Atlas Copco GA 22 VSD Instruction Book
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Atlas Copco GA 22 VSD Instruction Book

Atlas Copco GA 22 VSD Instruction Book

Oil-injected screw compressors
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Instruction book
Oil-injected screw compressors
GA 22 VSD, GA 26 VSD, GA 30 VSD, GA 37 VSD

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Summary of Contents for Atlas Copco GA 22 VSD

  • Page 1 Instruction book Oil-injected screw compressors GA 22 VSD, GA 26 VSD, GA 30 VSD, GA 37 VSD...
  • Page 3 Atlas Copco Oil-injected screw compressors GA 22 VSD, GA 26 VSD, GA 30 VSD, GA 37 VSD Instruction book Original instructions COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................6 Safety icons..........................6 General safety precautions....................6 Safety precautions during installation................8 Safety precautions during operation..................9 Safety precautions during maintenance or repair............10 Dismantling and disposal......................12 General description...................... 13 Introduction..........................13 Flow diagram..........................17 Condensate system........................19 Regulating system........................
  • Page 5 Instruction book Service menu..........................40 Week timer menu........................41 3.10 Event history menu........................42 3.11 Machine settings menu......................43 3.12 Controller settings menu..................... 45 3.13 Access level..........................48 Installation........................50 Dimension drawings......................... 50 Installation proposal......................53 Electrical connections......................60 Pictographs..........................63 Instructions for prolonged storage.................. 63 Energy recovery......................64 Energy recovery unit......................64 Energy recovery systems......................
  • Page 6 Instruction book Stopping.............................80 Taking out of operation......................81 Maintenance........................82 Preventive maintenance schedule..................82 Oil specifications........................85 Drive motor..........................86 Air filter............................87 Oil, oil filter and oil separator change................87 Coolers............................. 90 Air dryer............................92 RH sensor..........................93 Safety valves..........................93 7.10 Filters............................94 7.11 Service kits..........................94 7.12 Drain replacement........................
  • Page 7 Instruction book Instructions for use....................123 Guidelines for inspection...................124 Pressure equipment directives................. 125 Declaration of conformity..................126 2920 7212 90...

  • Page 8: Safety Precautions

    Instruction book Safety precautions Safety icons Danger: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Notice: Indicates a potential situation which, if not avoided, might result in property damage or in an undesirable result or state.
  • Page 9 Instruction book • If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer center for advice on specific filtration.

  • Page 10: Safety Precautions During Installation

    Instruction book Safety precautions during installation Warning: All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.

  • Page 11: Safety Precautions During Operation

    Instruction book • Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure relieving device or devices as required. •...

  • Page 12: Safety Precautions During Maintenance Or Repair

    Instruction book • Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse • All pre-filters are not clogged • If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air.
  • Page 13 Instruction book • Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels. •...

  • Page 14: Dismantling And Disposal

    Instruction book Dismantling and disposal The device must be disposed according to local regulations. The product is not designed for refurbishing after finished lifecycle. Dismantling Once the end of life of the machine is reached, please follow next steps: 1. Stop the machine. 2.

  • Page 15: General Description

    Instruction book General description Introduction GA 22 VSD up to GA 37 VSD are single-stage, oil-injected screw compressors driven by a Ferrite Assisted Synchronous Reluctance motor. The compressors are controlled by the Atlas Copco Elektronikon Touch controller (ER). The compressors use VSD (English: Variable Speed Drive) technology. This means that the motor speed is automatically adjusted, depending on compressed air demand.
  • Page 16 Instruction book Figure 2: Open side view, GA VSD Pack Full-Feature The Full-Feature compressors have an air dryer which is integrated in the sound-insulated bodywork. The dryer removes condensate from the compressed air by cooling the air to near freezing point. 2920 7212 90...
  • Page 17 Instruction book Figure 3: Front view, GA VSD Full-Feature Figure 4: Open side view, GA VSD Full-Feature Reference Description Air filter Air receiver (oil separator vessel) 2920 7212 90...
  • Page 18 Instruction book Reference Description Air outlet Air cooler Oil cooler Compressor drive / converter Automatic condensate outlet Manual condensate outlet Refrigerant dryer Compressor element Electronic water drain Elektronikon Touch controller Cooling fan Drive motor Oil filter Oil separator (element) Emergency stop button Relative humidity sensor Minimum pressure valve 2920 7212 90...

