Atlas Copco GA 55 VSD Instruction Book

Oil-injected rotary screw compressors

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Atlas Copco

Oil-injected rotary screw compressors

GA 55 VSD, GA 75 VSD, GA 90 VSD

Instruction book

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Summary of Contents for Atlas Copco GA 55 VSD

Page 1 Atlas Copco Oil-injected rotary screw compressors GA 55 VSD, GA 75 VSD, GA 90 VSD Instruction book...
Page 3 Atlas Copco Oil-injected rotary screw compressors GA 55 VSD, GA 75 VSD, GA 90 VSD From following serial No. onwards: API 665 000 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.
Page 4 Instruction book Table of contents Safety precautions......................6 ........................... 6 AFETY ICONS ......................6 ENERAL SAFETY PRECAUTIONS ................... 7 AFETY PRECAUTIONS DURING INSTALLATION ....................8 AFETY PRECAUTIONS DURING OPERATION ................9 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR SMARTBOX............10 PECIFIC SAFETY PRECAUTIONS FOR EQUIPMENT WITH General description......................
Page 5 Instruction book 3.10 ..........................46 ERVICE MENU 3.11 ........................50 ODIFYING THE SETPOINT 3.12 ........................52 VENT HISTORY MENU 3.13 ......................53 ODIFYING GENERAL SETTINGS 3.14 ............................55 NFO MENU 3.15 ...........................56 EEK TIMER MENU 3.16 ............................. 65 EST MENU 3.17 ........................66 SER PASSWORD MENU 3.18 ..........................
Page 6 Instruction book ........................ 103 NERGY RECOVERY DATA Installation........................105 ........................105 IMENSION DRAWINGS ......................... 106 NSTALLATION PROPOSAL .......................109 LECTRICAL CONNECTIONS .......................111 OOLING WATER REQUIREMENTS ..........................115 ICTOGRAPHS Operating instructions....................118 ..........................118 NITIAL START ..........................122 EFORE STARTING ............................ 123 TARTING ........................125 URING OPERATION ........................127 HECKING THE DISPLAY ............................127...
Page 7 Instruction book Problem solving......................140 Technical data......................151 11.1 ........................151 EADINGS ON DISPLAY 11.2 ......................152 LECTRIC CABLE SIZE AND FUSES 11.3 ........................157 ROTECTION SETTINGS 11.4 ...........................158 RYER SWITCHES 11.5 ..................158 EFERENCE CONDITIONS AND LIMITATIONS 11.6 ........................159 OMPRESSOR DATA 11.7 ® ..................163 ECHNICAL DATA LEKTRONIKON...
Page 8 Instruction book Safety precautions Safety icons Explanation Danger for 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 9 Instruction book Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
Page 10 Instruction book 16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touched by personnel in normal operation must be guarded or insulated. Other high temperature piping must be clearly marked. 17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure.
Page 11 Instruction book • Air cooling filters of the electrical cabinet are not clogged 9. 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. 10.
Page 12 Instruction book 12. 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. 13.
Page 13 Instruction book • Do not operate the SMARTBOX in areas where cellular modems are not advised without proper device certifications. These areas include environments where cellular radio can interfere such as explosive atmospheres, medical equipment, or any other equipment which may be susceptible to any form of radio interference.
Page 14 Instruction book General description Introduction Introduction GA 55 VSD up to GA 90 VSD are single-stage, oil-injected screw compressors driven by an electric motor. The compressors are enclosed in a sound-insulated bodywork and are available in air-cooled and water cooled version.
Page 15 Instruction book GA Workplace Front view, GA 55 VSD up to GA 90 VSD Workplace 2920 7105 14...
Page 16 Instruction book Rear view, GA 55 VSD up to GA 90 VSD Workplace Reference Name Air receiver Air outlet valve Air cooler Oil cooler CV/Vs Check valve/oil stop valve Automatic condensate outlet Compressor element Elektronikon® Graphic controller Cooling fan Condensate trap...
Page 17 The Workplace Full Feature compressors are provided with 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. Front view, GA 55 VSD up to GA 90 VSD Workplace Full-Feature 2920 7105 14...
Page 18 Instruction book Rear view, GA 55 VSD up to GA 90 VSD Workplace Full-Feature Reference Name Air filter Air receiver Air outlet valve Air cooler Oil cooler CV/Vs Check valve/oil stop valve Automatic condensate outlet Automatic condensate outlet, dryer Dryer Compressor element Elektronikon®...
Page 19 Instruction book Reference Name Electric cubicle Air flow Flow diagrams GA 55 VSD up to GA 90 VSD Workplace 2920 7105 14...
Page 20 Instruction book GA 55 VSD and GA 90 VSD Workplace Full-Feature Reference Description Air inlet Air/oil mixture Wet compressed air Condensate Dry compressed air (Full-Feature) Note: The cooling fan (FN) is not provided on water-cooled compressors. Description Air drawn in through filter (AF) and check valve (CV) is compressed in compressor element (E).
