Atlas Copco GA 110 VSD+ Instruction Book
  1. Manuals
  2. Brands
  3. Atlas Copco Manuals
  4. Air Compressor
  5. GA 110 VSD+
  6. Instruction book

Atlas Copco GA 110 VSD+ Instruction Book

Hide thumbs
Table of Contents

Advertisement

Quick Links

GA 110 VSD+, GA 132 VSD+,
GA 160 VSD+
Instruction book

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GA 110 VSD+ and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Atlas Copco GA 110 VSD+

Summary of Contents for Atlas Copco GA 110 VSD+

  • Page 1 GA 110 VSD+, GA 132 VSD+, GA 160 VSD+ Instruction book...
  • Page 3 Atlas Copco GA 110 VSD+, GA 132 VSD+, GA 160 VSD+ 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......................5 ........................... 5 AFETY ICONS ......................5 ENERAL SAFETY PRECAUTIONS ................... 6 AFETY PRECAUTIONS DURING INSTALLATION ....................8 AFETY PRECAUTIONS DURING OPERATION ................9 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR .......................10 ISMANTLING AND DISPOSAL General description...................... 12 ..........................12 NTRODUCTION ..........................13...
  • Page 5 Instruction book 3.13 ..........................50 CCESS LEVEL Installation........................52 ........................52 NSTALLATION REMARKS ........................53 IMENSION DRAWING ........................59 NSTALLATION PROPOSAL .........................62 LECTRICAL CONNECTIONS .......................69 UALITY OF SAFETY COMPONENTS ..........................69 ICTOGRAPHS ......................70 OOLING WATER REQUIREMENTS Operating instructions....................76 ..........................76 NITIAL START ..........................79 EFORE STARTING ............................
  • Page 6 Instruction book Integrated dryer......................95 ..........................95 NTRODUCTION ......................98 IR AND REFRIGERANT SYSTEM ...................... 102 UTOMATIC REGULATION SYSTEM ......................104 ONDENSATE DRAIN SYSTEM ........................106 LECTRICAL SYSTEM ..........................106 EGULATION ......................107 AINTENANCE INSTRUCTIONS ......................... 108 ROBLEM SOLVING Adjustments and servicing procedures..............110 ..........................

  • Page 7: Safety Precautions

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

  • Page 8: Safety Precautions During Installation

    Instruction book can not supply any torque-generating energy. The drive is reliably torque-free. This state is monitored internally in the drive. The Safe Torque Off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply! 10.
  • Page 9 Instruction book 8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials. 9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.

  • Page 10: Safety Precautions During Operation

    Instruction book 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.

  • Page 11: Safety Precautions During Maintenance Or Repair

    Instruction book Also consult following safety precautions: Safety precautions during installation Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment;...

  • Page 12: Dismantling And Disposal

    Instruction book devices are fitted and that they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled. 17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator vessel for carbon deposits;...
  • Page 13 Instruction book The equipment is labelled in accordance with the European Directive 2012/19/EU with the crossed-out wheelie bin symbol. At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate collection. For more information check with your local waste authority, customer center or distributor. Disposal of other used material Used filters or any other used material (e.g.

  • Page 14: General Description

    Elektronikon regulator. Energy recovery The compressor is provided with an Atlas Copco energy recovery system to recover the major part of the compression heat and heat losses of the drive motor gathered in hot water without any influence on the compressor performance.

  • Page 15: Flow Diagram

    Instruction book Flow diagram Air-cooled version 9829 3178 63...
  • Page 16 Instruction book Water-cooled version Reference Description Air inlet Energy recovery circuit (optional) Condensate drain, compressor Condensate drain, compressor Full-Feature Air outlet 9829 3178 63...
  • Page 17 Instruction book Reference Description Cooling water circuit Position of components Air flow Air comes in through filter (AF) and inlet valve (IV) and is compressed in the compressor element (E). A mixture of compressed air and oil flows into the air receiver/oil separator (AR), where oil and air are separated.

