Atlas Copco GHS 3800 VSD+ Instruction Book
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Atlas Copco GHS 3800 VSD+ Instruction Book

Oil-sealed rotary screw vacuum pumps
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Atlas Copco
Oil-sealed rotary screw vacuum pumps
GHS 3800 VSD+, GHS 4600 VSD+,
GHS 5400 VSD+
Instruction Book
6996 0227 38
Issue B

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  • Page 1 Atlas Copco Oil-sealed rotary screw vacuum pumps GHS 3800 VSD+, GHS 4600 VSD+, GHS 5400 VSD+ Instruction Book 6996 0227 38 Issue B...
  • Page 3 Atlas Copco Oil-sealed rotary screw vacuum pumps GHS 3800 VSD+, GHS 4600 VSD+, GHS 5400 VSD+ Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

  • Page 5: Table Of Contents

    Instruction book Table of contents Safety precautions ............................7 Safety icons ..............................7 General precautions ............................7 Safety precautions during installation ......................8 Safety precautions during operation ......................10 Safety precautions during maintenance or repair ..................11 General description........................... 13 What is vacuum and how is flow rate understood ..................
  • Page 6 Instruction book Pictographs ..............................79 Options ............................... 80 Energy recovery ............................80 Gas ballast ..............................84 Operating instructions ..........................85 Initial start-up ............................... 85 Starting ................................ 86 During operation ............................87 Taking out of operation ..........................88 Stopping ..............................88 Maintenance ...............................

  • Page 7: Safety Precautions

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

  • Page 8: Safety Precautions During Installation

    Instruction book 6. Avoid contact with pump intake during operation. 7. The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation. 8. It is not allowed to walk or stand on the unit or on its components. 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...
  • Page 9 Instruction book EMC Filter Switch Location DANGER: Ground the neutral point on the power supply to comply with the EMC Directive before turning on the EMC filter. Failure to obey can cause death or serious injury. DANGER: When using a drive with a non-grounding network, high resistance grounding, asymmetric grounding network, place the screw for the EMC filter switch in the OFF position and disable the built-in EMC filter.

  • Page 10: Safety Precautions During Operation

    16. Any vacuum pump placed in an application with inlet gas stream temperatures above the published maximum temperature should be approved by Atlas Copco before the start-up. 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: Safety Precautions During Maintenance Or Repair

    Instruction book • All electrical leads are secure and in good order • Safety valves and other pressure relief devices are not obstructed by dirt or paint • Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse •...
  • Page 12 Instruction book 11. 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. 12.

  • Page 13: General Description

    There are 2 common but different ways to denote the flow rate in a vacuum. The first one is based on the displacement or volumetric flow rate and the second one is based on the throughput or mass flow rate. Atlas Copco vacuum pumps use a volumetric flow rate to denote performance, the unit being Am³/hr. Displacement/volumetric flow rate...

  • Page 14: Introduction

    The GHS 3800 VSD+ up to GHS 5400 VSD+ are single-stage, oil-sealed screw vacuum pumps driven by an electric motor. The vacuum pumps are controlled by the Atlas Copco Elektronikon® Graphic regulator (C). The regulator is fitted to the front door. An electric cabinet (1) comprising fuses, transformers, relays, etc.
  • Page 15 Instruction book Open view front of air cooler version Open view back of air cooler version 6996 0227 38...
  • Page 16 Instruction book Front view of water cooler version Open view front of water cooler version 6996 0227 38...
  • Page 17 Instruction book Open view back of water cooler version 6996 0227 38...
  • Page 18 Instruction book Reference Name Air/ oil cooler Water/ oil cooler Element Elektronikon® Graphic controller Drive motor Oil separator tank Emergency stop button Electric cabinet Vacuum control valve Inlet connection Discharge connection Cable entry Air intake filter Oil filter Electronic thermostatic valve Cooling fan 6996 0227 38...

  • Page 19: Flow Diagram

    Instruction book Flow diagram Flow diagram of air cooler version Flow diagram of water cooler version 6996 0227 38...
  • Page 20 Instruction book Air flow Air comes in through air intake filter (AF) and Vacuum Control Valve (VC) and is displaced by the vacuum pump element (E). A mixture of air and oil flows into the oil separator tank (OT). After passing the air/oil separator filter, clean air, conditioned to a few parts per million, is discharged through the outlet.
  • Page 21 Instruction book Cooling The cooling system has an air/ oil cooler (OC) or water/ oil cooler (WC). For air cooled version, the variable speed fan sucks air over the cooler. The rotational speed of the fan is depending on the operating conditions according to a specific algorithm. 6996 0227 38...