Page 21 Instruction book Full-Feature compressors are provided with a dryer (DR). Oil system Flow diagram Reference Description Air inlet Air/oil mixture Wet compressed air To the air outlet valve in case of a Workplace version. To the dryer in case of a Workplace Full-Feature version. Note: The cooling fan (FN) is not provided on water-cooled compressors.
Page 22 Instruction book Cooling system Air-cooled compressors References Description Intake air Air/oil mixture Wet compressed air Condensate Description The cooling system on air-cooled compressors comprises air cooler (Ca) and oil cooler (Co). The cooling air flow is generated by fan (FN). This cooling fan is switched on and off depending on the operating conditions according a specific algorithm.
Page 23 Instruction book Water-cooled compressors Cooling system, water-cooled compressors References Description Intake air Air/oil mixture Wet compressed air Water flow Description The cooling system on water-cooled compressors comprises air cooler (Cwa) and oil cooler (Cwo). They are connected to a cooling water circuit. The water flows through the inlet pipe, the coolers and the outlet pipe.
Page 24 Instruction book Water-cooled air cooler and oil cooler Condensate system Drain connections Electronic condensate drains, typical example The compressors have an electronic water drain (EWD). The condensate formed in the air cooler accumulates in the collector. When the condensate reaches a certain level, it is discharged through the automatic drain outlet (Da).
Page 25 Instruction book Condensate drain connections, typical example Reference Designation Automatic drain connection Manual drain connection Automatic drain connection of the dryer (only on Full-Feature units) Manual drain connection of the dryer (only on Full-Feature units) Beside each automatic drain outlet is a manual (Dm) condensate drain connection for manually draining of the condensate.
Page 26 Instruction book Electric cabinet for GA 55 VSD up to GA 90 VSD, typical example Reference Designation Transformer Circuit breaker Circuit breaker Contactor Overload relay Z1+L1 EMC filter and choke Frequency converter Earthing terminal Main switch (optional) Electrical diagrams 9820 3140 01...
Page 27 Instruction book Air dryer Flow diagram Air dryer Reference Name Air inlet Air outlet Air/air heat exchanger Air/refrigerant heat exchanger/evaporator Condensate separator Automatic drain / condensate outlet Refrigerant compressor Refrigerant condenser Liquid refrigerant dryer/filter Capillary Bypass valve Condenser cooling fan Pressure switch, fan control Liquid separator Compressed air circuit...
Page 28 Instruction book The cold, dried air flows through heat exchanger (1) where it is warmed up by the incoming air. Refrigerant circuit Refrigeration dryers of ID type contain high efficient refrigerant R410A of the HFC group. Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most of the refrigerant condenses.
Page 29 Instruction book Elektronikon® Graphic controller ® Elektronikon Graphic controller Control panel ® Display of the Elektronikon Graphic controller Introduction The Elektronikon controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) Automatic control of the compressor operation The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor (on compressors running at a fixed speed) or by adapting the motor speed...
Page 30 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 31 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 32 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 33 Instruction book Name Icon Description Active protection functions Emergency stop Shutdown Warning Service Service required Main screen display Value lines display icon Chart display icon General icons No communication / network problem Not valid Input icons Icon Description Pressure Temperature Digital input Special protection 2920 7105 14...
Page 34 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 2920 7105 14...
Page 35 Instruction book Icon Description Test Settings Service Event history (saved data) Access key / User password Network Setpoint Info Navigation arrows Icon Description Down 2920 7105 14...
Page 36 Instruction book Main screen Control panel Scroll keys Enter key Escape key Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed. Typically, 5 different main screen views can be chosen: 1.
Page 37 Instruction book Text on figures Compressor Outlet Flow 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) Text on figures Compressor Outlet Flow Off, Shutdown,... (text varies upon the compressors actual condition) Menu Running hours Element outlet...
Page 38 Instruction book This bar shows the text that corresponds to the selected icon. • Section D shows the Action buttons. These buttons are used: • To call up or program settings • To reset a motor overload, service message or emergency stop •...
Page 39 Instruction book When the Chart (Medium Resolution) is selected, the chart shows the variation of the selected input per hour. The screen shows the last 4 hours. 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.
Page 40 Instruction book Calling up menus Control panel Control panel Scroll keys Enter key Escape key Description When the voltage is switched on, the main screen is shown automatically (see section Main screen): Typical Main screen (2 value lines) • To go to the Menu screen, select <Menu> (3), using the Scroll keys. •...
Page 41 Instruction book • The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings (Regulation) icon is selected. The status bar shows the name of the menu that corresponds with the selected icon. •...
Page 42 Instruction book Text on image Inputs Compressor Outlet Element Outlet Ambient Air Emergency Stop • The screen shows a list of all inputs with their corresponding icons and readings. • If an input is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively (i.c.
Page 43 Instruction book Select Yes to remove or No to quit the current action. In a similar way, another input signal can be highlighted and selected as Main Chart signal: (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.