  • Page 19: Flow Diagram

    Instruction book Flow diagram Figure 5: GA VSD Pack 2920 7212 90...
  • Page 20 Instruction book Figure 6: GA VSD Full-Feature Reference Description Air inlet Air/oil mixture Wet compressed air Condensate Dry compressed air (Full-Feature) 2920 7212 90...

  • Page 21: Condensate System

    Instruction book Air flow Air comes in through filter (AF) and inlet valve (IV) and is compressed in the compressor element (E). A mixture of compressed air and oil flows into the air receiver/oil separator (AR) where oil and air are separated.
  • Page 22 Instruction book Figure 7: Location of the electronic condensate drain, Pack Figure 8: Location of the electronic condensate drain, Full-Feature On Pack units, the condensate formed in the air cooler (Ca) is collected in the condensate trap (MT) and discharged by the electronic drain (ED). On Full-Feature units, a second electronic drain removes the condensate formed in the dryer that is collected in the lower part of the heat exchangere/evaporator When the condensate in the electronic drain reaches a certain level, it is drained via the automatic...
  • Page 23 Instruction book Figure 9: Condensate drain connections, Pack Figure 10: Condensate drain connections, Full-Feature Reference Designation Automatic drain connection Manual drain connection Figure 11: Electronic condensate drain (ED) The Test button (2) on top of the drain can be used in three different ways, according the situation: •...
  • Page 24 Instruction book • By pressing the Test button for at least 5 seconds, the self diagnosis routine will start. LED explanation Operation Description RGB LED Purge valve 1. Green LED The drain CPU blinks 3 times. starts up and loads internal 2.

  • Page 25: Regulating System

    Instruction book Operation Description RGB LED Purge valve If the floater is still Green LED stuck after the blinking: cleaning routine, connected mode. the drain switches to the timer 1. 1 second on. Timer routine routine. When the Yellow LED 2.

  • Page 26: Electrical System

    Instruction book When the pressure continues to increase although the motor already operates at minimum speed, the regulator stops the motor as soon the net pressure reaches a value, equal to the setpoint plus the indirect stop level (typically 0.3 bar above the setpoint). Should the net pressure rise very quickly to a value equal to the setpoint plus the direct stop level (typically 1 bar above the setpoint), the compressor is stopped immediately (without first decreasing the motor speed).

  • Page 27: Air Dryer

    Instruction book Electrical diagrams The complete electrical diagram can be found in the technical documentation, supplied with the unit. Air dryer Full-Feature units are equipped with an air dryer. Flow diagram Figure 13: Flow diagram, air dryer Reference Description Air inlet Air outlet Air/air heat exchanger Air/refrigerant heat exchanger/evaporator...
  • Page 28 Instruction book Refrigerant circuit Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most of the refrigerant condenses. The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to thermostatic expansion valve (8). The refrigerant leaves the capillary tube at about evaporating pressure. The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further evaporation at about constant pressure.

  • Page 29: Controller

    Instruction book Controller Controller functions ™ Figure 14: Elektronikon Touch controller Introduction The controller has the following functions: • Controlling the unit • Protecting the unit • Monitoring components subject to service • Automatic restart after voltage failure (ARAVF) Automatic control of the unit The controller maintains the net pressure between programmable limits by automatically loading and unloading the unit (fixed speed units) or by adapting the motor speed (units with frequency converter).
  • Page 30 Instruction book Shutdown Several sensors are provided on the unit. If one of the measured signals exceeds the programmed shutdown level, the unit will be stopped. Example: If the outlet pressure exceeds the programmed shutdown level, the unit will be stopped. This will be indicated on the display of the controller.

