im getting a mian convertor failure alarm on the ga30 nothing in the book about where to start motor doesnt feel to warm amps running normal i dont see any real issues with the motor going off of readings with the meter

Summary of Contents for Atlas Copco GA 30

Page 1 INSTRUCTION BOOK API327216 GA 30...
Page 3 Atlas Copco GA 30 API327216 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. This instruction book is valid for CE as well as non-CE labelled machines. It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity.
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 ....................7 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR .......................10 ISMANTLING AND DISPOSAL General description...................... 11 ..........................11 NTRODUCTION ............................
Page 5 Instruction book 3.10 ..........................45 ERVICE MENU 3.11 ..........................49 ETPOINT MENU 3.12 ........................50 VENT HISTORY MENU 3.13 ......................51 ODIFYING GENERAL SETTINGS 3.14 ............................53 NFO MENU 3.15 ...........................54 EEK TIMER MENU 3.16 ............................. 63 EST MENU 3.17 ........................64 SER PASSWORD MENU 3.18 ..........................
Page 6 Instruction book ..........................94 ERVICE KITS ......................94 ISPOSAL OF USED MATERIAL Adjustments and servicing procedures..............95 ..........................95 RIVE MOTOR ............................95 IR FILTER .......................96 IL AND OIL FILTER CHANGE ............................98 OOLERS ..........................99 AFETY VALVES Problem solving......................100 Technical data......................102 ........................
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 9. 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 9: Safety Precautions During Operation
Instruction book 12. The electrical connections must correspond to the applicable codes. The machines must be earthed and protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor. 13. On machines with automatic start/stop system or if the automatic restart function after voltage failure is activated, a sign stating "This machine may start without warning"...
Page 10: Safety Precautions During Maintenance Or Repair
Instruction book 6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out routine checks. Wear ear protectors when opening a door. On machines without bodywork, wear ear protection in the vicinity of the machine. 7.
Page 11 Instruction book 3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all damage or injuries caused by the use of non-genuine spare parts. 4. All maintenance work shall only be undertaken when the machine has cooled down. 5.
Page 12: Dismantling And Disposal
Instruction book Also consult following safety precautions: Safety precautions during installation Safety precautions during operation. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment;...
Page 13: General Description
General description Introduction General GA 11 up to GA 30 are single-stage, oil-injected screw compressors driven by an electric motor. The compressors are air-cooled. The compressors are enclosed in sound-insulated bodywork. GA 11 up to GA 26 are controlled by the Elektronikon™ Graphic controller (see section Elektronikon™...
Page 14 Instruction book Location of air outlet valve Elektronikon controller Emergency stop button Manual condensate drain Automatic condensate drain Front view, GA 11 up to GA 30 Workplace Ref. Name Air filter Air receiver Location of air outlet valve Air cooler...
Page 15: Air Flow
Instruction book Air flow Flow diagrams GA 11 up to GA 30 Workplace References Ref. Description Intake air Air/oil mixture Hot compressed air Description Air drawn through air inlet filter (AF) and open inlet valve (IV) into compressor element (E) is compressed.
Page 16: Oil System
Instruction book Oil system Flow diagram Oil system References Description Intake air Air/oil mixture Compressed air Wet (100 % saturated) compressed air Condensate Description The air/oil mixture coming from the compressor element flows into the oil separator/tank, where most of the oil is separated by centrifugal action. The oil collects in the lower part of air receiver/oil separator (AR) which serves as oil tank.
Page 17: Cooling System
Instruction book Cooling system Flow diagram Cooling circuit References Description Intake air Compressed air/oil Compressed air Wet (100 % saturated) compressed air Condensate Description The cooling system comprises air cooler (Ca) and oil cooler (Co). On air-cooled compressors, the cooling air flow is generated by fan (FN). API327216...
Page 18: Condensate System
Instruction book Condensate system Condensate drains Drain on air cooler Drain connections, Workplace Full-Feature Reference Designation Automatic drain connection, compressor Automatic drain connection, dryer (only on Full-Feature units) Manual drain connection, compressor Manual drain connection, dryer (only on Full-Feature units) Drain connection of the filters (option) GA Workplace compressors are equipped with a condensate trap, integrated in the air cooler.
Page 19: Regulating System
Instruction book Regulating system Flow diagram Regulating system (loaded condition) Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results: • The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank pressure (1) via the solenoid valve.
