, etc.

  • Page 86: Counters

    Instruction book Menu Regulation • Move the cursor to the Outputs icon (see above, section Menu icon, using the Scroll keys. • Press the Enter key. A screen similar to the one below appears: Outputs screen (typical) Text on image Outputs Fan motor contact Blow-off contact...
  • Page 87 Instruction book Scroll keys Enter key Escape key 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 powered •...

  • Page 88: Control Mode Selection

    Instruction book Counters Running hours Motor starts Load relay VSD 1-20 % rpm in % (the percentage of the time during which the motor speed was between 1 and 20 %) (compressors with frequency converter) The screen shows a list of all counters with their actual readings. Note: the example above is for a frequency converter driven compressor.
  • Page 89 Instruction book Next, use the scroll buttons to go to the regulation icon (2) and press the enter button: There are 3 possibilities: • Local control • Remote control • LAN (network) control After selecting the required regulation mode, press the enter button on the controller to confirm your selection. The new setting is now visible on the main screen.

  • Page 90: Service Menu

    Instruction book 4.10 Service menu Control panel Scroll keys Enter key Escape key Menu icon, Service Function • To reset the service plans which are carried out. • To check when the next service plans are to be carried out. •...
  • Page 91 Instruction book • Press the Enter key. Following screen appears: Text on image Service Overview Service plan Next service History • Scroll through the items to select the desired item and press the Enter key to see the details as explained below.
  • Page 92 Instruction book The figures within the bars are the number of hours to go till the next service intervention. In the example above, the compressor was just started up, which means it still has 4000 running hours or 8280 hours to go before the next Service intervention.
  • Page 93 Instruction book Modify the value as required using the ↑ or ↓ scroll key and press the Enter key to confirm. Note: Running hours can be modified in steps of 100 hours, real time hours can be modified in steps of 1 hour.

  • Page 94: Setpoint Menu

    Instruction book 4.11 Setpoint menu Control panel Scroll keys Enter key Escape key Menu icon, Setpoint Function On fixed speed compressors , the operator can program two different pressure bands. This menu is also used to select the active pressure band. Procedure Starting from the Main screen (see Main...
  • Page 95 Instruction book Menu Regulation • Move the cursor to the Setpoint icon (see above, section menu icon) using the Scroll keys. • Press the Enter key. Following screen appears: Text on figure Regulation Unloading pressure 1 Loading pressure 1 Unloading pressure 2 Loading pressure 2 Modify •...

  • Page 96: Event History Menu

    Instruction book 4.12 Event history menu Control panel Scroll keys Enter key Escape key Menu icon, Event History Function To call up the last shut-down and last emergency stop data. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: •...

  • Page 97: Modifying General Settings

    Instruction book Example of Event History screen • Scroll through the items to select the desired shut-down or emergency stop event. • Press the Enter key to find the date, time and other data reflecting the status of the compressor when that shut-down or emergency stop occurred.
  • Page 98 Instruction book • Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Next, move the cursor to the Settings icon (see above, section menu icon).using the Scroll keys. • Press the Enter key. Following screen appears: This screen shows again a number of icons.

  • Page 99: Info Menu

    Enter key Escape key Menu icon, Info Function To show the Atlas Copco internet address. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: 2920 7109 60...