  • Page 31: Control Panel

    Instruction book Control panel Figure 15: Control panel Reference Designation Function Shows the unit operating condition and several icons to Touch screen navigate through the menu. The screen can be operated by touch. Flashes in case of a shut-down, Warning sign is lit in case of a warning condition.
  • Page 32 Instruction book Menu Icon Menu Icon Menu Icon Inputs Outputs Counters Auxiliary Equipment Converters Parameters Service Service Overview Service Plan Service History Service Functions Clean Screen Week Timer Week Remaining Running Time Event History Saved Data Machine Alarms Settings Regulation Control Parameters Auxiliary...
  • Page 33 Instruction book Menu Icon Menu Icon Menu Icon Controller Network Ethernet Settings Settings Settings CAN Settings Localisation Language Date/Time Units User Password Help Information Status icons Icon Description Motor Stopped Motor Stopped Wait Running Unloaded Manual Unload Running Unloaded Wait Running Loaded Failed to Load Running Loaded Wait...
  • Page 34 Instruction book Icon Description Machine Control Mode, Local Machine Control Mode, Remote Machine Control Mode, LAN Automatic Restart After Voltage Failure Week Timer Active System icons Icon Description Basic User Advanced User Service User Antenna 25% Antenna 50% Antenna 75% Antenna 100% Change between screens (indication) Energy recovery...

  • Page 35: Main Screen

    Instruction book Icon Description Analogue Output Menu Reset Auto Restart Filter(s) Cooler Valve(s) Power Meter Input icons Icon Description Pressure Temperature Special Protection Open Closed Note: This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to every machine.

  • Page 36: Quick Access Screen

    Instruction book Description Reference Designation Function The home button is always shown and can be Home button tapped to return to the main screen. On the main screen, the screen information bar shows the serial number of the machine. When Screen information scrolling through menus, the name of the current menu is shown.
  • Page 37 Instruction book Procedure The quick access screen can be viewed by swiping left, starting from the main screen. Description Through this screen, several important settings can be viewed and modified. Reference Function Description Several setpoints can be modified by tapping Setpoints this icon.

  • Page 38: Menu Screen

    Instruction book Menu screen Function This screen is used to display the different menus where settings can be viewed or changed. Procedure The menu screen can be viewed by tapping the menu button or by swiping right, starting from the main screen.

  • Page 39: Data Menu

    Instruction book This is the main structure. It can differ depending on the configuration of the unit. Data menu Function This screen is used to display the following submenus: • Status • Inputs • Outputs • Counters • Auxiliary Equipment These submenus can be entered by tapping the icons.
  • Page 40 Instruction book Description Reference Designation Status menu Inputs menu Outputs menu Counters menu Auxiliary equipment menu Status menu Tap the Status icon to enter the Status menu. This menu shows the current status of the unit. If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the reset button.
  • Page 41 Instruction book Outputs menu Tap the Outputs icon to enter the Outputs menu. This menu shows information about all the outputs. Danger: Voltage-free outputs may only be used to control or monitor functional systems. They should NOT be used to control, switch or interrupt safety related circuits. Check the maximum allowed load on the label.

  • Page 42: Service Menu

    Instruction book Service menu Function This screen is used to display the following submenus: • Service • Service Functions (visible as advanced user) • Clean Screen These submenus can be entered by tapping the icons. Procedure To enter the Service menu screen: 1.

  • Page 43: Week Timer Menu

    Instruction book 3. Confirm by tapping ‘V’ or decline by tapping ‘X’. The service history can be viewed by tapping icon (3). When a service plan interval is reached, a message will appear on the screen. When service has been performed, the service timer can be reset by tapping the reset button (4). Service functions (visible for advanced user) Tap the Service Functions icon to enter the Service Functions menu.

  • Page 44: Event History Menu

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

  • Page 45: Machine Settings Menu

    Instruction book Saved data Tap the Saved Data icon to enter the Saved Data menu. Scroll through the items swiping up and down in this list. The event date and time is shown at the right side of the screen. Press on one of the items in the list for more information reflecting the status of the unit when the shutdown occurred.
  • Page 46 Instruction book A list of all alarms is shown. When pressing on one of the items in this list, the warning and/or shutdown levels are shown for this alarm. Regulation menu Tap the Regulation icon to enter the Regulation menu. Setpoints can be modified and capacity control can be consulted through this menu.