  • Page 22: Condensate System

    Instruction book Condensate system When discharge piping is used, water in the discharge air can condense in the piping and is accumulated in the collector of the outlet pipe, where a drain point (Dr) is available. The pump leaves the factory, with this drain point connected and the external valve (EV) supplied as loose part.
  • Page 23 Instruction book Electrical cabinet (typical example) Reference Description Transformer Circuit breaker Contactor Circuit breaker Frequency converter Electrical diagrams You can find the complete electrical diagram inside the electric cabinet. 6996 0227 38...

  • Page 24: 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 vacuum pump • Protecting the vacuum pump • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) Automatic control of the vacuum pump operation The controller maintains the pressure within programmable limits by automatically adapting the motor speed.
  • Page 25 For vacuum pumps leaving the factory, this function is made inactive. If desired, the function can be activated. Consult the Atlas Copco Customer Center. If activated and provided the regulator was in the automatic operation mode, the vacuum pump will automatically restart if the supply voltage to the module is restored.

  • Page 26: Control Panel

    Instruction book Control panel Elektronikon regulator Elektronikon regulator Reference Designation Function Shows the vacuum pump operating condition and a number of icons to navigate Display through the menu. Pictograph Automatic operation Pictograph General alarm General alarm Flashes if a shut-down warning condition exists. Pictograph Service Service LED...

  • Page 27: Icons Used

    Instruction book Icons used Status icons Name Icon Description When the vacuum pump is stopped, the icon stands still. Stopped/Running When the vacuum pump is running, the icon is rotating. Motor stopped Vacuum pump status Running Purge and Intermediate states Running Vacuum Control Local start/stop Machine control mode...
  • Page 28 Instruction book Name Icon Description Service Service required Value lines display icon Main screen display Chart display icon General icons No communication / network problem Not valid Input icons Icon Description Pressure temperature Digital input Special protection System icons Icon Description Vacuum pump element Frequency converter...
  • Page 29 Instruction book Menu icons Icon Description Inputs Outputs Alarms (Warnings, shutdowns) Counters Test Settings Service Saved data Access key/User password Network Regulation Info General Navigation arrows Icon Description Down 6996 0227 38...

  • Page 30: Main Screen

    Instruction book Main screen Control panel Scroll keys Enter key Escape key Function The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed. Typically, 5 different main screen views can be chosen: 1.
  • Page 31 Instruction book Text on figures Inlet pressure (ii) Flow (iii) Vacuum control, shutdown, (text varies upon the vacuum pumps actual condition) (iv) Menu ES, (text varies upon the vacuum pumps actual condition) Typical Main screen (4 value lines) Text on figures Inlet pressure (ii) Flow...
  • Page 32 Instruction book • Section C is called the Status bar 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 33: Calling Up Menus

    Instruction book 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. A screen similar to the one below opens: Select the layout required and press the Enter key.

  • Page 34: Inputs Menu

    Instruction book • To go to the Menu screen, select Menu, using the Scroll keys • Press the Enter key to select the menu. Following screen appears: • The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings (Regulation) icon is selected.
  • Page 35 Instruction book Menu icon, inputs Function • To display the actual value of the measured data (analog inputs) and the status of the digital inputs (e.g. emergency stop contact, motor overload relay, etc.). • To select the digital input to be shown on the chart in the main screen. Procedure Starting from the Main screen (see Main screen):...
  • Page 36 Instruction book Inputs (ii) Pump discharge (iii) Inlet pressure (iv) Emergency stop Pressure setting selection • 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 37: Outputs Menu

    Instruction book In a similar way, another input signal can be highlighted and selected as Main Chart signal: ( i ) Set as main chart signal Outputs menu Control panel Menu icon, outputs Function To call up Information regarding the actually measured data and the status of some outputs such as the motor overload protection.
  • Page 38 Instruction book • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figures Menu (ii) Regulation • Move the cursor to the outputs icon (see above, section Menu icon, using the scroll keys (1) •...