  • Page 100: Week Timer Menu

    Instruction book • Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon). • Press the Enter key. The Atlas Copco internet address appears on the screen. 4.15 Week timer menu Control panel Scroll keys...
  • Page 101 Instruction book Important remark: In the Elektronikon you can select different timers on one day.(up to 8 actions). It is however not possible to program 2 actions at the same time. The solution: leave at least 1 minute in between 2 actions. Example: Start Compressor: 5.00 AM, Pressure Setpoint 2: 5.01 AM (or later).
  • Page 102 Instruction book Programming week schemes • Select Week action schemes and press Enter. A new window opens. The first item in the list is highlighted in red. Press the Enter key on the controller to modify Week Action Scheme 1. Week Action Schemes Week Action Scheme 1 Week Action Scheme 2...
  • Page 103 Instruction book Monday Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller. When ready press the Enter key to confirm. Monday Actions Remove Start Stop Pressure Setpoint 1 Modify •...
  • Page 104 Instruction book Monday Start Save Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. Monday Start Save Modify • A pop-up window opens. Use the ↑ or ↓ key of Scroll keys to modify the values of the hours. Use the ← or →...
  • Page 105 Instruction book Monday Start Save Modify • A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions. Press the Enter key to confirm. Monday Are you sure? Save Modify Press the Escape key to leave this window. •...
  • Page 106 Instruction book Monday - Start Tuesday Wednesday Thursday Friday Saturday Sunday Press the Escape key on the controller to leave this screen. Programming the week cycle A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week schemes can be chosen.
  • Page 107 Instruction book Week 3 Week 4 Modify Press twice the Enter key on the controller to modify the first week. • A new window opens. Select the action, example: Week Action Scheme 1 Week Cycle Week 1 Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Modify...
  • Page 108 Instruction book Week Timer Week Week Timer Inactive Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active. Week Timer Week Action Schemes Week Cycle Status Remaining Running Time •...

  • Page 109: Test Menu

    Instruction book Week Timer Week Action Schemes Week Cycle Status Remaining Running Time • This timer is used when the week timer is set and for certain reasons the compressor must continue working, for example, 1 hour, it can be set in this screen. This timer is prior to the Week Timer action. Week Timer Week action schemes Remaining Running Time...
  • Page 110 Instruction book 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, • Move the cursor to the action button Menu and press the enter key (2), following screen appears: •...

  • Page 111: User Password Menu

    Instruction book 4.17 User password menu Control panel Scroll keys Enter key Escape key Menu icon, Password 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), •...

  • Page 112: Web Server

    Instruction book • Move the cursor to the Password icon (see above, section Menu icon) • Select <Modify> using the Scroll keys and press the Enter key. Next, modify the password as required. 4.18 Web server All Elektronikon controllers have a built-in web server that allows direct connection to the company network or to a dedicated PC via a local area network (LAN).
  • Page 113 Instruction book Configuration of the network card • Go to My Network places (1). • Click on View Network connections (1). • Select the Local Area connection (1), which is connected to the controller. • Click with the right button and select properties (1). 2920 7109 60...
  • Page 114 Instruction book • Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked. After selecting TCP/IP, click on the Properties button (2) to change the settings. • Use the following settings: •...
  • Page 115 Instruction book • Click on the Connections tab (1) and then click on the LAN settings button (2). • In the Proxy server Group box, click on the Advanced button (1). 2920 7109 60...
  • Page 116 Instruction book • In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given but they must be separated with semicolons (;). Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture).
  • Page 117 Instruction book All screen shots are indicative. The number of displayed fields depends on the selected options. • Open your browser and type the IP address of the controller you want to view in your browser (in this example http://192.168.100.100). The interface opens: Navigation and options •...
  • Page 118 Instruction book Compressor settings All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen. Analog inputs Lists all current analog input values.
  • Page 119 Instruction book Digital outputs Lists all Digital outputs and their status. Special protections Lists all special protections of the compressor. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours.

  • Page 120: Programmable Settings

    Instruction book A possible ESi screen 4.19 Programmable settings Parameters: unloading/loading pressures for compressors without built-in refrigeration dryer Minimum Factory Maximum setting setting setting Unloading pressures Unloading pressure (7.5 bar compressors) bar(e) Unloading pressure (7.5 bar compressors) psig 59.5 101.5 108.8 Unloading pressure (8.5 bar compressors) bar(e)
  • Page 121 Instruction book Minimum Factory Maximum setting setting setting Loading pressure (13 bar compressors) psig 172.6 187.1 Loading pressure (100 psi compressors) bar(e) Loading pressure (100 psi compressors) psig 91.4 105.9 Loading pressure (125 psi compressors) bar(e) Loading pressure (125 psi compressors) psig 130.5 Loading pressure (150 psi compressors)
  • Page 122 Instruction book Minimum Factory Maximum setting setting setting Loading pressure (100 psi compressors) psig 91.4 Loading pressure (125 psi compressors) bar(e) Loading pressure (125 psi compressors) psig 127.5 Loading pressure (150 psi compressors) bar(e) 10.5 Loading pressure (150 psi compressors) psig 140.7 152.5...
  • Page 123 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 124: Osci (Optional)

    Instruction book OSCi (optional) 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 most of this oil from the water and to sorb it in its replaceable filters, thus preventing contamination of the environment.

