Atlas Copco GA 5 VSDs Instruction Book

Oil-injected screw compressors

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Instruction book

Oil-injected screw compressors

GA 5 VSDs, GA 7 VSDs, GA 11 VSDs, GA 15 VSDs,

GA 18 VSDs

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Summary of Contents for Atlas Copco GA 5 VSDs

Page 1 Instruction book Oil-injected screw compressors GA 5 VSDs, GA 7 VSDs, GA 11 VSDs, GA 15 VSDs, GA 18 VSDs...
Page 3 Atlas Copco Oil-injected screw compressors GA 5 VSDs, GA 7 VSDs, GA 11 VSDs, GA 15 VSDs, GA 18 VSDs Instruction book Original instructions COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part thereof is prohibited.
Page 4: Table Of Contents
Instruction book Table of contents Safety precautions......................6 Safety icons..........................6 General safety precautions....................6 Safety precautions during installation................8 Safety precautions during operation..................9 Safety precautions during maintenance or repair............10 Dismantling and disposal......................11 General description...................... 13 Introduction..........................13 Flow diagram..........................
Page 5 Instruction book Service menu..........................42 Week timer menu........................43 3.10 Event history menu........................44 3.11 Machine settings menu......................45 3.12 Controller settings menu..................... 47 3.13 Access level..........................50 Installation........................52 Dimension drawings......................... 52 Installation proposal......................54 Electrical connections......................61 Pictographs..........................63 Instructions for prolonged storage.................. 64 Energy recovery......................65 Energy recovery (ER) unit.....................
Page 6 Instruction book Stopping.............................82 Taking out of operation......................82 Boostflow..........................83 Maintenance........................85 Preventive maintenance schedule..................85 Oil specifications........................88 Drive motor..........................89 Air filter............................89 Oil, oil filter and oil separator change................89 Coolers............................. 93 Air dryer............................94 RH sensor..........................95 Safety valves..........................95 7.10 Filters............................96 7.11 Service kits..........................
Page 7 Instruction book Instructions for use....................133 Guidelines for inspection...................134 Pressure equipment directives................. 135 Declaration of conformity..................137 2920 7218 60...
Page 8: Safety Precautions
Instruction book Safety precautions Safety icons Danger: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Notice: Indicates a potential situation which, if not avoided, might result in property damage or in an undesirable result or state.
Page 9 Instruction book • If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer center for advice on specific filtration.
Page 10: Safety Precautions During Installation
Instruction book Safety precautions during installation Warning: 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 • Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure relieving device or devices as required. •...
Page 12: Safety Precautions During Maintenance Or Repair
Instruction book • Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse • All pre-filters are not clogged • If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air.
Page 13: Dismantling And Disposal
Instruction book • Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
Page 14 Instruction book Dismantling Once the end of life of the machine is reached, please follow next steps: 1. Stop the machine. 2. Check all safety precautions mentioned in the previous chapters to secure safe handling (e.g. LOTO, cool-down, depressurize, discharge, etc.). 3.
Page 15: General Description
Instruction book General description Introduction GA 5 VSD up to GA 18 VSD are single-stage, oil-injected screw compressors driven by a reluctance motor. The compressors are controlled by the Elektronikon Touch controller (ER). The compressors use VSD (English: Variable Speed Drive) technology. This means that motor and fan speed are automatically adjusted, depending on compressed air demand.
Page 16 Instruction book Pack Figure 1: Front view, Pack Figure 2: Open side view, Pack 2920 7218 60...
Page 17 Instruction book Full-Feature The Full-Feature compressors have an air dryer which is integrated in the sound-insulated bodywork. The dryer removes condensate from the compressed air by cooling the air to near freezing point. Figure 3: Front view, GA5-11 VSD , Full-Feature 2920 7218 60...
Page 18 Instruction book Figure 4: Front view, GA15-18 VSD , Full-Feature Figure 5: Open side view, Full-Feature 2920 7218 60...
Page 19 Instruction book Reference Description Air filter Air receiver Air outlet Air cooler Oil cooler Compressor drive / converter Automatic condensate outlet Manual condensate outlet Refrigerant dryer Compressor element Electronic water drain Elektronikon Touch controller Cooling fan Drive motor Minimum pressure valve Oil filter Oil separator element Emergency stop button...
Page 20: Flow Diagram
Instruction book Flow diagram Figure 6: GA 5-18 VSD , Pack Figure 7: GA 5-11 VSD , Pack, Tank-mounted 2920 7218 60...
Page 21 Instruction book Figure 8: GA 5-18 VSD , Full-Feature Figure 9: GA 5-11 VSD , Full-Feature, Tank-mounted 2920 7218 60...