  • Page 39: Counters

    Instruction book • If an input is in warning or shut down, the original icon is replaced by the warning or shut down icon respectively. Counters Control panel Scroll keys Enter key Escape key Menu icon, counters Function To call up: •...
  • Page 40 Instruction book Text on figures Menu (ii) 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 figures Counters (ii) Running hours (iii) Motor starts (iv)

  • Page 41: 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 vacuum pump 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 (iv) is selected: Next, use the scroll buttons to go to the regulation icon (ii) and press the enter button: 6996 0227 38...

  • Page 42: 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 43 Instruction book Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Using the Scroll keys, move the cursor to the Service icon (see above, section Menu icon). •...
  • Page 44 Instruction book Text on figures Overview (ii) Running Hours (iii) Real Time hours (iv) Reset Example for service level (A): 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).
  • Page 45 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 can be modified in steps of 100 hours, real time hours can be modified in steps of 1hour.

  • Page 46: Modifying The Setpoint

    Instruction book 3.11 Modifying the setpoint Control panel Scroll keys Enter key Escape key Menu icon, setpoint Function On vacuum pumps 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 47 Instruction book Text on figures Regulation (ii) setpoint 1 (iii) Indirect stop level 1 (iv) setpoint Indirect stop level 2 (vi) Modify • The screen shows the actual settings. To modify the settings, move the cursor to the action button Modify and press the Enter key. Following screen appears: •...

  • Page 48: Event History Menu

    Instruction book 3.12 Event history menu Control panel Scroll keys Enter key Escape key Menu icon, Event History Function To call up the last shut-down and last emergency stop data. Procedure Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: •...

  • Page 49: Modifying General Settings

    Instruction book Example of Event History screen • Scroll through the items to select the desired shut-down or emergency stop event. • Press the Enter key to find the date, time and other data reflecting the status of the vacuum pump when that shut-down or emergency stop occurred.
  • Page 50 Instruction book • Next, move the cursor to the Settings icon (see above, section menu icon) using the Scroll keys. • Press the Enter key. Following screen appears: This screen shows again a number of icons. By default, the User Password icon is selected. The status bar shows the description that corresponds with the selected icon.
  • Page 51 Instruction book Text on figures General (ii) Language used (iii) Time (iv) Date Date format (vi) Modify • To modify, select the Modify button using the Scroll keys and press the Enter key. • A screen similar to the one above is shown, the first item (Language) is highlighted. Use the key of the Scroll keys to select the setting to be modified and press the Enter key.

  • Page 52: Info Menu

    Move the cursor to the action button Menu and press the Enter key. Following screen appears: • 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. 6996 0227 38...

  • Page 53: Week Timer Menu

    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 vacuum pump. • To program time-based change-over commands for the net pressure band. •...
  • Page 54 Instruction book Text on figures 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 55 Instruction book Week Action Scheme 1 Monday Tuesday Wednesday Thursday Friday Saturday Sunday • A new window opens. The Modify action button is selected. Press the enter button on the controller to create an action. Monday Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller.
  • Page 56 Instruction book 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 Scroll keys to go to the minutes. Monday Start Save Modify • •...
  • Page 57 Instruction book Save Modify Press the Escape key to leave this window. The action is shown below the day the action is planned. Week Action Scheme 1 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.
  • Page 58 Instruction book A list of 10 weeks is shown. Week Cycle Week 1 Week 2 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...
  • Page 59 Instruction book Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time • A new window opens. Select Week 1 to set the Week Timer active. 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...
  • Page 60 Instruction book • Press the Escape key on the controller to go to the main Week Timer menu. Select Remaining Running Time from the list and press the Enter key on the controller to Modify. Week Timer Week Action Schemes Week Cycle Status Remaining Running Time...

  • Page 61: User Password Menu

    Instruction book 3.16 User password menu Control panel Scroll keys Enter key Escape key Menu icon, Password Function If the password option is activated, it is impossible for not authorized persons to modify any setting. Procedure Starting from the Main screen (see Main screen), •...