Page 44 Instruction book Text on image Menu Regulation • Move the cursor to the Outputs icon (see above, section Menu icon, using the Scroll keys. • Press the Enter key. A screen similar to the one below appears: Outputs screen (typical) Text on image Outputs Fan motor...
Page 45 Instruction book Counters Control panel Scroll keys Enter key Escape key Menu icon, Counters Function To call up: • The running hours • The loaded hours • The number of motor starts • The number of hours that the regulator has been powered •...
Page 46 Instruction book Text on figure Menu Regulation • Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon) • Press the Enter key. Following screen appears: Text on figure Counters Running Hours Motor Starts Load Relay VSD 1-20 % rpm in % (the percentage of the time during which the motor speed was between 1 and 20 %)
Page 47 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: 2920 7105 14...
Page 48 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 49 Instruction book • 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 • Scroll through the items to select the desired item and press the Enter key to see the details as explained below.
Page 50 Instruction book warning when either 4000 running hours or 8760 real hours are reached, whichever comes first. Note that the real time hours counter keeps counting, also when the controller is not powered. The figures within the bars are the number of hours to go till the next service intervention. In the example above, the compressor was just started up, which means it still has 4000 running hours or 8280 hours to go before the next Service intervention.
Page 51 Instruction book 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 Level Running Hours...
Page 52 Instruction book 3.11 Modifying the setpoint Control panel Scroll keys Enter key Escape key Menu icon, Setpoint Function On compressors with a frequency converter driven main motor, it is possible to program two different setpoints. This menu is also used to select the active setpoint. Procedure Starting from the Main screen, •...
Page 53 Instruction book Text on image Menu Regulation • Activate the menu by pressing the enter key. A screen similar to the one below appears: Text on image Regulation Setpoint 1 Indirect stop level 1 Direct stop level 1 Setpoint 2 Modify •...
Page 54 Instruction book The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the ↑ or ↓ key of the Scroll keys to modify the settings as required and press the Enter key to accept. If necessary, change the other settings as required in the same way as described above.
Page 55 Instruction book Example of Event History screen • Scroll through the items to select the desired shutdown or emergency stop event. • Press the Enter key to find the date, time and other data reflecting the status of the compressor when that shutdown or emergency stop occurred.
Page 56 Instruction book This screen shows again a number of icons. By default, the User Password icon is selected. The status bar shows the description that corresponds with the selected icon. Each icon covers one or more items , such as •...
Page 57 • Move the cursor to the action button Menu and press the Enter key. Following screen appears: Text on image Menu Regulation • Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon). • Press the Enter key. The Atlas Copco internet address appears on the screen. 2920 7105 14...
Page 58 Instruction book 3.15 Week timer menu Control panel Scroll keys Enter key Escape key Menu icon, Week timer Function • To program time-based start/stop commands for the compressor • To program time-based change-over commands for the net pressure band • Four different week schemes can be programmed. •...
Page 59 Instruction book Text on figure Menu Week Timer • Press the Enter key on the controller. Following screen appears: Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time The first item in this list is highlighted in red. Select the item requested and press the Enter key on the controller to modify.
Page 60 Instruction book Week Action Schemes Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Week Action Scheme 4 • A weekly list is shown. Monday is automatically selected and highlighted in red. Press the Enter key on the controller to set an action for this day. Week Action Scheme 1 Monday Tuesday...
Page 61 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 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 If both the web server functionality and SMARTBOX are required, please contact your local Atlas Copco Customer Center for support. Make sure you are logged in as administrator. • Use the internal network card from your computer or a USB to LAN adapter (see picture below).
Page 70 Instruction book USB to LAN adapter • Use a UTP cable (CAT 5e) to connect to the controller (see picture below). Configuration of the network card (in Windows XP) • Go to My Network places (1). • Click on View Network connections (1). 2920 7105 14...
Page 71 Instruction book • Select the Local Area connection (1), which is connected to the controller. • Click with the right button and select properties (1). • Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked.
Page 72 Instruction book • Use the following settings: • IP Address 192.168.100.200 • Subnetmask 255.255.255.0 Click OK and close network connections. Configuration of the web server Configure the web interface (for Internet Explorer) • Open Internet Explorer and click on Tools - Internet options (2). •...
Page 73 Instruction book • In the Proxy server Group box, click on the Advanced button (1). • In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given but they must be separated with semicolons (;). 2920 7105 14...
Page 74 Instruction book Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture). Click OK (2) to close the window. Viewing the controller data All screen shots are indicative.
Page 75 Instruction book Screen shot (example!) Navigation and options • The banner shows the compressor type and the language selector. In this example, three languages are available on the controller. Compressor settings All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed.
Page 76 Instruction book Counters Lists all current counter values from controller and compressor. 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. 2920 7105 14...
Page 77 Instruction book Special protections Lists all special protections of the compressor. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours. It is also possible to show the current status of the service interval. 3.19 Programmable settings Compressor/motor Minimum...