  • Page 18: Cooling And Condensate System

    Instruction book Cooling and condensate system Condensate drain system Condensate drains, Pack version Condensate drains, Full-Feature version Reference Designation Automatic condensate drain outlet Manual condensate drain outlet A condensate trap is installed downstream of the air cooler to prevent condensate from entering the air outlet pipe.

  • Page 19: Regulating System

    Instruction book Cooling system On air-cooled compressors, the air and oil coolers are cooled by frequency controlled fans. Compressor running parameters will define the cooling fan speed. Water-cooled compressors are provided with a cooling water system. Regulating system Description When the compressor is started and the net pressure is below the setpoint, the motor speed increases until the net pressure reaches the setpoint or until the maximum motor speed is reached.

  • Page 20: Energy Recovery System

    The major part of the transformed heat is dissipated through the oil system. The Atlas Copco energy recovery systems are designed to recover most of the above- mentioned heat as warm or hot water without any adverse influence on the compressor performance.
  • Page 21 Instruction book Energy recovery system Pressure drop, water side Text on figure Pressure drop (kPa) Pressure drop (bar) Water flow (l/s) pd = 4.23 F + 1.62 F With: • pd = pressure drop in kPa • F = water flow in l/s The pressure drops calculated with the formulas above are indicative.
  • Page 22 Instruction book Energy recovery system for air-cooled compressors Energy recovery system for water-cooled compressors 9829 3178 63...
  • Page 23 Instruction book Flow diagram The recovery water enters the unit at the heat exchanger inlet connection. In the heat exchanger the compression heat is transferred from the compressor to the water. The water leaves the heat exchanger via the outlet connection. Installation The compressor frame is prepared for the Energy Recovery system.
  • Page 24 • Manually switch off energy recovery by use of the hand wheel. • Ask an Atlas Copco technician to increase the shut down value of the cooling water temperature of the energy recovery in the Elektronikon controller. It is advised to choose a temperature higher than the selected compressor element outlet temperature but at least 5 °C (9 °F) below the boiling point of the applied cooling medium and never higher than 120...
  • Page 25 Instruction book Condensation point determination Text on figure Air inlet temperature (°C) Condensation temperature (°C) Relative humidity (%) Working pressure (bar(e)) Thermostatic valve Y151 Working pressure Set point 8.5 bar 65 °C 125 psi 167 °F 10 bar 75 °C 150 psi 167 °F 9829 3178 63...
  • Page 26 Instruction book Calculation examples Text on figure Water outlet temperature (°C) Water inlet temperature (°C) Example point X High temperature rise, low water flow application, e.g. pre-heating of boiler feed water in open circuit: • Compressor unit: GA 160 VSD+ - 50 Hz •...
  • Page 27 The temperature of the vessel can be set to 100 °C (212 °F) as well. The installation can work in a higher curve, to obtain a higher water outlet temperature. This setting must be done by a service technician of Atlas Copco. • Compressor unit: GA 160 VSD+ •...
  • Page 28 Instruction book • Wear a safety helmet when working in the area of overhead or lifting equipment. • Protect hands to avoid injury from hot machine parts, e.g. during draining of oil. • Protection caps, bags, etc. must be removed before connecting the pipes. •...

  • Page 29: Elektronikon™ Touch Controller

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

  • Page 31: Control Panel

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

  • Page 32: Icons Used

    Instruction book Icons used Menu icons Menu Icon Menu Icon Menu Icon Data Status Inputs Outputs Counters Aux. Equipment Converters Parameters Service Service Overview Service Plan Service History Service functions Clean Screen Week Timer Week Remaining Running Time Event History Saved Data 9829 3178 63...
  • Page 33 Instruction book Menu Icon Menu Icon Menu Icon Machine Alarms Settings Regulation Control Parameters Aux. Equipment Converter(s) Parameters Internal SmartBox Auto Restart Controller Network Ethernet Settings Settings Settings CAN Settings Localisation Language Date/Time Units User Password Help Information Status icons Icon Description Motor Stopped...
  • Page 34 Instruction book Motor Stopped Wait Running Unloaded Manual Unload Running Unloaded Wait Running Loaded Failed to Load Running Loaded Wait Manual Stop Machine Control Mode, Local Machine Control Mode, Remote Machine Control Mode, LAN Automatic Restart After Voltage Failure Week Timer Active System icons Icon Description...
  • Page 35 Instruction book Antenna 50% Antenna 75% Antenna 100% Change between screens (indication) Energy recovery Dryer Element Drain(s) Analogue Output Menu Reset Auto Restart Filter(s) Cooler Valve(s) Power Meter Input icons Icon Description Pressure 9829 3178 63...