  • Page 62: Web Server

    To allow the web server functionality, the network cable that is connected to the SMARTBOX should be unplugged and replaced by the cable of the company network. If both the web server functionality and SMARTBOX are required, please contact your local Atlas Copco Customer Centre for support. Configure a dedicated PC connection •...
  • Page 63 Instruction book • Go the ‘Network and Sharing Center’: • Click “Change adapter settings”. • Select the Local Area connection which is connected to the controller. • Click with the right button and select properties • Use the checkbox Internet Protocol version 4 (TCP/IPv4) (see picture). 6996 0227 38...
  • Page 64 Instruction book • To avoid conflicts uncheck other properties if they are checked. • After selecting TCP/IPv4 click on the properties button to change the settings. • Use the following settings: • IP Address 192.168.100.200 • Subnet mask 255.255.255.0 • Click ok and close network connections 6996 0227 38...
  • Page 65 Instruction book Configure a company network (LAN) connection • Ask your companies IT responsible or IT department to generate a fixed IP address in your companies network. • That IP address will be excluded from the DNS server, so it will be reserved for the Elektronikon Mk5 •...
  • Page 66 Instruction book • Go to ‘Network’ • Go to ‘Ethernet • Switch ‘Off’ the Ethernet communication to allow editing the settings • Adapt IP address • Adapt Gateway address • Adapt Subnet mask • Switch ‘On’ the Ethernet communication again •...
  • Page 67 Instruction book Configuration of the web server. All screen shorts are indicative. The number of displayed fields depends on the selected. Configure your web interface of the Elektronikon The internal web server is designed and tested for Microsoft® Internet explorer. Also “Opera”, “Mozilla Firefox”, “Safari”...
  • Page 68 Instruction book On the left site of the interface you can find the navigation menu. If a license for ESi is foreseen, the menu contains 3 buttons. • Compressor: shows all compressor settings. • Es: shows the ESi status if a license is provided. •...
  • Page 69 Instruction book Digital Inputs Gives an overview of all Digital inputs and status Digital Outputs Shows a list of all the digital outputs and status Special Protections Give an overview of all special protections of the compressor. Service Plan Shows all levels of the service plan and status. This screen only shows the running hours.

  • Page 70: Programmable Settings

    Instruction book 3.18 Programmable settings Vacuum pump/motor Minimum Factory Maximum setting setting setting Set-point 1, Workplace vacuum pumps mbar(a) 1000 Set-point 1, Workplace vacuum pumps Torr Indirect stop level set-point 1 mbar 1000 Indirect stop level set-point 1 Torr Set-point 2, Workplace vacuum pumps mbar(a) 1000 Set-point 2, Workplace vacuum pumps...
  • Page 71 The built-in service timers will give a Service warning message after their respective pre-programmed 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. Terminology...

  • Page 72: Installation

    Instruction book Installation Dimension drawings 6996 0227 38...

  • Page 73: Installation Proposal

    Instruction book Installation proposal 6996 0227 38...
  • Page 74 Instruction book 1) Location: Locate the vacuum pump on a level surface that is clean, well lit, well ventilated and capable taking the weight of the pump. The entire length of the frame base must be supported. Shim where necessary (do not use wood).
  • Page 75 Instruction book Safety Apply all relevant safety precautions, including those mentioned in this book. Compressed air connection The inlet control valve and blow off solenoid are pressure controlled. In order to operate, they need to be connected to a compressed air source. The vacuum pump is supplied with a push-in coupling for nylon tube diameter 8x6 mm.
  • Page 76 In this case, consult Atlas Copco. Also, if operating above 1000 m (3300 ft), consult Atlas Copco. Moving/lifting The vacuum pumps 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 77: Electrical Connections

    These safety precautions depend on the kind of network used (TN, TT, IT system). For the detailed information, please refer to Safety precautions during installation or consult Atlas Copco. Electrical connections for GHS 3800 VSD+ up to GHS 5400 VSD+ Service diagram...
  • Page 78 Have the modifications checked by qualified person. Stop the vacuum pump and switch off the voltage before connecting external equipment. Only potential-free contacts are allowed. • LAN control: The vacuum pump is controlled via a local network. Consult Atlas Copco. 6996 0227 38...

  • Page 79: Pictographs

    Instruction book Vacuum pump status indication The Elektronikon controller is provided with potential-free auxiliary NO contacts (NO = normally open) (K07, K08 and K09) for remote indication of: • Manual or automatic operation (K07) • Warning condition (K08) • Shut-down condition (K09) Maximum contact load: 10 A / 250 V AC.

  • Page 80: Options

    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 vacuum performance. The water can be used for diverse applications.
  • Page 81 Water/ oil cooler Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the vacuum pump. 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 82 Instruction book Operation description The vacuum pump oil flow is controlled by an electronic thermostatic valve (BV), ensuring reliable vacuum pump operation and optimum energy recovery. An electronic thermostatic valve is integrated in the oil filter housing of the vacuum pump and controls the oil flow to the water/ oil cooler (WC) and the air/ oil cooler (OC) of the vacuum pump.
  • Page 83 To clean the oil side, soak the cooler in a degreasing solution. To remove scale formation in the water compartment, a proper descaling process should be applied. Consult Atlas Copco. Energy recovery data...