Page 78 Instruction book Minimum Factory Maximum setting setting setting Proportional band Integration time Parameters Minimum Factory Maximum setting setting setting Minimum stop time Power recovery time 3600 Restart delay 1200 Communication time-out Fan motor starts per day (air-cooled compressors) Protections Minimum Factory Maximum setting...
Page 79 The built-in service timers will give a Service warning message after their respective preprogrammed time interval has elapsed. For specific data, see section Preventive Maintenance. Consult Atlas Copco if a timer setting needs to be changed. The intervals must not exceed the nominal intervals and must coincide logically. See section Modifying general settings.
Page 80 Instruction book SMARTBOX and SMARTLINK SMARTBOX The machine is equipped with a SMARTBOX mounted in the electrical cabinet. The SMARTBOX allows read-out of a number of parameters of the machine on a user login-protected web site called SMARTLINK. The connected antenna is mounted on the outside of the machine. SMARTLINK In case SMARTLINK access is desired, at least one machine SMARTLINK-ready machine is required.
Page 81 Instruction book • You will receive an e-mail with login credentials. • Go to the SMARTLINK web site http://www.atlascopco.com/smartlink, log in with the user credentials. • Enjoy SMARTLINK! • In case more SMARTLINK-ready machines are available, you can add these via My Profile. 2920 7105 14...
Page 82 Instruction book OSCi (optional) Introduction Compressed air produced by oil-injected compressors contains a small quantity of oil. During the cooling of the air in the aftercooler and in the refrigeration dryer (on compressors with built-in refrigeration dryer), oil-containing condensate is formed. The OSCi is a condensate treatment device, designed to separate most of this oil from the water and to sorb it in its replaceable filters, thus preventing contamination of the environment.
Page 83 Instruction book Operation General Condensate flow scheme Condensate inlet Foam cover Oleophilic filter Service drains with valve Air injection connection OGC filter Activated carbon filter Condensate test outlet Condensate outlet The OSCi 3790 housing consists of 3 interconnected vessels. The oil-containing condensate is injected (1) in discontinuous bursts at a downward angle into the first vessel which acts as expansion chamber.
Page 84 Instruction book injected into the condensate. This airflow breaks stable emulsions by enhancing the sorption process of oil onto the OGC. The air supply also prevents the formation of certain anaerobic bacteria. Also the cover of the second vessel is equipped with ventilation holes to prevent pressure buildup. The airflow is taken from the aftercooler (on air cooled units) or from the water separator (WSD) (on water cooled units).
Page 85 Instruction book View of OSCi Clamping ring Foam cover Location of sample bottles and connection material (during shipping only) Service drains with valve Fixation bolts Wire and tube clamp Overflow switch Filter position sensor and visual indication of the filter position 2920 7105 14...
Page 86 Instruction book Detail views View of OSCi inlet Filter position sensor Condensate inlet connections View of OSCi outlet 2920 7105 14...
Page 87 Instruction book Condensate outlet Condensate test outlet Drain plate Condensate outlet connection of the OSCi Condensate sample valve Service drain Manual drain valve Automatic condensate drain 2920 7105 14...
Page 88 Instruction book Putting into operation (commissioning) 1. Verify that the OSCi drain valves (4) are closed. 2. Unscrew the clamping ring (1) of the cover of the first vessel of the OSCi and take off the cover (2). 3. Take out the CDROM and the box (3) with the test bottle and the reference bottle and keep them in a safe place nearby the compressor.
Page 89 Instruction book Drain plate 5. Connect an outlet tube leading to the sewage system (19 mm inner diameter). Since the OSCi functions at atmospheric pressure, the outlet piping must always be positioned below the outlet connection on the OSCi vessel 3, unless a pump (able to run dry) is installed (not provided). 6.
Page 90 Instruction book Elektronikon® display and warnings Following important parameters of the OSCi can be consulted from the Elektronikon® display: • The remaining filter lifetime, expressed as a percentage compared to new filters (100%) • The status of the overflow switch To consult these data, please follow the steps given in the following sections.
Page 91 Instruction book Reference Description OSCi overflow Warnings Service required This warning indicates that the remaining filter lifetime has dropped below 10%. In this case a service kit with new filters needs to be ordered. The service LED at the right side of the Elektronikon® Graphic controller will light up.
Page 92 Instruction book Reference Description Reference Description Protections Service Reset Level Once the filter has reached a lifetime below 10%, this warning will remain active until new filters are inserted correctly (sensor arm in tower 1 should rest on the filter edge!). When the new filters are installed correctly and the percentage is above 10% (normally between 90% and 100%), press enter to reset the status.
Page 93 Instruction book Reference Description Compressor outlet Warning Press the enter button to go into the submenus. Press the down arrow a few times until you reach the following display: In this display you can see that an overflow warning is issued (blinking “Yes”), indicating that the water level in the OSCi is too high.