Page 20: Electrical System
Instruction book Air output is stopped, the compressor runs unloaded. Electrical system General Also consult sections Electrical diagrams Electrical connections. Description The electrical system comprises following components: Electric cubicle, typical example Reference Designation F1/2/3 Fuses F4/5/6 Fuses Overload relay, compressor motor Circuit breaker, fan motor (on air-cooled compressors) Auxiliary contactor for dryer (only on Full-Feature compressors) Line contactor...
Page 21 Instruction book Reference Designation Terminal strip (voltage supply) X103/X108 Connectors Earthing terminal API327216...
Page 22: Electrical Diagrams
Instruction book Electrical diagrams Diagram Service diagram (part A) API327216...
Page 23 Instruction book Service diagram (part B) Reference Designation Customer’s installation Main switch (option) Dryer option (1 phase) Motor connection (M1) for all voltages, except 440-460 V - 60 Hz Motor connection (M1) for 440-460 V - 60 Hz API327216...
Page 24 Instruction book Reference Designation Star connection (M2) for all other voltages Delta connection (M2) for 200-220-230 V - 50/60 Hz - See motor data plate for correct connection Temperature sensor, element outlet Pressure transducer, delivery air (10) Temperature sensor LAT ID dryer (option) (11) Solenoid valve Load/Unload (12)
Page 25 Instruction book Reference Electric cabinet Overload relay, drive motor Line contactor Star contactor Delta contactor Phase sequence relay Contactor, cooling fan Circuit breaker, fan motor Transformer 1X0 -1X7 Terminal strips Reference Control module Elektronikon module Blocking relay Auxiliary relay, star contactor Auxiliary relay, delta contactor Auxiliary relay, loading/unloading Auxiliary relay, general shutdown...
Page 26 Instruction book Reference Optional equipment Solenoid valve, modulating control API327216...
Page 27: 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...
Page 28: Shut-Down Warning
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 29: 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 30: 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 31 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 API327216...
Page 32 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 API327216...
Page 33 Instruction book Icon Description Test Settings Service Event history (saved data) Access key / User password Network Setpoint Info Navigation arrows Icon Description Down API327216...
Page 34: 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.
Page 35 Instruction book Typical Main screen (2 value lines), fixed speed compressors Typical Main screen (2 value lines), compressors with frequency converter Text on figures Compressor Outlet Element Outlet (fixed speed compressors) Flow (compressors with frequency converter) 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...
Page 36 Instruction book Typical Main screen (4 value lines), compressors with frequency converter Text on figures Compressor Outlet Load relay (one of the input signals of fixed speed compressors) Flow (compressors with frequency converter) Off, Shutdown,... (text varies upon the compressors actual condition) Menu Running hours Element outlet...
Page 37 Instruction book Designation Function Menu To go to the menu Modify To modify programmable settings Reset To reset a timer or message To activate an action button, highlight the button by using the Scroll keys and press the Enter key. To go back to the previous menu, press the Escape key.
Page 38 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 39: 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), fixed speed compressors API327216...
Page 40: Inputs Menu
Instruction book Typical Main screen (2 value lines), compressors with frequency converter • To go to the Menu screen, highlight the Menu button (3), using the Scroll keys. • Press the Enter key to select the menu. Following screen appears: •...
Page 41 Instruction book Text on image Menu Regulation • Using the Scroll keys, move the cursor to the Inputs icon (see above, section Menu icon). • Press the Enter key. A screen similar to the one below appears: Text on image Inputs Compressor Outlet Element Outlet...
Page 42 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 43: Outputs Menu
Instruction book (1): Set as main chart signal Outputs menu 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. Procedure Starting from the Main screen, •...
Page 44: Counters
Instruction book Text on image Outputs Fan motor Blowoff General shutdown Automatic operation • The screen shows a list of all outputs with their corresponding icons and readings. If an output is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively.
Page 45 Instruction book Procedure Starting from the Main screen (see Main screen), • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on figure Menu Regulation • Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon) •...
Page 46: Control Mode Selection
Instruction book Control mode selection Control panel Scroll keys Enter key Escape key Function To select the control mode, i.e. whether the compressor is in local control, remote control or controlled via a local area network (LAN). Procedure Starting from the main screen, make sure the button Menu (1) is selected: Next, use the scroll buttons to go to the regulation icon (2) and press the enter button: API327216...
Page 47: Service Menu
Instruction book 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. See section Icons used for the meaning of the icons.