  • Page 84: Gas Ballast

    For gas ballast kit installation, please follow 1950840128 Option “High Water Handling Capability” installation instruction, consult your Atlas Copco Customer Center. After gas ballast kit installed, the vacuum pumps must be downloaded with high water handling capability (humid version) program.

  • Page 85: Operating Instructions

    Instruction book Operating instructions Initial start-up The operator must apply all relevant Safety precautions. Also consult section Problem solving. 1. Remove the service canopy panel(s) in order to get access to the internal components. 2. Remove the red transport spacers and the related bolts under element (1), coupling housing (2) and oil separator tank (3).

  • Page 86: Starting

    13. Take care that no dirt drops into the oil system. 14. Provide labels, warning the operator that: 15. The vacuum pump may automatically restart after voltage failure (if activated, consult Atlas Copco). 16. The vacuum pump is automatically controlled and may be restarted automatically.

  • Page 87: During Operation

    Instruction book During operation Keep the panels closed during operation When the motors are stopped and LED (8) (automatic operation) is alight, the motors may start automatically. When the automatic operation LED (8) is lit, the regulator is automatically controlling the vacuum pump, i.e.

  • Page 88: Taking Out Of Operation

    Instruction book Checking the display Control panel Elektronikon® Graphic Check the display (2) regularly for readings and messages. The display normally shows the vacuum pump vacuum pressure, while the status of the vacuum pump 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 89: 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 Center. General When servicing, replace all removed O-rings and washers.
  • Page 90 Check the silencer of the blow off valve, clean if necessary. (1) Depending on type of application (normal, medium, harsh) this needs to be done more frequently. Consult your Atlas Copco Customer Center. Preventive Maintenance schedule programmed in the Elektronikon for normal applications...
  • Page 91 * In medium and harsh applications an optional 500 hours oil sample is recommended. The lifetime is based on the mineral oil used for application. ** Based on oil temperature of 90°C. For more information contact Atlas Copco. High water handling capability (humid version) option always use synthetic oil and harsh service intervals...

  • Page 92: Oil Specification

    Any leakage should be attended to immediately. Damaged hoses or flexible joints must be replaced. Oil specification It is strongly recommended to use genuine Atlas Copco vacuum Lubricants. They are the result of years of field experience and research. See section Preventive maintenance schedule for the advised replacement intervals and consult your Spare Parts list for part number information.

  • Page 93: Drive Motor

    Atlas Copco vacuum foodgrade Fluid Special oil, delivered as an option. Atlas Copco’s vacuum Foodgrade Fluid is a unique high quality synthetic lubricant, specially created for oil sealed screw vacuum pumps that provide vacuum for the food industry. This lubricant keeps the vacuum pump in excellent condition.

  • Page 94: Oil And Oil Filter Change

    Instruction book Procedure 22. Stop the vacuum pump. Switch off the voltage. 23. Vent the vacuum pump by opening the plug (Ip) on the lit of the air inlet filter. 24. Remove the cover of the air filter (AF). Remove the filter element. 25.
  • Page 95 Instruction book 4. Open the vent plug (VP) of the oil cooler. 5. Connect a hand drill or cordless screwdriver to the oil drain pump (Op). • Insert the pump shaft into the drill chuck and tighten. • Open the 3-way ball valve (Do). •...
  • Page 96 Instruction book 8. Remove the oil filters. • Clean the seat on the manifold. • Lubricate the gasket of the new oil filters and screw them into place. • Tighten the gasket firmly by hand. 9. Disconnect the oil injection hose (1) and drain the oil. •...

  • Page 97: Coolers

    Instruction book 13. Remove the filler plug (FC). • Fill the oil separator vessel with oil until the level reaches the top of the oil sight glass. • Take care that no dirt drops into the system. Refit and tighten the filler plug (FC). 14.

  • Page 98: Oil Separator Change

    Clean with an air jet in the reverse direction to normal flow. • If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco. After maintenance on the fan and on the coolers: Remove the loose parts that are used as cover.
  • Page 99 Instruction book • Open the required service panels. • Unscrew the bolts of the cover of the oil separator tank • Open the cover of the oil separator tank backwards • Remove the oil separator elements (OS) by turning one quarter counter-clockwise •...