Page 22 Instruction book Reference Description Air inlet Air/oil mixture Wet compressed air Condensate Dry compressed air (Full-Feature) Air flow Air comes in through filter (AF) and inlet valve (IV) and is compressed in the compressor element (E). A mixture of compressed air and oil flows into the air receiver/oil separator (AR) where oil and air are separated.
Page 23: Condensate System
Instruction book Condensate system Drain connections The compressors have an electronic condensate drain (ED). Figure 10: Location of the electronic condensate drain, Pack Figure 11: Location of the electronic condensate drain, Pack, Tank-mounted 2920 7218 60...
Page 24 Instruction book Figure 12: Location of the electronic condensate drain, Full-Feature Figure 13: Location of the electronic condensate drain, Full-Feature, Tank-mounted On Pack units, the condensate formed in the air cooler (Ca) is collected in the condensate trap (MT) and discharged by the electronic drain (ED). On Pack, tank-mounted units, a second electronic drain removes the condensate formed in the air tank that is collected in the lower part of the air tank.
Page 25 Instruction book Figure 14: Condensate drain connections, Pack Figure 15: Condensate drain connections, Full-Feature Reference Description Automatic drain connection Manual drain connection Figure 16: Electronic condensate drain (ED) The Test button (2) on top of the drain can be used in three different ways, according the situation: •...
Page 26 Instruction book • When pressed during an alarm, it resets the control logic. • By pressing the Test button for at least 5 seconds, the self diagnosis routine will start. LED explanation Operation Description RGB LED Purge valve 1. Green LED The drain CPU blinks 3 times.
Page 27: Regulating System
Instruction book Operation Description RGB LED Purge valve If the floater is still Green LED stuck after the blinking: cleaning routine, connected mode. the drain switches to the timer 1. 1 second on. Timer routine routine. When the Yellow LED 2.
Page 28: Electrical System
Instruction book When the pressure continues to increase although the motor already operates at minimum speed, the regulator stops the motor as soon the net pressure reaches a value, equal to the setpoint plus the indirect stop level (typically 0.3 bar above the setpoint). Should the net pressure rise very quickly to a value equal to the setpoint plus the direct stop level (typically 1 bar above the setpoint), the compressor is stopped immediately (without first decreasing the motor speed).
Page 29: Air Dryer
Instruction book Air dryer Full-Feature units are equipped with an air dryer. Flow diagram Figure 18: Flow diagram, air dryer Reference Description Air inlet Air outlet Air/air heat exchanger Air/refrigerant heat exchanger/evaporator Condensate separator Automatic drain/condensate outlet Refrigerant compressor Refrigerant condenser Liquid refrigerant dryer/filter Thermostatic bypass valve Hot gas bypass valve...
Page 30 Instruction book Refrigerant circuit Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most of the refrigerant condenses. The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to thermostatic expansion valve (8). The refrigerant leaves the capillary tube at about evaporating pressure. The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further evaporation at about constant pressure.
Page 31: Controller
Instruction book Controller Controller functions ™ Figure 19: Elektronikon Touch controller Introduction The controller has the following functions: • Controlling the unit. • Protecting the unit. • Monitoring components subject to service. • Automatic restart after voltage failure (ARAVF). This function can only be activated by a service technician. 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...
Page 32 Instruction book 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 outlet pressure exceeds the programmed shutdown level, the unit will be stopped. This will be indicated on the display of the controller.
Page 33: Control Panel
Instruction book Control panel Figure 20: Control panel Reference Designation Function Shows the unit operating condition and several icons to Touch screen navigate through the menu. The screen can be operated by touch. Flashes in case of a shut-down, Warning sign is lit in case of a warning condition.
Page 34 Instruction book Menu Icon Menu Icon Menu Icon Inputs Outputs Counters Auxiliary Equipment Converters Parameters Service Service Overview Service Plan Service History Service Functions Clean Screen Week Timer Week Remaining Running Time Event History Saved Data Machine Alarms Settings Regulation Control Parameters Auxiliary...
Page 35 Instruction book Menu Icon Menu Icon Menu Icon STC valve 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 Motor Stopped Wait Running Unloaded Manual Unload Running Unloaded Wait Running Loaded Failed to Load...
Page 36 Instruction book Icon Description 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 Basic User Advanced User Service User Antenna 25% Antenna 50% Antenna 75% Antenna 100%...
Page 37 Instruction book Icon Description Element Drain(s) Analogue Output Menu Reset Auto Restart Filter(s) Cooler Valve(s) Power Meter Input icons Icon Description Pressure Temperature Special Protection Open Closed Note: This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to every machine.
Page 38: Main Screen
Instruction book 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. Description Reference Designation Function The home button is always shown and can be Home button tapped to return to the main screen.