Page 48 Instruction book Text on image Menu Regulation • Using the Scroll keys, move the cursor to the Service icon (see above, section Menu icon). • Press the Enter key. Following screen appears: Text on image Service Overview Service Plan Next Service History •...
Page 49 Instruction book The figures at the left are the programmed service intervals. For Service interval A, the programmed number of running hours is 4000 hours (upper row) and the programmed number of real time hours is 8760 hours, which corresponds to one year (second row). This means that the controller will launch a service warning when either 4000 running hours or 8760 real hours are reached, whichever comes first.
Page 50 Instruction book Press the Enter key. Following screen appears: Modify the value as required using the ↑ or ↓ scroll key and press the Enter key to confirm. Note: Running hours and real time hours can be modified in steps of 100 hours. Next Service Text on image Next service...
Page 51: Setpoint Menu
Instruction book Service level, Running hours or Real time hours), use the Scroll keys to select the desired action and press the Enter key. 3.11 Setpoint menu 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.
Page 52: Event History Menu
Instruction book Loading Pressure 1 Unloading Pressure 2 Loading Pressure 2 Modify • The screen shows the actual unloading and loading pressure settings for both pressure bands. To modify the settings, move the cursor to the action button Modify and press the Enter key. Following screen appears: •...
Page 53: Modifying General Settings
Instruction book Function To call up the last shutdown 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: Text on image Menu Regulation •...
Page 54 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 • Next, move the cursor to the Settings icon (see above, section menu icon), using the Scroll keys.
Page 55: Info Menu
Enter key to confirm. 3.14 Info menu 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...
Page 56: Week Timer Menu
Menu Regulation • 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. 3.15 Week timer menu Control panel Scroll keys...
Page 57 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 58 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 59 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 60 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 ←...
Page 61 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 62 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 63 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 64 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 65: 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.
Page 66: User Password Menu
Instruction book • Using the scroll keys (1), move the cursor to the test icon (see above, section Menu icon) • Press the enter key (2), following screen appears: Text on image Test Safety Valve Test Not allowed Audit Data •...
Page 67: Web Server
Instruction book • Using the Scroll keys, select the Settings icon (see section Modifying general settings) • Press the Enter key. Following screen appears: • 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.
Page 68 Instruction book • Click on Change adapter settings (1). • Select the Local Area Connection, which is connected to the controller. • Click with the right button and select Properties (1). • Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked.
Page 69 Instruction book • Use the following settings: • IP Address 192.168.100.200 (1) • Subnetmask 255.255.255.0 (2) Click OK (3) and close network connections. Configure a company network (LAN) connection • Ask your IT department to generate a fixed IP address in your company’s network. •...
Page 70 Instruction book • Adapt the network settings in the controller: • Go to Main Menu • Go to Settings (1) • Go to Network (1) API327216...
Page 71 Instruction book • Go to Ethernet (1) • Switch Off (1) the Ethernet communication to allow editing the settings • Adapt IP Address (1) • Adapt Gateway IP (2) • Adapt Subnet Mask (3) • Switch On (4) the Ethernet communication API327216...
Page 72 Instruction book • Wait a few minutes so the LAN network can connect to the controller Configuration of the web server ® The internal web server is designed and tested for Microsoft Internet Explorer. Also "Opera", "Mozilla Firefox", "Safari"and "Chrome" should work. Viewing the controller data All screen shots are indicative.
Page 73 Instruction book Navigation and options • The banner shows the unit type and the language selector. In this example, three languages are available on the controller. • On the left side of the interface, you can find the navigation menu. If a license for ESi is foreseen, the menu contains 3 buttons.
Page 74: Digital Inputs
Instruction book Info status Machine status is always shown on the web interface. Digital inputs Lists all digital inputs and their status. Digital outputs Lists all digital outputs and their status. Special protections Lists all special protections of the unit. Service plan Displays all levels of the service plan and their status.
Page 75: Programmable Settings
Minimum stop time Programmed stop time Power recovery time (ARAVF) 3600 Restart delay 1200 Communication time-out Protections Minimum Factory Maximum setting setting setting Compressor element outlet temperature ˚C 114 (GA 30) (shutdown warning level) Compressor element outlet temperature ˚C (shutdown level) API327216...
Page 76 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 77: Installation
Instruction book Installation Dimension drawings Dimension drawings Dimensions GA 26 and GA 30 Reference Designation Reference Designation Cooling air outlet, cooler Manual drain Cooling air outlet, motor Cooling air inlet, motor API327216...