  • Page 125: Operation

    Instruction book 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 126 Instruction book condensate. This airflow breaks stable emulsions by enhancing the sorption process of oil onto the OGC. The air supply also prevents the formation of certain anaerobic bacteria. Also the cover of the second vessel is equipped with ventilation holes to prevent pressure buildup. The airflow is taken from the aftercooler (on air cooled units) or from the water separator (WSD) (on water cooled units).
  • Page 127 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 2920 7109 60...
  • Page 128 Instruction book Detail views View of OSCi inlet Filter position sensor Condensate inlet connections View of OSCi outlet 2920 7109 60...

  • Page 129: Putting Into Operation (Commissioning)

    Instruction book Condensate outlet Condensate test outlet Condensate outlet connection of the OSCi Condensate sample valve 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.

  • Page 130: Pictographs

    Instruction book Drain plate 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 131: Elektronikon® Display And Warnings

    Instruction book Elektronikon® display and warnings Following important parameters of the OSCi can be consulted from the Elektronikon® display: • The remaining filter lifetime, expressed as a percentage compared to new filters (100%) • The status of the overflow switch To consult these data, please follow the steps given in the following sections.

  • Page 132: Warnings

    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 at the right side of the Elektronikon® Graphic controller will light up.
  • Page 133 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.

  • Page 134: 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, this warning will disappear automatically. Reference Description Reference...
  • Page 135 Instruction book 1. Open the condensate sample valve at the side of the compressor (drain plate) for 5 seconds and dispose of the collected condensate according to local regulations for oil containing water. (This is to remove the water that remains in the test outlet tube between the OSCi and the compressor back panel). 2.

  • Page 136: Service Kits

    14. Reset the service counter of the Elektronikon®. See section Elektronikon Warnings. Service kits Atlas Copco has a complete range of service kits available. Service kits comprise all parts needed for servicing components and offer the benefits of using genuine Atlas Copco parts while keeping the maintenance budget low.

  • Page 137: Problem Solving

    Instruction book OSCi service kit Oleophilic filter Buckets (can be used to receive the used filters after maintenance) OGC filter Gloves Activated carbon filter part number Filter kit OSCi: 2901 1734 00 5.10 Problem solving Condition Fault Remedy A lot of oil entered the Compressor Replace all filters.
  • Page 138 Instruction book Condition Fault Remedy Water is present on the A connection is Stop the compressor. Open the side panel and inspect the floor around the leaking. OSCi (remove the covers from the vessels). Verify that the compressor (and on A push-in coupling is drain valves (4 - Condensate flow scheme and View of OSCi) the compressor...
  • Page 139 Instruction book OSCi air injection Aftercooler (WSD in case of a water-cooled Strainer compressor) Air tube to OSCi vessel 2 Y-connection Solenoid valve Air tube to EWD Automatic as well as manual safety devices to prevent overflow are present. Besides the automatic overflow switch (7-View of OSCi), which is mounted in a side-chamber on the second vessel and gives an alarm when condensate level is too high, the customer can check for high condensate level through the sight glass.

  • Page 140: Energy Recovery (Optional)

    Instruction book Energy recovery (optional) Energy recovery unit Description A large part of the energy required for any compression process is transformed into heat. For GA oil-injected screw compressors, the major part of the compression heat is dissipated through the oil system. The Atlas Copco energy recovery (ER) systems are designed to recover most of the above-mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance.
  • Page 141 Instruction book Energy recovery unit (ER-unit) Main components of the ER unit Reference Designation Water inlet pipe Water outlet pipe Temperature sensor, water inlet pipe Temperature sensor, water outlet pipe 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 142: 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 143: 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 Description The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable compressor operation and optimum energy recovery.
  • Page 144 Instruction book BV2 starts closing the bypass line over the heat exchanger (HE) at the lower limit of its temperature range. At the upper limit of its temperature range, the bypass line is completely closed and all the oil flows through the ER heat exchanger.
  • Page 145 Instruction book Attention: It is only allowed to turn the wheel completely in or out. No in-between position is allowed! The oil cooler bypass valve (BV1) starts closing the bypass over the oil cooler (Co) at the lower limit of its temperature range.