Page 39: Quick Access Screen
Instruction book Quick access screen Function The screen is used to directly access some frequently used functions. Procedure The quick access screen can be viewed by swiping left, starting from the main screen. Description Through this screen, several important settings can be viewed and modified. Reference Function Description...
Page 40: Menu Screen
Instruction book Reference Function Description Auto restart can be activated by tapping this Auto Restart icon. Menu screen Function This screen is used to display the different menus where settings can be viewed or changed. Procedure The menu screen can be viewed by tapping the menu button or by swiping right, starting from the main screen.
Page 41: Data Menu
Instruction book Menu structure Operating the controller can be done by swiping through screens and tapping icons or menu items. This is the main structure. It can differ depending on the configuration of the unit. Data menu Function This screen is used to display the following submenus: •...
Page 42 Instruction book Description Reference Description Status menu Inputs menu Outputs menu Counters Auxiliary equipment menu Status menu Tap the Status icon to enter the Status menu. This menu shows the current status of the unit. If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the reset button.
Page 43 Instruction book Outputs menu Tap the Outputs icon to enter the Outputs menu. This menu shows information about all the outputs. Danger: Voltage-free outputs may only be used to control or monitor functional systems. They should NOT be used to control, switch or interrupt safety related circuits. Check the maximum allowed load on the label.
Page 44: Service Menu
Instruction book Service menu Function This screen is used to display the following submenus: • Service • Service Functions (visible as advanced user) • Clean Screen These submenus can be entered by tapping the icons. Procedure To enter the Service menu screen: 1.
Page 45: Week Timer Menu
Instruction book 1. Tap the desired service plan. A selection screen will pop up. 2. Change the Running Hours by tapping ‘–’ or ‘+’. 3. Confirm by tapping ‘V’ or decline by tapping ‘X’. The service history can be viewed by tapping icon (3). When a service plan interval is reached, a message will appear on the screen.
Page 46: Event History Menu
Instruction book Description Reference Designation Function If less than 4 weeks are programmed, tap the ‘+’ Add or select week button to add a week. Remove week Tap to remove a programmed week timer. A selection screen pops up. The user can choose the correct week by tapping ‘–’...
Page 47: Machine Settings Menu
Instruction book Reference Description 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 48 Instruction book 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 the underlying list, the warning and/or shutdown levels are shown for this alarm. Regulation menu Tap the Regulation icon to enter the Regulation menu.
Page 49: Controller Settings Menu
Instruction book Auxiliary equipment parameters menu Tap the Aux. Equipment Parameters icon to enter the Aux. Equipment Parameters menu. This menu shows an overview of all the auxiliary equipment fitted. Through this menu, the parameters of the auxiliary equipment can be changed. Modify a setting When tapping a list item, a selection screen pops up.
Page 50 Instruction book • Information These submenus can be entered by tapping the icons. Procedure To enter the Controller Settings menu screen: 1. Tap the Menu button. 2. Tap the Controller Settings icon. Description Reference Description Network Settings menu Localisation menu User Password menu Help menu Information menu...
Page 51 Instruction book Localisation menu Tap the Localisation icon to enter the Localisation menu. Language The language setting of the controller can be modified through this menu. Date/Time The date and time settings of the controller can be modified through this menu. Units The units displayed can be modified through this menu.
Page 52: Access Level
Instruction book This menu can show a link to the web page of your supplier, a helpdesk phone number or other helpful information. Information menu Tap the Information icon to enter the Information menu. This menu shows information about the controller. 3.13 Access level Function...
Page 53 Instruction book Reference Designation Function Confirm Tap to confirm the selected user level. 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.
Page 54: Installation
Instruction book Installation Dimension drawings The dimension drawing can be found in the technical documentation, supplied with the unit. Pressure variant Model Model variant Voltage (V) Weight (kg) (bar(e)) 380/400/460 Pack 200/230 500/575 380/400/460 Full-Feature 200/230 500/575 GA 5 VSD 10/13 380/400/460 Pack, tank...
Page 55 Instruction book Pressure variant Model Model variant Voltage (V) Weight (kg) (bar(e)) 380/400/460 Pack 200/230 500/575 380/400/460 Full-Feature 200/230 500/575 380/400/460 Pack, tank 200/230 mounted 500/575 380/400/460 Full-Feature, tank 200/230 Mounted 500/575 GA 11 VSD 380/400/460 Pack 200/230 500/575 380/400/460 Full-Feature 200/230 500/575...
Page 56: Installation Proposal
Instruction book Installation proposal Safety Warning: The operator must apply all relevant safety precautions, including those mentioned in this manual. • Read the manual before installing the compressor. The instruction book contains the necessary information regarding to the detailed values. •...