  • Page 36: Main Screen

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

  • Page 37: Quick Access Screen

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

  • Page 38: Menu Screen

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

  • Page 40: Data Menu

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

  • Page 42: Service Menu

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

  • Page 44: Week Timer Menu

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

  • Page 45: Event History Menu

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

  • Page 46: Machine Settings Menu

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

  • Page 49: Controller Settings Menu

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

  • Page 52: Access Level

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

  • Page 54: Installation

    • Working with machinery controlled by a frequency converter requires special safety precautions, which depend on the type of network (TN, TT or IT). Consult Atlas Copco. • When good EMC practices for installation are followed, the compressor qualifies for installation in EMC category C3, according to EN61800-3, for use in a 2...

  • Page 55: Dimension Drawing

    Instruction book Dimension drawing Compressor dimensions Dimension drawing of water-cooled Full-Feature compressor, metric units 9829 3178 63...
  • Page 56 Instruction book Dimension drawing of water-cooled Full-Feature compressor, imperial units 9829 3178 63...
  • Page 57 Instruction book Dimension drawing of air-cooled Full-Feature compressor, metric units 9829 3178 63...
  • Page 58 Instruction book Dimension drawing of air-cooled Full-Feature compressor, imperial units 9829 3178 63...
  • Page 59 Instruction book Dimension drawing of Pack compressor, metric units 9829 3178 63...
  • Page 60 Instruction book Dimension drawing of Pack compressor, imperial units Reference table Reference Description Data plate Electrical cable entry (cable box, optional CTS kit) Air-cooled compressor: Cooling air outlet Air-cooled compressor: Dryer cooling air outlet Water-cooled compressor: Canopy ventilation outlet Air-cooled compressor: Dryer cooling air inlet Cubicle ventilation inlet 4 slotted holes 9829 3178 63...

  • Page 61: Installation Proposal

    Instruction book Reference Description Compressor air inlet Air-cooled compressor: Cooling air inlet Water-cooled compressor: Canopy ventilation inlet Compressed air outlet Manual drain, compressor (10) Automatic drain, compressor (11) Automatic drain, dryer (12) Energy recovery water outlet (13) Energy recovery water inlet (14) Water-cooled compressor: Cooling water inlet Air-cooled compressor: Not used...
  • Page 62 Instruction book Compressor room example, imperial units Text on figures Reference Description Install the compressor on a level floor suitable for taking its weight. Compressed air outlet valve (not in scope of supply). For SI units Delivery pipe: The maximum pipe length can be calculated as follows: 1.85 L = (dp x d x p) / (450 x Qc...
  • Page 63 Drain pipes to condensate collector. The drain pipes may not enter in the collector. Individual drain pipes may not be interconnected to avoid interference Compressor condensate contains oil. Depending on local legislation, it is recommended to install an oil/water separator (consult Atlas Copco) Control cubicle with monitoring panel Main cable entry...