Page 78: Installation Proposal
If the compressor is installed where the ambient temperature can be below 0 ˚C (32 ˚F), precautions must be taken. 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 on the side of the frame. Take care not to damage the bodywork during lifting or transport.
Page 79 Instruction book Text on drawing Reference Designation Ventilation proposals Minimum free area to be reserved for the compressor installation All piping to be connected stress free to the compressor. Installation guidelines 1. Install the compressor unit on a solid, level floor suitable for taking its weight. 2.
Page 80 The maximum allowable pressure drop over the cooling air ducts is 30 Pa (0.12 in wc). If it exceeds this value, a fan is needed at the outlet of the ducts. Consult Atlas Copco. For ventilation alternatives 1 and 3, the required ventilation capacity to limit the compressor room temperature can be calculated as follows: •...
Page 81: Electrical Connections
Instruction book = cycle frequency = 1 cycle/ 30 s ΔP = P in bar unload load Ti = compressor air inlet temperature in K To = air receiver temperature in K 11. Dryer bypass Electrical connections Important remark 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 82 Instruction book Electrical connections Reference Designation Customer’s installation Main switch (option) Dryer option (1 phase) Motor connection (M1) for all voltages, except 440-460 V - 60 Hz API327216...
Page 83 • Local control: The compressor will react to commands entered by means of the buttons on the control panel. Compressor start/stop commands via Clock function are active, if programmed. • LAN control: The compressor is controlled via a local network. Consult Atlas Copco. Compressor status indication on compressors equipped with an Elektronikon™ Graphic controller...
Page 84: Pictographs
Instruction book Pictographs Description Pictographs Reference Designation Manual condensate drain Automatic condensate drain Warning: voltage Warning: switch off the voltage and depressurize compressor before repairing Warning: before connecting compressor electrically, consult Instruction book for motor rotation direction Torques for steel (Fe) or brass (CuZn) bolts Consult instruction book before greasing Lightly oil gasket of oil filter, screw it on and tighten by hand (approx.
Page 85: Operating Instructions
Instruction book Operating instructions Initial start-up Safety The operator must apply all relevant Safety precautions. Procedure For the position of the air outlet valve and the drain connections, see sections Introduction Condensate system. 1. Consult the sections Electric cable size,Installation proposals Dimension drawings 2.
Page 86 Instruction book Cubicle GA 11 up to GA 30 5. Fit the air outlet valve (AV); see section Introduction for the position of the valve. Close the valve. Connect the air net to the valve. 6. Fit the manual condensate drain valve(s) (Dm). Close the valve. Connect the valve to a drain collector.
Page 87 9. Provide labels, warning the operator that: • The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco). • The compressor is automatically controlled and may be restarted automatically. 10. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of the drive motor (M1) while the motor is coasting to a stop.
Page 88: Before Starting
Instruction book Before starting Procedure Check the oil level, top up if necessary. See section Initial start-up. Starting Procedure For the position of the air outlet valve and the drain connections, see sections Introduction and Condensate system. Control panel of the Elektronikon™ Graphic controller Step Action Switch on the voltage.
Page 89: During Operation
Instruction book During operation Procedure Control panel of the Elektronikon™ Graphic controller Position of the oil level sight glass Regularly check the oil level. During operation, the oil level should be in the centre of the sight glass. If the level is too low: stop the compressor, wait until the compressor has stopped, depressurise the oil system by unscrewing oil filler plug (FC) one turn and wait a few minutes.
Page 90: Checking The Display
Instruction book Checking the display Procedure Control panel of the Elektronikon™ Graphic controller Compressors with Elektronikon™ Graphic 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 means of a number of icons.
Page 91: Taking Out Of Operation
Instruction book Procedure Step Action Press stop button on the control panel. The automatic operation LED goes out and the compressor stops after 45 seconds of unloaded operation. To stop the compressor in the event of an emergency, press emergency stop push button on the control panel.
Page 92: Maintenance
For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits). Service contracts Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work. Consult your Atlas Copco Customer Centre. General When servicing, replace all removed gaskets, O-rings and washers.
Page 93 Test safety valve. 8000 (2) If Atlas Copco Roto-Xtend Duty Fluid is used, change oil and oil filter. Have the oil separator element replaced. Test safety valves. Replace the separator element also if the pressure drop over the separator exceeds 1 bar (14.5 psi).
Page 94: Oil Specifications
In order to achieve the best machine performance and guarantee the reliability, it is required to use genuine Atlas Copco Lubricants. Their tailor made formulation is the result of years of field experience, research and in-house development. Consult the Spare Parts list for part number information.