  • Page 146: Maintenance

    To clean the oil side, soak the heat exchanger in a degreasing solution. To remove scale formation in the water compartment, a proper descaling process should be applied. Consult Atlas Copco. Energy recovery data...
  • Page 147 Instruction book For air-cooled units: • The water inlet temperature of the energy recovery system • The water outlet temperature of the energy recovery system For water-cooled units: • The water inlet temperature of the energy recovery system • The water outlet temperature of the energy recovery system •...
  • Page 148 Instruction book Parameter Unit GA 55 GA 75 GA 90 GA 55 GA 75 Recoverable energy 64.9 67.7 88.5 88.5 106.2 Water flow l/min 10.2 13.3 13.3 Water flow 0.35 0.36 0.47 0.47 0.57 Temperature at inlet ˚C Temperature at inlet ˚F Temperature at outlet ˚C...

  • Page 149: Installation

    Instruction book Installation Dimension drawings Reference Designation Reference Designation Electric cable passage Automatic drain, dryer Cooling water outlet Automatic drain, aftercooler 2920 7109 60...
  • Page 150 Instruction book Reference Designation Reference Designation Cooling water inlet Compressed air connection for OSCi Compressor cooling air outlet Manual drain, dryer Dryer cooling air outlet Manual drain, aftercooler Compressed air outlet Electrical connection for OSCi Compressor cooling air inlet Dryer cooling air inlet Water outlet (Energy recovery - Cubicle cooling air outlet option)

  • Page 151: Installation Proposal

    Instruction book Weights (oil included) +/- 50 kg (110 lb) Dimensions and weights in tables for air cooled units, 380V-460V. Installation proposal Compressor room example Compressor room example Air cooling Water cooling The direction of the cooling flows may never be inverted 2920 7109 60...
  • Page 152 The cooling air of the dryer can be ducted outside. 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 oil from the condensate to ensure that the condensate meets the requirements of the environmental codes.
  • Page 153 Instruction book Power supply cable to be sized and installed by a qualified electrician. To preserve the protection degree of the electric cubicle and to protect its components from dust from the environment, it is mandatory to use a proper cable gland when connecting the supply cable to the compressor.

  • Page 154: Electrical Connections

    If frost might occur, the appropriate measures should be taken to avoid damage to the machine and its ancillary equipment. In this case, and also if operating above 1000 m (3300 ft), consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame.
  • Page 155 Maximum contact load: 10 A / 250 V AC. Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas Copco. Compressor control mode On compressors equipped with an Elektronikon® controller, consult section...

  • Page 156: Cooling Water Requirements

    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. See section Electrical system to locate the connectors.
  • Page 157 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 158 Instruction book • A : depends on the total solids concentration • B : depends on the water temperature at the outlet of the heat exchanger • C : depends on the calcium hardness (CaCO • D : depends on the HCO concentration or M-alkalinity The values of A, B, C and D can be found in below table: Total...
  • Page 159 Instruction book RSI < 5.5 5.6 < RSI < 6.2 6.3 < RSI < 6.8 6.9 < RSI < 7.5 7.6 < RSI (ppm) For energy recovery systems, the limit is 100 ppm. 7. Sulphates (SO Sulphate (ppm) Type of cooling system Standard Energy recovery Single pass...