  • Page 64: Electrical Connections

    Instruction book Electrical connections Reference Description Customer's installation Main drive motor Relay 1 Relay 2 Winding temperature Run enable 9829 3178 63...
  • Page 65 Instruction book Reference Description Service mode 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. Warnings •...
  • Page 66 Instruction book Cable size and main fuses Overview of fuse types Electrical approval Fuse type CSA/UL class RK5 Class RK5 according UL248-9 Electrical approval SSCCR gG/gL type 2 HRC form II SSCCR = Standard Short Circuit Current Rating gG/gL type 2 according to IEC609471-4-1, IEC60269, DIN43620, VDE0636 Class RK5 according UL248-9 Maximum fuse size •...
  • Page 67 Instruction book Cable configuration Single supply cables Parallel supply cables (1): Power distribution panel (2): Compressor starter panel Fuse calculations for IEC are done according to IEC 60364–4–43 (Low voltage electrical installations — Part 4–43: protection against overcurrent). Fuse calculations for cUL, CSA and UL: The indicated fuse size is the maximum fuse size in order to protect the motor.
  • Page 68 Instruction book Installation method E or F, according table B.52.1; Single-core or multi-core cables, touching in free air; Clearance to wall not less than 0,3 times cable diameter for method E or one cable diameter for method F. Maximum allowable current in function of the ambient temperature for installation method E (Multi-core cables with 3 loaded conductors and maximum conductor temperature 90 °C) Cable section 30 °C...
  • Page 69 Instruction book Cable section 30 °C 40 °C 45 °C 50 °C 55 °C 150 mm² < 444 A < 404 A < 386 A < 364 A < 337 A 185 mm² < 510 A < 464 A < 443 A <...
  • Page 70 Instruction book Cable sizing according UL The table below indicates the current carrying capacities of cables for commonly used installation methods, according to standard UL 508A. Ampacities of insulated conductors, copper 75°C. AWG or kcmil Ampacity < 30 A < 50 A <...

  • Page 71: Quality Of Safety Components

    Instruction book Ampacity Size of PE < 200 A 4 AWG < 225 A 2 AWG < 400 A 1/0 AWG < 500 A 1/0 AWG < 800 A 2/0 AWG < 1000 A 3/0 AWG Note: The above table has been prepared for user convenience. Only the latest editions of the UL standard and its amendment(s) are to be considered as the official documents.

  • Page 72: Cooling Water Requirements

    Instruction book Other locations Reference Description Automatic condensate drain Automatic condensate drain for optional oil/water separator (type OSD) Manual condensate drain Stop the compressor before maintenance or repair Warning: under tension Read Instruction book before starting the compressor Switch off the voltage and depressurize the compressor before maintenance or repair Before connecting the compressor electrically, consult the Instruction book for the motor rotation direction Torques for steel (Fe) or brass (CuZn) bolts...
  • Page 73 • the application: • standard (max water temperature 65°C / 149°F at the outlet) • Energy Recovery (water temperature up to 95°C / 203°F) A full instruction for handling cooling water data is available at Atlas Copco. 9829 3178 63...
  • Page 74 Instruction book In case water is not in line with recommended values or if any doubt, please refer to Atlas Copco. Technical specifications Parameter Unit Single Pass Single Pass Recirculating Closed Closed (65°C / (95°C / (65°C / 149°F) System System 149°F)
  • Page 75 Instruction book Parameter Remarks Sulphates Rejection < 2000 ppm. To be measured for calculating RSI. Chemical Corrosion Index Index = (Chlorides + Sulphates + Nitrates) / (M-Alkalinity) (all expressed in meq/l) Ammonium limit not applicable for Cu-free systems Suspended Solids (max No particles >...
  • Page 76 Instruction book Chloride Water condition Maximum 65°C / Maximum 95°C / 203 limit 149°F °F 4.0<RSI<5.5 200 ppm High scale formation Regular control and Not applicable. descaling operation necessary. Not recommended for plate heat exchangers 5.6<RSI<6.2 350 ppm Slight scale formation Water treatment not Not applicable.
  • Page 77 Instruction book Chloride Water condition Maximum 65°C / 149°F limit 6.9<RSI<7.5 350 ppm Slight corrosion Water treatment not necessary. Occasional inspection recommended. 7.6<RSI<9.0 200 ppm Strong corrosion Regular control necessary. Use of corrosion inhibitor recommended 9.1<RSI<11 200 ppm Very strong corrosion Regular control necessary.