Page 57 Instruction book Figure 22: Minimum service room Foundation, placement of the compressor unit Install the compressor unit on a solid, level floor, suitable for the compressor mass. It is not allowed to place any extra (damping) material between the floor and the base frame so the frame is not supported on the complete surface.
Page 58 Instruction book Electrical connections • The supply voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is highly recommended to keep the voltage drop over the supply cable at nominal current below 5% of the nominal voltage. •...
Page 59 Instruction book Oil/water separators are used to separate oil from the condensate to ensure that the condensate meets the requirements of the environmental codes. Drain pipes of the same or different compressors may not be interconnected before the (atmospheric) collector as this can damage the electronic drains.
Page 60 Instruction book Additional allowed pressure Unit Cooling air flow drop GA 5 VSD 30 Pa 0.83 m GA 7 VSD 30 Pa 0.83 m GA 11 VSD 30 Pa 0.83 m GA 15 VSD 30 Pa 1.16 m GA 18 VSD 30 Pa 1.16 m Table 2: Duct sizing information...
Page 61 Instruction book The condensate collecting tubes should have a minimum length of two meter before they are interconnected. After the interconnecting point, the drain tube requires twice the diameter of the original tubes. It is not allowed to connect pressurized electronic drains on the draining tubes of the filters. Air delivery pipe The pressure drop over the air delivery pipe can be calculated from: 1.85...
Page 62 Instruction book Air tank Install the air tank (if purchased separately) in a frost free room and on a solid level floor, suitable for its mass. The air tank must be fitted with a correctly sized and approved safety valve that is directly connected with the vessel.
Page 63: Electrical Connections
Instruction book particularly damaging. Care must be taken to minimize the entry of moisture* at the inlet air. No water droplets should enter the air intake. 100% RH 35°C (95°F) 70% RH 40°C (104°F) 30% RH 46°C (115°F) Table 3: Maximum acceptable relative humidity per ambient temperature Use of generators and transformers When installing the compressor connected to a generator or transformer, it is commended to have at least the indicated power available per compressor.
Page 64 Instruction book Electrical connections Reference Description Customer's installation Power circuit Motor The complete electrical diagram can be found in the technical documentation, supplied with the unit. Description Note: You can find the correct position for the electrical connections in the section Dimension drawings.
Page 65: Pictographs
Instruction book • Remote control: The compressor will react to commands from external switches. Emergency stop remains active. Compressor start/stop commands via Clock function are still possible. Note: Have the modifications checked by your supplier. Stop the compressor and switch off the voltage before connecting external equipment. Only potential free contacts are allowed.
Page 66: Instructions For Prolonged Storage
Instruction book Reference Description Keep doors closed during operation Cooling water inlet (option energy recovery) Cooling water outlet (option energy recovery) Electronic water drain (EWD) installation Hot surface Instructions for prolonged storage Procedure Run the compressor regularly, e.g. twice a week, until warm. Note: If the compressor is going to be stored without running from time to time, protective measures must be taken.
Page 67: Energy Recovery
Instruction book Energy recovery Energy recovery (ER) unit Description A large part of the energy required for any compression process is transformed into heat. The major part of the compression heat is dissipated through the oil system. Energy recovery (ER) systems are designed to recover most of this heat by transforming it into warm or hot water without any adverse effects on compressor performance.
Page 68: Energy Recovery (Er) Systems
Instruction book Reference Description Valve 1 Valve 2 Valve 3 Thermostatic bypass valve Overpressure valve Heat exchanger Oil drain valve Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor. Consult your supplier for installing and connecting the energy recovery (ER) unit.
Page 69: Energy Recovery (Er) Operation
Instruction book Water requirements for open water circuits In open, non-recirculating water circuits, major problems that are usually encountered are related to deposit control, corrosion control, and microbiological growth control. To minimize these problems, the water that is being used should meet a number of requirements. Energy recovery (ER) operation Description The compressor oil flow is controlled by a Smart Temperature Control (STC) valve, ensuring...
Page 70 Instruction book The Smart Temperature Control (STC) valve starts directing the oil flow to the oil/water heat exchanger as soon as the compressor temperature is sufficiently high to avoid condensate formation and recover energy. Unlike a standard thermostat the temperature setpoint is variable, this to optimize the amount of recovered energy.
Page 71: Energy Recovery (Er) Maintenance
Instruction book Stopping the unit for a long period In case of an open water system and/or if freezing temperatures can be expected, isolate the compressor water system and blow it through with compressed air. Energy recovery (ER) maintenance Compressor oil For references used consult section Energy recovery (ER) unit.