  • Page 160: Pictographs

    Instruction book If biology is present, it must be aerobic. Anaerobic biology (in closed systems) must be avoided. Biology (CFU/ml) Type of cooling system Standard Energy recovery Single pass < 10 / < 10 < 10 / < 10 Recirculating (with tower) not applicable <...
  • Page 161 Instruction book Pictographs, water-cooled compressors Reference Designation Automatic condensate drain Warning: voltage Warning: switch off the voltage and depressurise compressor before repairing Warning: before connecting compressor electrically, consult Instruction book for motor rotation direction Torques for steel (Fe) or brass (CuZn) bolts Lightly oil gasket of oil filter, screw it on and tighten by hand (approx.

  • Page 162: Operating Instructions

    Instruction book Operating instructions Initial start-up The operator must apply all applicable Safety precautions. For the location of the air outlet valve and the drain connections, see sections Introduction Condensate system. Preparations 1. Consult the sections Electrical cable size, Installation proposal Dimension drawings.
  • Page 163 Instruction book 3. Check that the electrical connections correspond to the applicable codes and that all wires are clamped tight to their terminals. The installation must be earthed and protected against short circuits by fuses of the inert type in all phases. An isolating switch must be installed near the compressor.
  • Page 164 The drain pipes to the drain collector must not dip into the water. If there is a risk for freezing, the pipes must be insulated. For draining of pure condensate water, install an oil/water separator which is available from Atlas Copco as an option. See section OSCi 8.

  • Page 165: Before Starting

    Instruction book 2. On water-cooled compressors, close the cooling water drain valves. Open the cooling water inlet valve and the regulation valve. 3. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of drive motor (M1) while the motor is coasting to a stop.
  • Page 166 Instruction book Position of oil level sight glass 3. If necessary, empty the dust trap of the filter, see section filter. If the red part of the air filter service indicator shows full out, replace the air filter element. Reset the service indicator (VI) by pushing the knob in the extremity of the indicator.

  • Page 167: Starting

    100° C, this will lead to more rapid oil deterioration, which will have an impact on oil service intervals. Consult Atlas Copco for best practices in this case. Also consult Atlas Copco in case condensate should form in the oil.

  • Page 168: During Operation

    Instruction book Minimum compressor element outlet temperature for water-cooled units Air inlet temperature (°C) Condensation temperature (°C) Working pressure (bar(e)) Relative air humidity (%) Example: If operating at a pressure of 10 bar(e) (145 psig) in an ambient temperature of 20 ˚C (68 ˚F) and at a relative air humidity of 100 %, the minimum temperature to prevent condensation formation in the oil is 68 ˚C (154 ˚F).
  • Page 169 Instruction book Checking the oil level Control panel Elektronikon® Control panel Elektronikon® Graphic Regularly check the oil level. To do so: 1. Press stop button (9). 2. A few minutes after stopping, the oil level should be between the oil filler neck (FC) and the top of the sight glass (Gl).
  • Page 170 Instruction book 4. 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. See section Condensate system location of the outlet valve and water drain. 5.

  • Page 171: Checking The Display

    Instruction book Checking the display Compressors with Elektronikon® controller: Control panel of the Elektronikon® controller Check the display (2) regularly for readings and messages. The display normally shows the compressor outlet pressure, while the status of the compressor is indicated by pictographs. Remedy the trouble if alarm LED (7) is lit or flashes, see section Shutdown warning Shutdown...

  • Page 172: Stopping

    Instruction book Stopping Control panel Elektronikon® Control panel Elektronikon® Graphic 2920 7109 60...

  • Page 173: Taking Out Of Operation

    Instruction book Procedure Step Action Press stop button (9). Automatic operation LED (8) goes out and the compressor stops after 30 seconds of unloaded operation. To stop the compressor in the event of an emergency, press emergency stop button (10). Alarm LED flashes (7).

  • Page 174: Maintenance

    Instruction book Maintenance Preventive maintenance schedule Warning Control panel Elektronikon® Control panel Elektronikon® Graphic Always apply all relevant Safety precautions. Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Close the air outlet valve and press the test button on top of the electronic water drain(s) until the air system between air receiver and outlet valve is fully depressurized.
  • Page 175 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 O-rings and washers.

  • Page 176: Oil Specifications

    Oil specifications It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of field experience and research. See section Preventive maintenance schedule for the advised replacement intervals and consult the Spare Parts list for part number information.