  • Page 78: Operating Instructions

    Instruction book Operating instructions Initial start-up Warning The operator must apply all relevant Safety precautions. Switch off the voltage before making any adjustment. Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below freezing point, precautions must be taken.
  • Page 79 Instruction book General preparations Step Action Install the compressor, see the sections Dimension drawing, Installation proposal Main fuses and supply cables. Stick labels near the control panel to warn the operator that: • the compressor may start automatically after a voltage failure •...
  • Page 80 Instruction book Step Action The gear casing, motor support and air receiver supports are secured to the frame, immobilizing the vibration dampers during transport. Remove the bushes (1) from the gear casing supports and the motor support. Remove the brackets fitted next to the air receiver supports. Electric cabinet Step Action...

  • Page 81: Before Starting

    If the rotation direction is wrong, press the emergency stop button, switch off the voltage and reverse two incoming electric lines. If the rotation direction of the fan motor is wrong, consult your Atlas Copco customer centre. Run the compressor for a few minutes and check that it is operating normally.
  • Page 82 Instruction book Control panel Reference Designation Function Touchscreen Shows the compressor operating condition and a number of icons to navigate through the menu. The screen can be operated by touch. Warning sign Flashes in case of a shut-down, is lit in case of a warning condition.

  • Page 83: Starting

    Instruction book Starting Warning The operator must apply all relevant Safety precautions. On Full-Feature compressors, switch on the voltage 4 hours before starting in order to energize the crankcase heater of the refrigerant compressor. Control panel Reference Designation Function Touchscreen Shows the compressor operating condition and a number of icons to navigate through the menu.
  • Page 84 Instruction book Procedure Step Action Press the start button. The compressor starts running in unloaded condition. The operation sign (4) lights up. On water-cooled compressors, regulate the cooling water flow with the compressor running loaded. Adjust the water flow to obtain the most suitable air temperature at the outlet of the compressor elements.

  • Page 85: During Operation

    Instruction book During operation Warning The operator must apply all relevant Safety precautions. The operator should immediately stop the machine in case of oil leaks internally in the machine as well as externally and consult a competent technician to resolve the cause. The machine should not be restarted before the problem has been remedied.

  • Page 86: Checking The Display

    Instruction book 1. Check the readings on the display. 2. On Full-Feature compressors, regularly check the pressure dew-point on the display of the control panel. The pressure dew-point will deviate from nominal if the air inlet conditions or volume differ from nominal. If the compressor is stopped, it may start automatically.

  • Page 87: Stopping

    Instruction book Reference Designation Function Voltage sign Indicates that the voltage is switched on. Stop button This button stops the compressor. Start button This button starts the compressor. The operation sign (4) lights up. The controller is operative. 1. Regularly check the display for readings and messages. Normally, the main display is shown.

  • Page 88: Taking Out Of Operation

    Instruction book Reference Designation Function Start button This button starts the compressor. The operation sign (4) lights up. The controller is operative. Procedure Frequently stopping the compressor using the emergency stop button may damage the compressor. Only use the emergency stop button in case of emergency. Step Action Press stop button (6).

  • Page 89: Use Of Air Receiver

    Instruction book Use of air receiver Instructions 1. This vessel may only be used for separating oil from compressed air and this within the limits of pressure and temperature as specified on the nameplate. 2. A safety valve must be installed by the user to protect the vessel against overpressure. The protection must ensure that the pressure will not permanently exceed the maximum allowable working pressure.

  • Page 90: Maintenance

    Check the condition of the cooling fan assembly. 3-Monthly Check the condition of the air filters and cubicle filters, replace if necessary. See Oils Change oil. Contact Atlas Copco to schedule the following maintenance intervals: • Yearly or 8000 hours 9829 3178 63...

  • Page 91: Motors

    Damaged flexibles must be replaced immediately. Service agreements Atlas Copco Customer Centres have a range of service agreements to suit your needs: • An Inspection Plan • A Preventive Maintenance Plan • A Warranty+ Plan •...