Page 72 Instruction book They must be provided with suitable stabilizers and inhibitors. Specifications are also depending on the type of cooling circuit (open, once through / recirculating with tower / closed) and on the application (Standard – max 65 °C cooling water temperature at the outlet) or energy recovery (water temperature up to 95 °C).
Page 73 Instruction book Ca (ppm Ca CO Type of cooling system Standard Energy recovery (ER) Single pass < 500 < 2 Recirculating (with tower) < 500 not applicable Closed loop < 1000 < 50 4. The Ryznar Stability Index (RSI) The Ryznar Stability Index is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate.
Page 74 Instruction book Total Temperature Ca hardness dissolved (°C) (ppm CaCO Alkalinity solids (ppm (mg/l) CaCO 62 - 67 142 - 177 142 - 177 68 - 73 178 - 223 178 - 223 74 - 79 224 - 281 224 - 281 80 - 85 282 - 355 282 - 355...
Page 75 Instruction book Dissolved iron (ppm) Dissolved manganese (ppm) Type of cooling Standard Energy Standard Energy system recovery (ER) recovery (ER) Single pass < 1 < 0.2 < 0.2 < 0.05 Recirculating < 1 not applicable < 0.2 not applicable (with tower) Closed loop <...
Page 76: Energy Recovery (Er) Data
Instruction book Note: If additives are used in the cooling water, take into account that the cooling capacity will change. Δm = ((C ) * X) / (C *(1-X) + X*C ) * 100 % with Δm: change of mass flow of the coolant : specific heat capacity of water : specific heat capacity of the additives X: the percentage of additives...
Page 77 Instruction book • The water inlet temperature of the energy recovery system • The water outlet temperature of the energy recovery system Modifying settings If the programmed warning settings for the water temperatures are exceeded, a warning indication is shown on the controller: Minimum Nominal Maximum...
Page 78 Instruction book GA 5 VSD GA 7 VSD GA 11 VSD GA 15 VSD GA 18 VSD Parameter Unit 7 bar 7 bar 7 bar 7 bar 7 bar 4500 rpm 5400 rpm 4600 rpm 5850 rpm 7600 rpm Water flow kJ/kgK 4.18 4.18...
Page 79: Operating Instructions
Instruction book Operating instructions Initial start-up Warning: The operator must apply all relevant safety precautions. Also consult section Problem solving. Note: For the location of the air outlet valve and the drain connections, see sections Introduction and Condensate system. 1. Remove the canopy panel(s) in order to get access to the internal components. Remove the transport spacers.
Page 80 Instruction book Close the valve. 7. Check the oil level. The oil level should reach the bottom of the oil filler neck (FC). Figure 27: Low pressure variant 2920 7218 60...
Page 81 Instruction book Figure 28: High pressure variant Minimum level should reach the oil sight glass (GI) when the compressor is stopped. If needed, top up the oil. Take care that no dirt drops into the oil system. Refit and tighten the filler plug (FC). 8.
Page 82: Starting
Instruction book Starting Figure 29: Control panel 1. Open the air outlet valve. 2. Switch on the voltage. Check that voltage on LED (5) lights up. 3. Press start button (7) on the control panel. The compressor starts running and the automatic operation LED (4) lights up.
Page 83 Instruction book Regularly check that condensate is discharged during operation. See section Condensate system. The amount of condensate depends on environmental and working conditions. Figure 30: Low pressure variant Figure 31: High pressure variant 2. Regularly check the controller display. Check the display (1) regularly for readings and messages.
Page 84: Stopping
Instruction book Stopping 1. Press stop button on the control panel. Automatic operation LED goes out and the compressor stops. 2. Close the air outlet valve. 3. Press the test button on top of the electronic water drain(s) to the depressurize the piping between air receiver and outlet valve, next open the manual drain valve (Dm).
Page 85: Boostflow
Instruction book • Isolate and disconnect the water system from the cooling water net. • Drain the water circuit. Boostflow The unit comes with Boostflow Mode, allowing you to temporarily stretch the limit of your compressor without negative operational or reliability consequences. The extra boost delivers 5% more flow for a total period of 100 hours throughout the entire lifetime of the compressor.
Page 86 Instruction book 2920 7218 60...
Page 87: Maintenance
Instruction book Maintenance Preventive maintenance schedule Warning: Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Close the air outlet valve. • Open the condensate drain valve to depressurize the air system between air receiver and outlet valve.
Page 88 Instruction book Service plans Besides the daily and 3-monthly checks, preventive maintenance actions are specified in the schedule below. Each plan has a programmed time interval at which all service actions belonging to that plan are to be carried out. When reaching the interval, a message will appear on the screen indicating which service plans are to be carried out.