Page 94 Instruction book • If the filters are not installed properly, oil-containing condensate can leave the OSCi. • When new activated carbon filters are placed, the outgoing water may initially look black (caused by carbon dust). This is not harmful. • Each new filter is provided with a label. The correct position is marked on the label. •...
Page 95 14. Reset the service counter of the Elektronikon®. See section Elektronikon Warnings. Service kits Atlas Copco has a complete range of service kits available. Service kits comprise all parts needed for servicing components and offer the benefits of using genuine Atlas Copco parts while keeping the maintenance budget low.
Page 96 Instruction book OSCi service kit Oleophilic filter Buckets (can be used to receive the used filters after maintenance) OGC filter Gloves Activated carbon filter part number Filter kit OSCi: 2901 1734 00 5.10 Problem solving Condition Fault Remedy A lot of oil entered the Compressor Replace all filters.
Page 97 Instruction book Condition Fault Remedy Water is present on A connection is Stop the compressor. Open the side panel and inspect the the floor around the leaking. OSCi (remove the covers from the vessels). Verify that the compressor (and on A push-in coupling is drain valves (4 - Condensate flow scheme and View of the compressor...
Page 98 Instruction book OSCi air injection Aftercooler (WSD in case of a water- Strainer cooled compressor) Air tube to OSCi vessel 2 Y-connection Solenoid valve Air tube to EWD Automatic as well as manual safety devices to prevent overflow are present. Besides the automatic overflow switch (7-View of OSCi), which is mounted in a side-chamber on the second vessel and gives an alarm when condensate level is too high, the customer can check for high condensate level through the sight glass.
Page 99 The Atlas Copco energy recovery (ER) systems are designed to recover most of the above-mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance.
Page 100 Safety valve Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor. Consult Atlas Copco for installing and connecting the energy recovery unit. Energy recovery systems General The energy recovery systems can be applied as low temperature rise/high water flow systems or as high temperature rise/low water flow systems.
Page 101 Consult section Cooling water requirements to minimise problems due to bad water quality. If in any doubt, consult Atlas Copco. Add an anti-freeze product such as ethylene-glycol to the water in proportion to the expected temperature to avoid freezing.
Page 102 Instruction book Reference Designation Reference Designation Thermostatic bypass valve of ER Oil filter unit Oil/water heat exchanger (ER Oil separator vessel unit) Compressor element Thermostatic bypass valve in oil filter housing Oil cooler (compressor) Aftercooler (compressor) Water inlet Water outlet BV2 starts closing the bypass line over the heat exchanger (HE) at the lower limit of its temperature range.
Page 103 Instruction book ER label Attention: It is only allowed to turn the wheel completely in or out. No in-between position is allowed! The oil cooler bypass valve (BV1) starts closing the bypass over the oil cooler (Co) at the lower limit of its temperature range.
Page 104 Instruction book The temperature of the oil leaving heat exchanger (HE) rises. When the temperature rises above its set point, oil cooler bypass valve (BV1) will gradually allow the oil to be cooled in the oil cooler (Co). • Recovery water flow too high/temperature too low In this case, bypass valve (BV2) will open the bypass line allowing oil from heat exchanger (HE) to be mixed with oil from separator (AR).
Page 105 Instruction book in a degreasing solution. To remove scale formation in the water compartment, a proper descaling process should be applied. Consult Atlas Copco. Energy recovery data Reference conditions See section Reference conditions and limitations. Effective working pressure Consult section Compressor data for the normal working pressure.
Page 106 RECOVERED ENERGY (kW) = 4.2 x water flow (l/s) x water temperature rise (˚C) In the tables below, typical examples are given. Data for low temperature rise/high water flow systems Parameter GA 55 VSD GA 75 VSD GA 90 VSD Recoverable energy 41.3...
Page 107 The drawings are on the CD, supplied with your machine Dimension drawing Model 9820 9467 00 GA 55 VSD, GA 75 VSD, GA 90 VSD Text on drawings Translation or Explanation Compressor cooling air outlet Cooling air outlet of compressor and motor...
Page 108 Instruction book Installation proposal Compressor room example Compressor room example Air cooling Water cooling The direction of the cooling flows may never be inverted Description Compressor Install the compressor unit on a solid, level floor, suitable for taking its weight. 2920 7105 14...
Page 109 Instruction book Position of the compressed air outlet valve. The pressure drop over the air delivery pipe can be calculated from: 1.85 Δp = (L x 450 x Q ) / (d x P), with d = inner diameter of the pipe in mm Δp = pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi)) L = length of the pipe in m P = absolute pressure at the compressor outlet in bar(a)
Page 110 T0 = air receiver temperature in K Bypass system to bypass the dryer during service operations (available as an option, consult Atlas Copco). Air-cooled compressors: To prevent feedback of exhaust air into the cooling inlet, sufficient space should be foreseen above the unit to evacuate the exhaust air.
Page 111 Instruction book should be taken to avoid damage to the machine and its ancillary equipment. In this case, and also if operating above 1000 m (3300 ft), consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Take care not to damage the bodywork during lifting or transport.