  • Page 92: Oil Specifications

    Oil specifications Atlas Copco Roto-Xtend Duty Fluid Atlas Copco Roto-Xtend Duty Fluid is a high-quality synthetic lubricant for oil-injected scroll and screw compressors which keeps the compressor in excellent condition. Roto-Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F) (see section...
  • Page 93 Instruction book Vent and drain plugs on air-cooled compressors Filler and drain plugs on water-cooled compressors Procedure Step Action Run the compressor until warm. Stop the compressor. Close the air outlet valve. Switch off the voltage. Wait a few minutes. Depressurize by unscrewing the plug only one turn to permit any pressure in the system to escape.

  • Page 94: Oil Filter Change

    Instruction book Step Action Remove the filler plug. Fill the air receiver / oil separator with oil until the level reaches the filler opening. Refit and tighten the plug. Tighten the vent plug of the oil cooler. Disconnect the air inlet hose from the inlet valve. Pour 10 liter of oil into the compressor stage.

  • Page 95: Oil Separator Change

    Instruction book Procedure Step Action Stop the compressor, close the air outlet valve and switch off the voltage. Wait a few minutes and depressurize the air receiver by unscrewing the oil filler plug (of the air receiver) only one turn to permit any pressure in the system to escape. Use an oil pan to avoid possible oil spillage.

  • Page 96: Storage After Installation

    General Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. All service kits are indicated in the relevant Parts Lists. Atlas Copco Roto-Xtend Duty Fluid Roto-Xtend Duty Fluid can be ordered in the following quantities: •...

  • Page 97: Integrated Dryer

    Instruction book Integrated dryer Introduction Description The air dryer removes moisture from compressed air by cooling the air to near freezing point. This causes water to condense. The condensate is automatically drained. The air is warmed up before leaving the dryer (approx. 5 ˚C (9 ˚F) below the incoming air temperature). The air dryer cools down the compressed air to the preset temperature.
  • Page 98 Instruction book Water-cooled dryer Position of components Water-cooled dryer 9829 3178 63...
  • Page 99 Instruction book Air-cooled dryer Heat exchanger On air-cooled dryers, cooling fan(s) On water-cooled dryers, water regulating valve On air-cooled dryers, air-cooled condenser On water-cooled dryers, water-cooled condenser Sight-glass Refrigerant compressor Liquid separator Thermostatic expansion valve Refrigerant dryer/filter Non-return valve 9829 3178 63...

  • Page 100: Air And Refrigerant System

    Instruction book Air and refrigerant system Flow diagram Air-cooled dryer 9829 3178 63...
  • Page 101 Instruction book Water-cooled dryer Reference Name 301a Air/air heat exchanger 301b Air/refrigerant heat exchanger Condensate separator Non-return valve 9829 3178 63...
  • Page 102 Instruction book Reference Name Air-cooled condenser (air-cooled version) Water-cooled condenser (water-cooled version) Fan blower (air-cooled version) Water regulating valve (water-cooled version) Thermostatic expansion valve Pressure shut-down switch Refrigerant dryer/filter Liquid separator Hot-gas by-pass valve Refrigerant compressor Solenoid valve Sight-glass 89, 90 Temperature sensor Pressure sensor Automatic drain...
  • Page 103 Instruction book refrigerant contains moisture, indicating that the refrigerant dryer/filter (405) needs to be replaced. Refrigerant gas specifications Please check the data plate of the integrated dryer for the type designation and refer to the table below. Dryer Cooling Refrigerant gas Global Amount Amount...

  • Page 104: Automatic Regulation System

    Instruction book Automatic regulation system Air and refrigerant flow diagram Air and refrigerant flow diagram for air-cooled dryer 9829 3178 63...
  • Page 105 Instruction book Air and refrigerant flow diagram for water-cooled dryer Description The condenser pressure must be kept as constant as possible to obtain stable operation, therefore: • For air-cooled versions, the regulator stops and starts the cooling fans • For water-cooled versions, the water regulating valve in the water outlet regulates the cooling water flow 9829 3178 63...