  • Page 100: Pressure Switch

    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 101: Problem Solving

    The pump cannot reach ultimate pressure Oil contaminated Replace oil Solenoid-valve malfunctioning Replace valve Vacuum pump element out of Consult Atlas Copco order Air consumption exceeds air Check equipment connected delivery of vacuum pump Clogged air filter element Replace the filter...
  • Page 102 Temperature of pressure air too Check process air temperature high Vacuum pump element out of Consult Atlas Copco order Converter fault codes If a problem is detected by the converter, a specific code (Main motor converter alarm) will appear on the graphic regulator display, together with a fault code.
  • Page 103 Instruction book Protection General The display shows the problem (Main Motor Converter Alarm) and a fault code (31 in this case). Main motor convertor alarm Fault 6996 0227 38...
  • Page 104 Typical display, Main Motor Converter Alarm (1), Fault (2) Code (0x7130) and description (Motor over temperature (3)) in this case. Below table lists the most important error codes. If another code appears, please contact Atlas Copco. Fault code Fault...
  • Page 105 Check inlet valve Check back pressure oil separator vessel Check drive train Check oil injection Dynamic Braking Transistor (rr) Contact Atlas Copco Braking Resistor Overheat (rH) Contact Atlas Copco External Fault at Input Terminal S3 (EF3) Check control wiring External Fault at Input Terminal S4 (EF4)
  • Page 106 Instruction book Fault code Fault Remedy Overspeed (oS) Contact Atlas Copco Speed Deviation (dEv) Contact Atlas Copco PG Disconnect (PGo) Contact Atlas Copco Input Phase Loss (PF) Check supply voltage Check input wiring Check EMC filter Output Phase Loss (LF)
  • Page 107 Instruction book Fault code Fault Remedy External Fault 2, Input Terminal S2 (EF2) Contact Atlas Copco Mechanical Weakening Detection 1 (oL5) Contact Atlas Copco Mechanical Weakening Detection 2 (UL5) Contact Atlas Copco Current Offset Fault (CoF) Contact Atlas Copco PLC Detection Error 1 (PE1)
  • Page 108 Instruction book Fault code Fault Remedy Terminal Board is Not Properly Connected. Contact Atlas Copco (CPF25) ASIC BB Circuit Error (CPF26) Contact Atlas Copco ASIC PWM Setting Register Error (CPF27) Contact Atlas Copco ASIC PWM Pattern Error (CPF28) Contact Atlas Copco...
  • Page 109 Instruction book Fault code Fault Remedy Drive Timeout Waiting for Response (oFA37) Contact Atlas Copco Control Command Selection Error (oFA38) Contact Atlas Copco Drive Timeout Waiting for Response (oFA39) Contact Atlas Copco Control Response Selection 1 Error (oFA40) Contact Atlas Copco...
  • Page 110 Instruction book Fault code Fault Remedy Same Type of Option Card Already Contact Atlas Copco Connected (oFC02) A/D Conversion Error (oFC05) Contact Atlas Copco Option Response Error (oFC06) Contact Atlas Copco Option RAM Fault (oFC10) Contact Atlas Copco Option Operation Mode Fault (SLMOD)

  • Page 111: Technical Data

    Instruction book Technical data Reading on display Elektronikon® Graphic controller Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limitations). Reference Reading Vacuum pressure Depends on the setpoint (desired net pressure). element outlet Depends on the vacuum pressure setpoint temperature Discharge...

  • Page 112: Electrical Cable Size

    Instruction book Electrical cable size Important The voltage on the vacuum pump terminals must not deviate more than 10% of the nominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1). •...
  • Page 113 Instruction book Vacuum pump specification Itot Imax undervoltage Primary Secondary Primary Secondary Pump Voltage Frequency Approval I tot I tot I tot I tot GHS 4600VSD+ 143.4 159.3 GHS 4600VSD+ 295.6 143.4 328.5 159.3 GHS 4600VSD+ CSA/UL 258.2 125.2 286.9 139.1 GHS 4600VSD+ 118.2...
  • Page 114 Instruction book Installation method B2 according to table B.52.1. Multi-core cable in conduit on a wooden wall. Maximum allowed current in function of the ambient temperature for installation method B2 Installation method C according to table B.52.1. Single-core or multi-core cable on a wooden wall. Maximum allowed current in function of the ambient temperature for installation method C.
  • Page 115 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 Calculation method for IEC: •...
  • Page 116 Instruction book • For a cable of 25 mm², B2 at 45 °C, the maximum current is 63 A x 0.8 = 50.4 A. So 2 parallel cables of 3 x 25 mm² + 25 mm² are sufficient. • Install 50 A fuses on each cable instead of 100 A. Cable sizing according UL/cUL Calculation method according UL 508A, table 28.1 column 5: allowable ampacities of insulated copper conductors (75°C (167°F)).