Page 95 Atlas Copco. Roto Synthetic Fluid XTEND DUTY Atlas Copco's Roto Synthetic Fluid XTEND DUTY is a high quality synthetic 8000 hours lubricant for oil injected screw compressors which keeps the compressor in excellent condition. Because of its excellent oxidation stability, Roto Synthetic Fluid XTEND DUTY can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F).
Page 96: Storage After Installation
Instruction book Note: the presence of dust and/or high humidity may require a shorter exchange interval. Consult Atlas Copco. * Whichever comes first. Storage after installation Procedure Run the compressor regularly, e.g. twice a week, until warm. Load and unload the compressor a few times.
Page 97: Adjustments And Servicing Procedures
Instruction book Adjustments and servicing procedures Drive motor General Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a brush and/or compressed air jet. Bearing maintenance The bearing at the drive end side is lubricated by the oil system and requires no periodic maintenance.
Page 98: Oil And Oil Filter Change
Instruction book Procedure 1. Stop the compressor. Switch off the voltage. 2. Remove the cover of air filter (AF) by turning it anti-clockwise. Remove the filter element. If necessary, clean the cover. 3. Fit the new element and the cover. 4.
Page 99 Instruction book Oil drain plugs Oil drain plug, gear casing 1. Run the compressor until warm. Stop the compressor. Close the air outlet valve and switch off the voltage. Depressurise the compressor by opening manual drain valve(s) (Dm, Dm1). Wait a few minutes and depressurise the air receiver/oil tank (AR) by unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape.
Page 100: 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. • Mount the side baffle that encloses the fan compartment.
Page 101: Safety Valves
Instruction book Safety valves Location of safety valve Operating Operate the safety valve from time to time by unscrewing the cap one or two turns. Retighten it afterwards. Testing Before removing the valve, depressurize the compressor. See also section Problem solving. The safety valve (SV) can be tested on a separate air line.
Page 102: Problem Solving
Instruction book Problem solving Warning Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped, press the emergency stop button and switch off the voltage. Close the air outlet valve and lock it if necessary. If provided, open the manual condensate drain valves.
Page 103 Oil separator clogged Have element replaced Air leakage Have leaks repaired Safety valve leaking Have valve replaced Compressor element out of order Consult Atlas Copco Condition Fault Remedy Excessive oil consumption; oil Oil level too high Check for overfilling. Release...
Page 104: Technical Data
Instruction book Technical data Readings on display Elektronikon™ Control panel of the 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 50-60 ˚C (90-108 ˚F) above cooling air temperature.
Page 105 Cable size Type Approval Recommended Recommended Main wire section (2) wire section (3) fuses (A) (4) GA 30 UL/cUL 4 x AWG2/0 8 x AWG1 (8 x AWG2) (110) GA 30 UL/cUL 4 x AWG2/0 8 x AWG1 (8 x AWG4)
Page 106: Settings Of Fan Motor Circuit Breaker
Instruction book Settings of fan motor circuit breaker Circuit breaker GA 26 and GA 30 Frequency (Hz) Voltage (V) Fan motor circuit breaker Q15 (A) UL/cUL 200-230-460 3.3 / 3.1 / 2.0 Settings for overload relay and fuses GA 30...
Page 107: Compressor Data
Instruction book Compressor data Reference conditions All data specified below apply under reference conditions, see section Reference conditions and limitations. GA 30 Units 125 psi Frequency Maximum unloading bar(e) pressure Nominal working bar(e) pressure Motor shaft speed r/min 3560 Set point, ˚C...
Page 108: Analog Inputs
Instruction book Noise immunity IEC61000-6-2 Mounting Cabinet door Digital outputs Number of outputs 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. Rated voltage DC 30 V DC / 10 A max.
Page 109: Instructions For Use
Instruction book Instructions for use Oil separator vessel This vessel can contain pressurized 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 110: Guidelines For Inspection
Instruction book Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.
Page 111: 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/EC. Compressor Component Description...
Page 112: Declaration Of Conformity
Instruction book Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium (2): Applicable directives (3): Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
Page 114 COMMITTED TO SUSTAINABLE PRODUCTIVITY We stand by our responsibilities towards our customers, towards the environment and the people around us. We make performance stand the test of time. This is what we call — Sustainable Productivity. www.atlascopco.com...

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Atlas Copco GA 30 Instruction Book

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