Page 89 Instruction book A-service every 4000 B-service every 8000 D-Service every running hours running hours 24000 running hours Check for water and oil leakages Change the air filter Check the prefilters Change the drain(s) filter mesh (4)(7) Change the oil (4)(7) Change the oil filter Change the oil separator element...
Page 90: Oil Specifications
Roto Synthetic Fluid XTEND DUTY. Roto Synthetic Fluid XTEND DUTY Atlas Copco's Roto Synthetic Fluid XTEND DUTY is a high quality synthetic lubricant for oil injected screw compressors which keeps the compressor in excellent condition. Because of its excellent oxidation stability, Roto Synthetic Fluid XTEND DUTY can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F).
Page 91: Drive Motor
If the compressor is equipped with an Energy Recovery unit, also consult section Maintenance for energy recovery systems. Warning: Only genuine Atlas Copco oils to be used. Oil level to be checked on a daily basis. 2920 7218 60...
Page 92 Instruction book Timely service of consumables is needed. Use the correct personal protection equipment (gloves and safety goggles). Procedure 1. Run the compressor until warm and stop the compressor. • Close the air outlet valve. • Open the manual drain valve slowly. •...
Page 93 Instruction book Figure 33: High pressure variant 4. Completely drain the vessel. 5. Start the oil draining algorithm: a. Log in as expert. b. In the controller, go to Test > Re-greasing / oil draining algorithm. c. Enter the security code. d.
Page 94 Instruction book Figure 34: Low pressure variant Figure 35: High pressure variant Take care that no dirt drops into the system. Refit and tighten filler plug (FC). 10. Run the compressor loaded for a few minutes. 11. Stop the compressor. 12.
Page 95: Coolers
Instruction book 13. Fill the air receiver (AR) with oil until the level reaches the filler neck. See section During operation. 14. Refit and tighten filler plug (FC). 15. When the oil level is too low, go back to step 13. Coolers General Keep the coolers clean to maintain their efficiency.
Page 96: Air Dryer
Instruction book 2. Clean with an air jet in the direction of the normal flow. 3. Clean the condenser area with a fiber brush. Air dryer Safety precautions Danger: Refrigeration dryers of ID type contain refrigerant HFC. When handling refrigerant, all applicable safety precautions must be observed. Please be specifically aware of the following points: •...
Page 97: Rh Sensor
Instruction book RH sensor Cleaning Reference Description Relative humidity sensor 1. Remove the front service panel with the key delivered with the compressor. 2. Disconnect the RH sensor and remove it from the panel by loosening the bolt. 3. Clean the RH sensor with isopropanol (fast solution) or de-mineralised water and let it dry. 4.
Page 98: Filters
Instruction book Figure 37: High pressure variant Testing Warning: The safety valve (SV) test can only be performed by authorized personnel and is protected by a security code. If the safety valve does not open at the set pressure stamped on the valve, it needs to be replaced. 7.10 Filters DD, DD+ and UD+ filters...
Page 99: Drain Replacement
Instruction book 7.12 Drain replacement User access level To replace the drain, you need to be in expert mode. This can be done as follows: 1. Tap the Access Level button (1) at the upper right corner of the screen. 2.
Page 100 Instruction book 4. Navigate to Install Device. The drain you just removed should now be available in the list. Select it and confirm the installation. Confirm and restart the controller from the CAN Troubleshooting menu. 5. Verify drain communication in the CAN Troubleshooting > IO modules menu. 6.
Page 101: Problem Solving
Instruction book Problem solving Warning: Before carrying out any maintenance, repair work or adjustment, stop the compressor, wait 3 minutes and close the air outlet valve. Press the emergency stop button and switch off the voltage. Lock Out Tag Out (LOTO) the electrical supply.
Page 102 Oil separator clogged Have element replaced. pressure below normal Air leakage Have leaks repaired. Safety valve leaking Have valve replaced. Compressor element out of Consult Atlas Copco. order Condition Fault Remedy Minimum pressure valve Check and have defective malfunctioning parts replaced.
Page 103 Instruction book Condition Fault Remedy Solenoid valve malfunctioning Replace valve. Low Load Alarm triggered: Increase loading profile Compressor running with too (longer and/or more load Extreme low usage of low oil temperature over a cycles required). compressor longer period of time If not possible, consult your supplier.
Page 104 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) 12816 0x3210 Overvoltage Overvoltage on Check if the main supply is within DC bus detected. 12817 0x3211 Overvoltage specifications. 12833 0x3221 Undervoltage Check for transient voltage phenomena (e.g.
Page 105 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) Overtemperature Drive 17169 0x4311 detected in main overtemperature inverter IGBT. Overtemperature Drive detected in IGBT 17172 0x4314 overtemperature junction UH Check for (thermal model). overloads.