  • Page 106: Condensate Drain System

    Instruction book When at partial or no load the dew-point pressure stays below the set-point, the regulator opens solenoid valve (411) and hot, high-pressure gas is fed through hot-gas by-pass valve (412) to the evaporator circuit to prevent the evaporator temperature from dropping below 0 ˚C (32 ˚F). Condensate drain system Description Electronic water drain location...
  • Page 107 Instruction book The condensate enters the electronic water drain via inlet (1) and accumulates in collector (6). A capacitive sensor (5) continuously measures the liquid level. The pilot valve (3) is activated as soon as the collector is filled up to a certain level. Diaphragm (4) opens outlet (8), discharging the condensate.

  • Page 108: Electrical System

    Instruction book • Check that a warning is generated on the display of the regulator. • Release the test button. Electrical system Dryer protection The high-pressure shut-down switch stops the compressor motor when the pressure in the refrigerant circuit reaches the upper set-point of the switch. After tripping: •...

  • Page 109: Maintenance Instructions

    Instruction book Maintenance instructions Important The dryers contain refrigerant HFC. When the automatic operation LED is lit, starting and stopping of the dryer are controlled automatically. If the dryer start/stop timer is active, the dryer may start automatically, even if it was stopped manually.

  • Page 110: Problem Solving

    Instruction book General The following remarks should be kept in mind: • Keep the dryer clean. • On air-cooled dryers, brush or blow off the finned surface of the condenser regularly. On water-cooled dryers, regularly check for water leaks. • Inspect and clean the electronic water drain once a year . Problem solving Attention Use only authorized parts.
  • Page 111 Instruction book Condition Fault Remedy Motor overload protection of Have motor checked refrigerant compressor motor For resetting: see the section has tripped Electrical system High-pressure switch tripped See above Condensate drain remains Automatic drain system Flush the assembly by opening inoperative clogged manual drain valve.

  • Page 112: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filters Warning Stop the compressor, close the air outlet valve, press the emergency stop button and switch off the voltage. The operator must apply all relevant Safety precautions. Position of air filters Air filters (1) Procedure Step Action...
  • Page 113 Instruction book Procedure Air-cooled cooler block Water-cooled cooler block On air-cooled compressors proceed as follows: 9829 3178 63...

  • Page 114: Safety Valve

    Clean the coolers 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 clean the coolers with a cleaning agent, consult Atlas Copco. Mount the service panel.
  • Page 115 Location of safety valve on air-cooled compressor The valve can be tested on a separate compressed air line. Consult the Atlas Copco Customer Centre if the valve does not open at the correct pressure (see the section Settings of safety valve).

  • Page 116: Problem Solving

    Instruction book Problem solving Problem solving Warning Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the emergency stop button and switch off the voltage. Close the air outlet valve and open the manual condensate drain valves. Open and lock the isolating switch.
  • Page 117 Multiple shut-down If there are multiple sequential failures with short time intervals on a specific shut-down functionality, consult your Atlas Copco Customer Centre. Excessive oil consumption Have the compressor inspected by your Atlas Copco Customer Centre. Condition Fault Remedy Condensate is not discharged from Discharge pipe of condensate Check and correct as necessary.

  • Page 118: Technical Data

    Instruction book Technical data 10.1 Readings on display Important The readings are valid when operating under reference conditions. See the section Reference conditions. Normally the main display is shown, indicating the actual air outlet pressure and the actual compressor status. The arrow down key allows the operator to call up other information such as actually measured pressures and temperatures.

  • Page 119: Reference Conditions

    Instruction book 10.2 Reference conditions Reference conditions Absolute inlet pressure bar(a) Absolute inlet pressure 14.5 Relative air humidity Air inlet temperature ˚C Air inlet temperature ˚F Nominal working pressure See Compressor data Cooling medium inlet temperature ˚C Cooling medium inlet temperature ˚F Cooling water temperature rise °C...