  • Page 177: Drive Motor

    Roto-Inject Fluid Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specific composition keeps the compressor in excellent condition. Roto-Inject Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 40 ˚C (104 ˚F). If the compressor is regularly operating in ambient temperatures above 35 °C (95 °F), oil lifetime is reduced...

  • Page 178: Air Filter

    Instruction book Air filter Location of air filter 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. Procedure 1. Stop the compressor. Switch off the voltage. 2.

  • Page 179: Oil And Oil Filter Change

    Instruction book Oil and oil filter change Warning The operator must apply all relevant Safety precautions. Always drain the compressor oil at all drain points. Used oil left in the compressor can contaminate the oil system and can shorten the lifetime of the new oil. Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties.
  • Page 180 Instruction book Oil drain plugs, check valve and gear casing Vent plug, oil cooler Step Description Run the compressor until warm. Stop the compressor after 3 minutes of unloaded operation. Close the air outlet valve and switch off the voltage. Wait a few minutes and depressurise by unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape.

  • Page 181: Coolers

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

  • Page 182: Safety Valves

    Instruction book Safety valves Location of safety valve Position of safety valve (typical view) 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 183: 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 184: Disposal Of Used Material

    Instruction book 9.11 Disposal of used material Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation.

  • Page 185: Problem Solving

    Instruction book Problem solving Warning Always apply all relevant Safety precautions. Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped and close the air outlet valve. Open the manual drain valve(s). Press the emergency stop button and switch off the voltage.
  • Page 186 Safety valve leaking Replace valve Inlet valve does not fully open Have valve checked Compressor element out of order Consult Atlas Copco Excessive oil flow through air inlet Check valve leaking or oil stop valve Replace defective parts. Replace filter after stopping...
  • Page 187 On water-cooled compressors, Increase flow cooling water flow too low On water-cooled compressors, Consult Atlas Copco Customer restriction in cooling water system Centre Oil cooler clogged Clean cooler Bypass valve malfunctioning Have valve tested...
  • Page 188 Instruction book Condition Fault Remedy Condenser pressure too high Fan control switch out of order Replace or too low Fan blades or fan motor out of Have checked fan/fan motor, if necessary order replace. Ambient temperature too high Check and correct; if necessary, draw cooling air via a duct from a cooler place or relocate the compressor Condenser externally clogged Clean condenser...

  • Page 189: Technical Data

    Instruction book Technical data 11.1 Readings on display Elektronikon® controller Elektronikon® Graphic controller Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limitations). Reference Reading Air outlet pressure Modulates between programmed unloading and loading pressures. Compressor element For air-cooled units: approx.

  • Page 190: Electric Cable Size And Fuses

    Instruction book 11.2 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 191 Instruction book Compressor type I (1) Max. fuse (1) I (2) Max. fuse (2) gL/gG gL/gG GA 75 GA 75 GA 75 GA 75 GA 75 GA 75 Compressor type I (1) Max. fuse (1) I (2) Max. fuse (2) gL/gG gL/gG GA 75...
  • Page 192 Instruction book • (1): Single supply cables. • (2): Parallel supply cables • (3) is only valid for Y-D versions Cable sizing according IEC The tables below indicate the current carrying capacities of cables for 3 commonly used installation methods, calculated according to standard 60364-5-52 - electrical installations of buildings part 5 - selection and erection equipment and section 52 - current carrying capacities in wiring systems.
  • Page 193 Instruction book Installation method C according table B.52.1. Single-core or multi-core cable on a wooden wall Maximum allowed current in function of the ambient temperature for installation method C Ambient temperature Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm²...

  • Page 194: Protection Settings

    Instruction book • When using 2 x 3 phases + PE as in (3): • Add 10 % to the total compressor current (I Pack or I FF from the tables) and divide by √3 • Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1)) •...

  • Page 195: Dryer Switches

    Instruction book Frequency Voltage (V) GA 55 GA 55 P GA 75 GA 75 P GA 90 (Hz) Q15 (A) Q15 (A) Q15 (A) Q15 (A) Q15 (A) 14.9 11.4 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.