Page 106 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) Check for overloads. Let the drive cool off. Check for excessive ambient Overtemperature temperature. Drive detected by Clean the heat 17206 0x4336 overtemperature simplified thermal sink with model.
Page 107 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) Check if the main supply is within specifications. Check for Drive failure Internal power transient voltage 20756 0x5114 (hardware) supply tripped. phenomena (e.g. voltage dips, surges, etc.).
Page 108 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) Check the CAN- cable connection between the controller and the converter. Check Drive failure 24851 0x6113 communication the position of the (software) overload. CAN termination switch at both sides of the CAN cable.
Page 109 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) BB MCU did not jump into Drive failure bootloader state 24854 0x6116 (software) during the initialization phase. BB MCU did not jump into Drive failure application state 24855 0x6117...
Page 110 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) CB hardware Drive failure revision is not 24862 0x611E (software) recognized by CB MCU. BB FW Boot Reboot the Drive failure version is not 24863 0x611F system or turn off...
Page 111 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) First ADC regular Drive failure acquisition Try to reset the 24873 0x6129 (software) sequence not error. If the error executed in time. returns, contact your supplier.
Page 112 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) Negative value obtained for the Drive failure rotor time during 24885 0x6135 Reset the error (software) IM parameters and repeat the identification procedure. If the procedure.
Page 113 Instruction book NEOS browser Controller alarm Detailed alarm code Fault description Actions code (Decimal) description (Hexadecimal) Drive failure 33025 0x8101 (software) Check the CAN- Drive failure 33041 0x8111 cable connection (software) between the Drive failure 33042 0x8112 controller and the (software) converter.
Page 114 Instruction book Faults and remedies, dryer For all references hereafter, consult section Air dryer. Condition Fault Remedy Air inlet temperature too Check and correct; if necessary, clean high the aftercooler of the compressor. Check and correct; if necessary, draw Ambient temperature too cooling air via a duct from a cooler high place or relocate the compressor.
Page 115 Instruction book Condition Fault Remedy The bypass valve is broken or out of calibration. No compressed air passes The pipes are frozen inside The room temperature is too low and through the dryer outlet the evaporator piping is obstructed with ice.
Page 116: Technical Data
Instruction book Technical data Readings on display Figure 38: Elektronikon Touch controller Note: The data is valid under the reference conditions. See section Reference conditions and limitations. Reference Reading Air outlet pressure Depends on the setpoint (desired net pressure). Compressor element Approx.
Page 117 Instruction book Use the original cable entry. See section Dimension drawings. To preserve the IP protection degree of the electrical 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 118 Instruction book Max fuse Max fuse Type gL/gG gL/gG 50/60 50/60 GA 11 VSD Table 9: IEC approval Max fuse Max fuse Type gL/gG gL/gG 50/60 50/60 GA 15 VSD Table 10: IEC approval Max fuse Max fuse Type gL/gG gL/gG 50/60 50/60...
Page 119 Instruction book Max fuse Max fuse Class Class Class Class Type 50/60 50/60 GA 7 VSD Table 13: UL/cUL approval Max fuse Max fuse Class Class Class Class Type 50/60 50/60 GA 11 VSD Table 14: UL/cUL approval Max fuse Max fuse Class Class...
Page 120 Instruction book Earthing The earthing cable connected to the compressor (PE) should be minimum 10 mm (according to EN 60204-1 section 828). Motor cables Cable assembly Model Size Quantity Wire ends number GA 5 VSD 1649 8102 34 GA 7 VSD 1649 8102 34 GA 11 VSD 1649 8102 34...
Page 121 Instruction book • Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1)) • Install fuses of half the size of the recommended maximum fuse size on each cable. • Size of the PE cable: • For supply cables up to 35 mm²: same size as supply cables •...
Page 122 Instruction book Make sure to mount the pyramid gland after connecting the supply cable to safeguard the IP rating of the converter. AWG or kcmil Maximum current < 30 A < 50 A < 65 A < 85 A < 100 A <...
Page 123 Instruction book • For supply cables larger than AWG8: use maximum allowed ampacity of the selected supply cables and compare with value in table below (see CEC Part 1 table 17) < 100 A: use AWG8 < 200 A: use AWG6 <...
Page 124: Reference Conditions And Limitations
Instruction book SF is more than 1.15, so multiply FLA with SF+10% i.e., FLA *130%. Single supply cables (3phases + 1PE – configuration (1)): • According to CEC part1 (C22.1-09) we will need a cable suitable for: • Multiply FLA of the main motor with 120% +10% = 130%, 91 * 130% = 118.3A Add the additional loads I cable = 118.3 + 15.8 = 134.1A...