Page 112 Instruction book Electrical connections for GA 55 VSD up to GA 90 VSD Reference Designation Customer’s installation (Available as) option Compressor motor Note The complete electrical diagram can be found in the electrical cubicle. The complete electrical diagram can be found on the CD supplied with the machine.
Page 113 Have the modifications checked by Atlas Copco. Stop the compressor and switch off the voltage before connecting external equipment. Only potential-free contacts are allowed. • LAN control: The compressor is controlled via a local network. Consult Atlas Copco. Cooling water requirements General Cooling water needs to fulfill certain requirements in order to avoid problems of scaling, fouling, corrosion or bacterial growth.
Page 114 Instruction book monitoring of concentrations and properties, prevention of sludge formation and maintenance of the system. This applies also to treatment with antifreeze products. 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 –...
Page 115 Instruction book The Ryznar Stability Index is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate. The adhesion of scaling depositions and their effect are different on different materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by the saturation pH value (pH ).
Page 116 Instruction book Interpretation of the values obtained: • RSI < 6: boiler scale formation • 6 < RSI < 7: neutral water • RSI > 7: corrosive water As a general rule, the RSI index should be between 5.6 and 7.5. If that is not the case, contact a specialist.
Page 117 Instruction book The limitation only applies for copper containing systems. 11. Suspended solids Large particles (size > 10 µm) should not be present as they can be filtered out. Small particles (< 0.5 µm) are not taken into account. For particles between 0.5 µm and 10 µm, the following limits apply: Suspended solids (ppm) Type of cooling system Standard...
Page 118 Instruction book Reference Designation Warning: Always read the manual, switch off the voltage, depressurise compressor and lock out/ tag out before repairing. Keep the doors closed during operation 2920 7105 14...
Page 119 Instruction book Reference Designation Switch off the voltage before removing protecting cover inside electric cubicle Warning, voltage Automatic condensate drain Stop the compressor before cleaning the coolers Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx. half a turn) Before connecting the compressor electrically, consult the Instruction book for the motor rotation direction Compressor remains pressurized for 180 seconds after switching off the voltage...
Page 120 Instruction book Operating instructions Initial start-up Safety The operator must apply all relevant Safety precautions. Also consult section Problem solving. For the location of the air outlet valve and the drain connections, see sections Introduction Condensate system. Preparations 1. Consult the sections Electrical cable size, Installation proposal...
Page 121 Transport fixtures of GA 55 VSD up to GA 90 VSD Dryer transport fixtures of GA 55 VSD up to GA 90 VSD 3. Check that the electrical connections correspond to the local codes and that all wires are clamped tight to their terminals.
Page 122 For Full-Feature units: also connect the condensate drain outlet of the dryer to a drain collector. The drain pipes to the drain collector must not dip into the water. For draining of pure condensate water, install an oil/water separator which is available from Atlas Copco as an option. See section Introduction OSCi.
Page 123 1. Loosen the hose clip (2) and disconnect the inlet hose (3). 2. Remove the unloader (1) 3. On GA 55 VSD and GA 90 VSD, lift inlet hose (2), open check valve (CV) and pour 0.75 l (0.20 US gal, 0.17 Imp gal) of compressor oil into the compressor element.
Page 124 Instruction book 2. On water-cooled compressors, close the cooling water drain valves. Open the cooling water inlet valve and the regulation valve. 3. Switch on the voltage. On Full-Feature compressors: switch on the voltage and actuate contactor K12 (dryer fan) on the dryer rail for a few seconds (e.g.
Page 125 Instruction book 4. On water-cooled compressors, also: • Check that the cooling water drain valves in the inlet and outlet pipes are closed. • Open the cooling water inlet valve. • Open the water flow regulating valve. This step can be skipped if the setting of this valve has not been changed.
Page 126 Consult Atlas Copco for best practices in this case. Also consult Atlas Copco in case condensate should form in the oil. For optimal operation, the cooling water outlet temperature must never exceed the value specified in...
Page 127 Instruction book During operation Warnings The operator must apply all relevant Safety precautions. Also consult section Problem solving. Keep the doors closed during operation. They may be opened for short periods only to carry out checks. When the motors are stopped and LED (8) (automatic operation) is alight, the motors may start automatically.
Page 128 Instruction book 3. If the oil level is too low, push the emergency stop button (10) to avoid the compressor to start unexpectedly. 4. Next, close the air outlet valve and open the manual drain valve (Dm) until the air system between oil separator/air receiver vessel and outlet valve is fully depressurized.
Page 129 Instruction book Checking the display Compressors with Elektronikon® Graphic controller: Control panel of the 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. Remedy the trouble if alarm LED (7) is lit or flashes, see section Icons used.
Page 130 Instruction book Procedure Step Action Press stop button (9). Automatic operation LED (8) goes out and the compressor stops after 30 seconds of unloaded operation. To stop the compressor in the event of an emergency, press emergency stop button (10). Alarm LED flashes (7).