  • Page 196: Compressor Data

    Instruction book On water-cooled units also: Maximum cooling water outlet temperature ˚C Maximum cooling water outlet temperature ˚F Maximum cooling water inlet pressure bar(e) Maximum cooling water inlet pressure psig 72.5 11.6 Compressor data Reference conditions All data specified below apply under reference conditions, see section Reference conditions and limitations.
  • Page 197 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Nominal motor power 73.7 73.7 73.7 73.7 73.7 73.7 73.7 73.7 Temperature of air ˚C leaving outlet valve, Workplace units Temperature of air ˚F leaving outlet valve, Workplace units...
  • Page 198 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Cooling water 2.30 2.30 2.30 2.30 2.30 2.30 2.30 2.30 consumption (at water inlet temperature below 95 ˚F and temperature rise of 27 ˚F), water- cooled units Cooling water l/min...
  • Page 199 Instruction book 7.5 bar 8.5 bar 10 bar 100 psi 125 psi 150 psi Pressure drop over dryer, Workplace Full- bar(e) 0.25 0.25 0.25 0.25 0.25 0.25 Feature units Pressure drop over dryer, Workplace Full- psig 3.63 3.63 3.63 3.63 3.63 3.63 Feature units...
  • Page 200 Instruction book 7.5 bar 8.5 bar 10 bar 100 psi 125 psi 150 psi Cooling water consumption (at water inlet 2.65 2.65 2.65 2.65 2.65 2.65 temperature between 95 and 104 ˚F and temperature rise of 18 ˚F), water-cooled units Oil capacity, air-cooled units Oil capacity, air-cooled units US gal...
  • Page 201 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Nominal motor power 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 Temperature of air ˚C leaving outlet valve, Workplace units Temperature of air ˚F leaving outlet valve, Workplace units...
  • Page 202 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Cooling water 3.18 3.18 3.18 3.18 3.18 3.18 3.18 3.18 consumption (at water inlet temperature below 95 ˚F and temperature rise of 27 ˚F), water- cooled units Cooling water l/min...
  • Page 203 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Maximum (unloading) psig pressure, Workplace Full-Feature units Reference working bar(e) 12.5 10.3 pressure Reference working psig pressure Pressure drop over dryer, bar(e) 0.25 0.25 0.25...
  • Page 204 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Dryer power at no load, 2.82 2.82 1.65 1.65 3.08 3.08 1.88 1.88 Workplace Full-Feature units Refrigerant type, R410A R410A R410A R410A R410A R410A R410A R410A Workplace Full-Feature units Refrigerant quantity,...
  • Page 205 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Sound pressure level dB(A) (according to ISO 2151 (2004)) GA 90 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Frequency Maximum (unloading) bar(e)
  • Page 206 Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Pressure dew point, ˚F 37.4 37.4 37.4 37.4 37.4 37.4 37.4 37.4 Workplace Full-Feature units Temperature of air ˚C leaving outlet valve, Workplace Full-Feature units Temperature of air...

  • Page 207: Technical Data Elektronikon® Controller

    Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Cooling water 4.59 4.59 4.59 4.59 4.59 4.59 4.59 4.59 consumption (at water inlet temperature between 95 and 104 ˚F and temperature rise of 18 ˚F), water-cooled units Oil capacity, air-cooled units...
  • Page 208 Instruction book Digital outputs Number of outputs 6 (Elektronikon® controller - p.n. 1900 5200 00 …. 1900 5200 09) 9 (Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900 5200 19) Type Relay (voltage free contacts) Rated voltage AC 250 V AC / 10 A max.

  • Page 209: Instructions For Use

    Instruction book Instructions for use 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 tank and must be operated within the limits specified on the data plate.
  • Page 212 Atlas Copco's pursuit of innovation never ceases, driven by our need for reliability and efficiency. Always working with you, we are committed to providing you the customized quality air solution that is the driving force behind your business.

This manual is also suitable for:

Ga 55Ga 75Ga 90

Table of Contents

Save PDF