  • Page 117: Reference Condition And Limitations

    Instruction book • Install the prescribed maximum fuse (150 A) on each cable • Parallel supply cable (2 x 3 phases + 2 PE - configuration (2)): • I = (128 A + 25%)/2 = (128 x 1.25)/2 = 80 A •...

  • Page 118: Vacuum Pump Data

    Instruction book Vacuum pump data Reference condition All data specified below apply under reference conditions, see section Reference conditions limitations. Common vacuum pump data Unit Number of compression stages mbar(a) Ultimate pressure Torr mbar(g) Maximum exhaust back pressure mbar(g) °C Temperature of the air leaving the discharge (approx.) °F GHS 3800 VSD+...
  • Page 119 Instruction book Sound pressure level (according to ISO 2151 (2004)) dB(A) 83 (+/- 3) GHS 4600 VSD+ Nominal motor power Maximum motor shaft speed 3500 Minimum motor shaft speed l/min Maximum cooling water flow Minimum cooling water flow l/min Minimum cooling water flow US GAL Oil capacity Imp.
  • Page 120 Instruction book Imp. GAL 18.7 cu. ft. Sound pressure level (according to ISO 2151 (2004)) dB(A) 85 (+/- 3) GHS 5400 VSD+ (option high water handling capacity) Nominal motor power Maximum motor shaft speed 4000 Minimum motor shaft speed l/min Maximum cooling water flow l/min Minimum cooling water flow...

  • Page 121: Technical Data Elektronikon® Controller

    Instruction book Technical data Elektronikon® controller General 24V AC/16 VA 50/60Hz (+40%/-30%) Supply voltage 24V DC/0.7 A IP54 (front) Type of protection IP21 (back) Ambient and temperature condition IEC60068-2 Operating temperature range -10°C..+60°C (14°F..140°F) Storage temperature range -30°C..+70°C (-22°F..158°F) Permissible humidity Relative humidity 90%No condensation Noise emission IEC61000-6-3...

  • Page 122: Cooling Water Requirement

    Instruction book Cooling water requirement General Cooling water needs to fulfill certain requirements in order to avoid problems of scaling, fouling, corrosion or bacterial growth. In open circuit cooling towers, protective measures must be taken to avoid the growth of harmful bacteria such as legionella pneumophila when there is a risk of inhalation of the water droplets.
  • Page 123 Instruction book Cooling water parameters 1. pH The effect of pH is already included in the Ryznar Stability Index (RSI - see item 4 below), but also the pH itself is subject to limitations: Energy Type of cooling system Materials Standard recovery Containing copper...
  • Page 124 Instruction book saturation pH value (pHs). The saturation pH value is determined by the relationship between the calcium hardness, the total alkalinity, the total solids concentration and the temperature. The Ryznar Stability Index is calculated as follows: RSI = 2*pHs - pH, in which, •...
  • Page 125 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 126 Instruction book 10. Ammonium The limit of 0.5 ppm is a rejection limit. 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 (<...

  • Page 127: Instructions For Use

    Instruction book Instructions for use Air/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 an air/oil separator and must be operated below 0.5bar(g). No alterations must be made to this vessel by welding, drilling or any other mechanical methods without the written permission of the manufacturer.

  • Page 128: 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 vacuum pump.

  • Page 129: Declaration Of Conformity

    Instruction book Declaration of conformity 6996 0227 38...
  • Page 130 Instruction book 6996 0227 38...
  • Page 132 We make performance stand the test of time. This is what we call - Sustainable Productivity Atlas Copco AB (publ) SE-105 23 Stockholm, Sweden Phone: +46 8 743 80 00 Reg. no: 556014-2720 www.atlascopco.com...

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Ghs 4600 vsd+Ghs 5400 vsd+

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