Page 131 Instruction book Maintenance Preventive maintenance schedule Warning Control panel Always apply all relevant Safety precautions. Before carrying out any maintenance, repair work or adjustments, do as follows: • Stop the compressor. • Close the air outlet valve and press the test button on top of the electronic water drain(s) until the air system between air receiver and outlet valve is fully depressurized.
Page 132 Instruction book Service contracts Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work. Consult your Atlas Copco Customer Centre. General When servicing, replace all removed O-rings and washers. Intervals The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor.
Page 133 Oil specifications It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of field experience and research. See section Preventive maintenance schedule for the advised replacement intervals and consult the Spare Parts list for part number information.
Page 134 Instruction book Roto-Inject Fluid Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specific composition keeps the compressor in excellent condition. Roto-Inject Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 40 ˚C (104 ˚F). If the compressor is regularly operating in ambient temperatures above 35 °C (95 °F), oil lifetime is reduced...
Page 135 Instruction book Air filter Location of air filter Recommendations 1. Never remove the element while the compressor is running. 2. For minimum downtime, replace the dirty element by a new one. 3. Discard the element when damaged. Procedure 1. Stop the compressor. Switch off the voltage. 2.
Page 136 Instruction book Procedure Oil drain and filler plug on the oil separator vessel Oil drain plugs, check valve and gear casing 2920 7105 14...
Page 137 Instruction book Vent plug, oil cooler Step Description Run the compressor until warm. Stop the compressor after 3 minutes of unloaded operation. Close the air outlet valve and switch off the voltage. Wait a few minutes and depressurise by unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape. Air cooled units: loosen the vent plug (VP) of the oil cooler and wait for 5 minutes.
Page 138 • Next, clean with an air jet in the reverse direction to normal flow. Use low pressure air. If necessary, the pressure may be increased up to 6 bar(e) (87 psig). • If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco. • Remove the cover used during cleaning.
Page 139 Instruction book Safety valves Location of safety valve Position of safety valve (typical view) 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 140 Service kits For overhauling and for preventive maintenance, a wide range of service kits is available. Service kits comprise all parts required for servicing the component and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low.
Page 141 Instruction book 9.11 Disposal of used material Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation.
Page 142 Instruction book Problem solving Warning Always apply all relevant Safety precautions. Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped and close the air outlet valve. Open the manual drain valve(s). Press the emergency stop button and switch off the voltage.
Page 143 If installed, check capacity of compressor room fan On water-cooled compressors, Increase flow cooling water flow too low On water-cooled compressors, Consult Atlas Copco Customer restriction in cooling water system Centre Oil cooler clogged Clean cooler 2920 7105 14...
Page 144 Thermostatic valve malfunctioning Have valve tested. Replace if necessary. Air cooler clogged Clean cooler Compressor element out of order Consult Atlas Copco Customer Centre Excessive oil consumption; oil Incorrect oil causing foam Change to correct oil carry-over through discharge line Oil level too high Check for overfilling.
Page 145 Instruction book Condition Fault Remedy Condensate trap continuously Automatic drain out of order Have system checked. If necessary, discharges air and water replace the automatic drain. Evaporator pressure is too Hot gas bypass valve Have hot gas bypass valve adjusted high or too low at unload incorrectly set or out of order Condenser pressure too high...
Page 146 Main Motor Converter Alarm Fault Below table lists the most important error codes. If another code appears, please contact Atlas Copco. Neos If a problem is detected by the Neos converter, a specific code (Main motor converter alarm) will appear on the Elektronikon display, together with a fault code and a fault description.
Page 147 Short Circuit detected in U phase overcurrent 0x2316 Motor Short Circuit detected in V phase Try to reset the error. overcurrent If error returns, contact Atlas Copco. 0x2317 Motor Short Circuit detected in W phase overcurrent 0x3210 Overvoltage Overvoltage detected...
Page 148 Instruction book Fault Fault Cause Actions code description 0x4311 Drive Overtemperature detected in an IGBT overtemperature 0x4312 Drive Overtemperature detected in the overtemperature heatsink 0x4314 Drive Overtemperature detected in IGBT overtemperature junction UH 0x4315 Drive Overtemperature detected in IGBT overtemperature junction UL 0x4316 Drive...
Page 149 0x6103 Drive failure General fault detected (hardware) Try to reset the error. 0x6104 Drive failure Internal checksum error detected If error returns, contact Atlas Copco. (hardware) 0x6105 Drive failure Internal communication timeout (hardware) 0x6106 Drive failure Internal checksum error detected...
Page 150 CAN cable. Both should be OFF. 0x6112 Drive failure Requested command cannot be Try to reset the error. (software) executed because of limited access If error returns, contact Atlas Copco. level 0x6113 Drive failure CAN communication overload Check CAN-cable connection (software) between Elektronikon and converter.