Page 125: Compressor Data
Instruction book Relative humidity Working pressure See section Compressor data. Limitations Maximum working pressure See section Compressor data. Minimum working pressure bar(e) Minimum working pressure psig Maximum air inlet temperature ˚C Maximum air inlet temperature ˚F Minimum ambient temperature ˚C Minimum ambient temperature ˚F Compressor data...
Page 126 Instruction book Sound pressure level (according to dB(A) 2151(2004)) GA 7 VSD Normal effective bar(e) working pressure Maximum effective bar(e) working pressure, Pack Maximum effective working bar(e) 12.75 12.75 12.75 12.75 pressure, Full- Feature Maximum motor shaft 5400 5400 4600 3800 speed Minimum...
Page 127 Instruction book Maximum effective working bar(e) 10.25 10.25 10.25 pressure, Full- Feature Maximum motor 4600 4600 3829 shaft speed Minimum motor 1000 1000 1000 shaft speed Nominal motor power Total amount of refrigerant, Full- 0.44 0.44 0.44 Feature Oil capacity Sound pressure level (according to dB(A)
Page 128 Instruction book Sound pressure level (according to dB(A) 2151(2004)) Table 20: High pressure variant GA 15 VSD Normal effective bar(e) working pressure Maximum effective working bar(e) 10.5 10.5 10.5 pressure, Pack Maximum effective working bar(e) 10.25 10.25 10.25 pressure, Full- Feature Maximum motor 5850...
Page 129 Instruction book Maximum motor shaft 9150 9150 8957 7800 speed Minimum motor shaft 1900 1900 1900 1900 speed Nominal motor power Total amount of refrigerant, 0.75 0.75 0.75 0.75 Full-Feature Oil capacity Sound pressure level (according to dB(A) 2151(2004)) Table 22: High pressure variant GA 18 VSD Normal effective...
Page 130: Technical Data Controller
Instruction book Sound pressure level (according to dB(A) 2151(2004)) Technical data controller General 24 V AC /16 VA 50/60Hz (+40%/-30%) Supply voltage 24 V DC/0.7 A IP54 (front) Type of protection IP21 (back) • Operating temperature range • -10°C…..+60°C (14 °F ..140 °F) •...
Page 131: Inputs And Outputs
Instruction book Inputs and outputs Digital input Strip Description DI01 Remote start/stop DI02 Remote pressure selection DI03 Remote pressure sensing Power duct fan alarm DI04 (option) Empty DI05 Empty Empty DI06 Empty Empty DI07 Empty Empty DI08 Empty Empty DI09 Empty Empty DI10...
Page 132 Instruction book Digital out Strip Description DO01 Empty General warning DO02 Empty General shutdown DO03 Empty Automatic operation DO04 Empty Empty DO05 Empty Empty DO06 Empty Empty DO07 Dryer (GND) Dryer (24V) DO08 Empty Empty DO09 Y1 Blow-off Solenoid Valve DO10 Y2 recirculation Solenoid Valve (CPC)
Page 133 Instruction book Analog input pressure Strip Description PT20 - Outlet pressure PT12 - Vessel pressure (option*) Empty MT01/TT01 - Humidity temperature sensor (ambient temperature) Empty MT01/TT01 - Humidity temperature sensor (relative humidity) *These options are not released as standard options. Additional programming needs to be done in controller database to activate these.
Page 134 Instruction book Connector Description Wiring recommendations Wire size 2.5mm Digital output relay suitable for 250VAC, 8A Wire size 1x1.5 mm Pt1000 temperature sensors Shielded twisted pair Wire size 1x1.5 mm Pressure sensor Shielded twisted pair Wire size 1x1.5 mm 24V digital output Output current: 2A max Wire size 1x1.5 mm 24VDC output...
Page 135: Instructions For Use
Instruction book Instructions for use Air/oil separator vessel This vessel can contain pressurised air; this can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator and must be operated within the limits specified on the data plate.
Page 136: Guidelines For Inspection
Instruction book Guidelines for inspection On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.
Page 137: Pressure Equipment Directives
Instruction book Pressure equipment directives Components subject to 2014/68/EU Pressure Equipment Directive The following table contains the necessary information for the inspection of all pressure equipment of category II and higher according to the Pressure Equipment Directive 2014/68/EU and all pressure equipment according to the Simple Pressure Vessel Directive 2014/29/EU.
Page 138 Instruction book (2) Other inspection techniques such as ultrasonic or X-ray are equivalent to hydrostatic testing for this equipment. 2920 7218 60...
Page 139: Declaration Of Conformity
Instruction book Declaration of conformity Figure 39: Typical example of a Declaration of Conformity document Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium Applicable directives Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
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