  • Page 120: Settings Of Safety Valve

    Instruction book Maximum cooling water outlet temperature (open systems) ˚C Maximum cooling water outlet temperature (open systems) ˚F Maximum cooling water outlet temperature (recirculating ˚C systems) Maximum cooling water outlet temperature (recirculating ˚F systems) Maximum cooling water inlet pressure bar(e) Maximum cooling water inlet pressure psig 10.4 Settings of safety valve...
  • Page 121 Instruction book Setting of dryer protection for water-cooled Full-Feature 50 Hz compressors Model Working pressure (bar) Supply voltage (V) Q40 (A) GA 110 VSD+ GA 110 VSD+ GA 132 VSD+ GA 132 VSD+ GA 160 VSD+ GA 160 VSD+ Setting of dryer protection for air-cooled Full-Feature 60 Hz compressors Q41, Model Working pressure (psi)
  • Page 122 Instruction book Model Working pressure (psi) Supply voltage (V) Q40 (A) GA 132 VSD+ GA 132 VSD+ GA 132 VSD+ GA 132 VSD+ GA 160 VSD+ GA 160 VSD+ GA 160 VSD+ GA 160 VSD+ GA 160 VSD+ GA 160 VSD+ Maximum customer fuse setting Model Supply voltage (V) Electrical approval Field circuit...

  • Page 123: Compressor Data

    Instruction book 10.6 Compressor data For high ambient temperature versions operating above 46 °C (115 °F) a derating factor has been applied. The derating factor lowers the maximum motor speed/input power (at constant maximum pressure) to avoid overheating of the oil circuit and motor. Data for 50 Hz, 8.5 bar (123.3 psi) Full-Feature compressors Units GA 110 VSD+...
  • Page 124 Instruction book Data for 50 Hz, 8.5 bar (123.3 psi) Pack compressors Units GA 110 VSD+ GA 132 VSD+ GA 160 VSD+ Effective working pressure bar(g) Effective working pressure psi(g) Motor shaft speed 3919 3598 3329 Maximum effective working pressure bar(g) Maximum effective working pressure psi(g)
  • Page 125 Instruction book Units GA 110 VSD+ GA 132 VSD+ GA 160 VSD+ Total electrical power input 134.3 159.2 191.3 Total electrical power input 213.4 256.4 Mean sound pressure level dB(A) Oil capacity (approx.) Oil capacity (approx.) US gal 24.83 25.89 25.89 Oil capacity (approx.) Imp gal...
  • Page 126 Instruction book Data for 60 Hz, 125 psi (8.6 bar) Full-Feature compressors Units GA 110 VSD+ GA 132 VSD+ GA 160 VSD+ Effective working pressure bar(g) Effective working pressure psi(g) Motor shaft speed 3895 3577 3311 Maximum effective working pressure bar(g) Maximum effective working pressure psi(g)
  • Page 127 Instruction book Units GA 110 VSD+ GA 132 VSD+ GA 160 VSD+ Total electrical power input 130.6 155.9 188.5 Total electrical power input 175.1 252.7 Mean sound pressure level dB(A) Oil capacity (approx.) Oil capacity (approx.) US gal 24.83 25.89 25.89 Oil capacity (approx.) Imp gal...
  • Page 128 Instruction book Units GA 110 VSD+ GA 132 VSD+ GA 160 VSD+ Maximum effective working pressure bar(g) 10.9 10.9 10.9 Maximum effective working pressure psi(g) 158.1 158.1 158.1 Air-cooled compressor version Total electrical power input 132.8 158.6 192.2 Total electrical power input 212.6 257.6 Mean sound pressure level...
  • Page 130 This is what we call - Sustainable Productivity. Atlas Copco Wuxi Oil-free Air Division No. 9829 3178 63 / 2019 - 12 - Printed in Atlas Copco Wuxi. All rights reserved. Designs and specifications are subject to change without notice or obligation.

This manual is also suitable for:

Ga 132 vsd+Ga 160 vsd+

Table of Contents

Save PDF