Page 151 Contact Atlas Copco. Missing motor phase Connect motor cable. Contact Atlas Copco. Safety circuit trigger See Fault 31. Contact Atlas Copco. Safety circuit trigger See Fault 31. Contact Atlas Copco. Too high temperature Check converter cooling fan. Contact Atlas Copco.
Page 152 Instruction book Fault Cause Actions code Too high temperature (general) Check the ambient temperature. Check the cubicle cooling. Check inside of cabinet and heat sink for dust contamination. Contact Atlas Copco. 2920 7105 14...
Page 153 Instruction book Technical data 11.1 Readings on display 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 Depends on the setpoint (desired net pressure). Compressor element Approx.
Page 154 IEC approval Compressor type I (1) Max fuse (1) I (2) Max fuse (2) gL/gG gL/gG GA 55 VSD GA 55 VSD GA 55 VSD GA 55 VSD GA 55 VSD GA 55 VSD GA 55 VSD GA 55 VSD...
Page 155 UL/cUL approval Compressor type I (1) Max fuse (1) I (2) Max fuse (2) HRC form HRC form GA 55 VSD GA 55 VSD GA 55 VSD GA 55 VSD IEC approval Compressor type I (1) Max fuse (1) I (2)
Page 156 Instruction book IEC approval Compressor type I (1) Max fuse (1) I (2) Max fuse (2) gL/gG gL/gG GA 90 VSD GA 90 VSD GA 90 VSD GA 90 VSD UL/cUL approval Compressor type I (1) Max fuse (1) I (2) Max fuse (2) HRC form HRC form...
Page 157 Instruction book Installation method F according table B.52.1. Single-core cables, touching in free air Clearance to wall not less than one cable diameter Maximum allowed current in function of the ambient temperature for installation method F,conductor temperature 70°C Ambient temperature Cable section 30 °C 40 °C...
Page 158 Instruction book • Add 10 % to the total compressor current (I Pack or I FF from the tables) and divide by 2 • 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. •...
Page 159 • Install 80 A fuses on each cable. 11.3 Protection settings Settings for fan motor overload protection (Q15) (F15 for IT) Frequency (Hz) Voltage (V) GA 55 VSD GA 75 VSD GA 90 VSD Q15 (A) Q15 (A) Q15 (A) 10.6...
Page 160 Instruction book Frequency (Hz) Voltage (V) GA 55 VSD GA 75 VSD GA 90 VSD Q15 (A) Q15 (A) Q15 (A) 11.6 11.6 UL/cUL 11.6 11.6 11.4 Dryer switches General The regulating and safety devices are factory-adjusted to give optimum performance of the dryer.
Page 161 Maximum altitude operation (1) 1000 m above sea level Maximum altitude operation (1) 3281 ft above sea level (1): For operation at higher altitude: contact Atlas Copco On water-cooled units also: Maximum cooling water outlet temperature ˚C Maximum cooling water outlet temperature ˚F...
Page 162 Instruction book 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi Temperature of air leaving the outlet valve (approx.), ˚F Workplace Full-Feature Nominal motor power Nominal motor power Dryer power at full load, Workplace Full-Feature units 50 Hz 60 Hz Dryer power at full load, Workplace Full-Feature units 50 Hz...
Page 163 Instruction book Unit 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi Maximum effective working pressure, Workplace bar(e) Maximum effective working pressure, Workplace psig Maximum effective working pressure, Workplace Full- bar(e) 12.8 Feature Maximum effective working pressure, Workplace Full- psig Feature Maximum motor shaft speed...
Page 164 Instruction book Unit 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi Cooling water consumption (at water inlet temperature 4.59 4.59 4.59 between 95 and 104 ˚F and temperature rise of 18 ˚F), water-cooled units Sound pressure level, 50 Hz (according to ISO 2151 dB(A) (2004)) Sound pressure level, 60 Hz (according to ISO 2151...
Page 165 Instruction book Unit 13 bar 13 bar 13 bar 175 psi 175 psi 175 psi Oil capacity, air-cooled US gal 7.13 7.13 7.13 Oil capacity, air-cooled Imp gal 5.94 5.94 5.94 Oil capacity, water-cooled Oil capacity, water-cooled US gal Oil capacity, water-cooled Imp gal Cooling water consumption (at water inlet temperature l/min...
Page 166 Instruction book 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. Digital inputs Number of inputs 10 (Elektronikon®...
Page 167 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 168 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 169 Component Description Number Minimum Inspection of cycles wall frequency (2) thickness GA 55 VSD up to GA 90 VSD 1625 7251 99 Vessel 8 mm 10 years 2 x 10 1202 5401 00 Safety valve 1202 5749 00 Safety valve...
Page 170 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 2920 7105 14...
Page 171 Instruction book 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. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this device.
Page 174 Atlas Copco delivers the products and services that help to increase your business’ efficiency and profitability. Atlas Copco's pursuit of innovation never ceases, driven by our need for reliability and efficiency. Always working with you, we are committed to providing you the customized quality air solution that is the driving force behind your business.

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Ga 75 vsd Ga 90 vsd