  • Page 47: Controller Settings Menu

    Instruction book This menu shows an overview of all the auxiliary equipment fitted. Through this menu, the parameters of the auxiliary equipment can be changed. Modify a setting When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’...
  • Page 48 Instruction book Procedure To enter the Controller Settings menu screen: 1. Tap the Menu button. 2. Tap the Controller Settings icon. Description Reference Designation Network Settings menu Localisation menu User Password menu Help menu Information menu Network settings menu Tap the Network Settings icon to enter the Network Settings menu. Ethernet Settings The list of Ethernet Settings is shown.
  • Page 49 Instruction book Language The language setting of the controller can be modified through this menu. Date/Time The date and time settings of the controller can be modified through this menu. Units The units displayed can be modified through this menu. Modify a setting When tapping a list item, a selection screen pops up.

  • Page 50: Access Level

    Instruction book This menu can show a link to the web page of your supplier, a helpdesk phone number or other helpful information. Information menu Tap the Information icon to enter the Information menu. This menu shows information about the controller. 3.13 Access level Function...
  • Page 51 Instruction book Reference Designation Function Confirm Tap to confirm the selected user level. Service access level Tap the Service access level icon (1) and confirm (2). The screen information bar (1) now shows the current status of the unit instead of the machine serial number.

  • Page 52: Installation

    Instruction book Installation Dimension drawings The dimension drawing can be found in the technical documentation, supplied with the unit. Outlet Model Voltage Weight Length Width Height connectio Model variant (kg) (mm) (mm) (mm) n size (inch) 380/400/4 387.4 1725 G1 1/2 Pack 200/230 678.4...
  • Page 53 G1 1/2 Table 2: Dimensions and weight Model Length Height Model Voltage (V) Weight (kg) Width (mm) variant (mm) (mm) 380/400/460 387.4 Pack 200/230 678.4 500/575 548.4 GA 22 VSD 380/400/460 516.4 Full-Feature 200/230 743.4 500/575 613.4 2920 7212 90...
  • Page 54 (inch) (inch) 380/400/460 854.07 14.45 16.73 21.37 Pack 200/230 1495.61 23.03 19.96 17.44 500/575 1209.01 25.78 19.96 19.40 GA 22 VSD 380/400/460 1138.46 28.18 19.96 21.37 Full-Feature 200/230 1638.91 23.03 19.96 17.44 500/575 1352.31 25.78 19.96 19.40 380/400/460 865.09 14.45 16.73...

  • Page 55: Installation Proposal

    Instruction book Model Weight Length Width Height Model Voltage (V) variant (lbs) (inch) (inch) (inch) 380/400/460 902.57 14.45 16.73 21.37 Pack 200/230 1599.23 22.71 19.96 17.44 500/575 1389.79 24.48 19.96 19.40 GA 37 VSD 380/400/460 1213.42 28.18 19.96 21.37 Full-Feature 200/230 1768.98 22.71...
  • Page 56 Instruction book Figure 17: Minimum service room Foundation, placement of the compressor unit Install the compressor unit on a solid, level floor, suitable for the compressor mass. It is not allowed to place any extra (damping) material between the floor and the base frame so the frame is not supported on the complete surface.
  • Page 57 Instruction book Electrical connections • The supply voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is highly recommended to keep the voltage drop over the supply cable at nominal current below 5% of the nominal voltage. •...
  • Page 58 Instruction book Oil/water separators are used to separate oil from the condensate to ensure that the condensate meets the requirements of the environmental codes. Drain pipes of the same or different compressors may not be interconnected before the (atmospheric) collector as this can damage the electronic drains.
  • Page 59 Instruction book Note: If the pressure drop of the ducting is too big to be overcome by the standard fan, it is recommended to equip the unit with the “Power Duct Fan” option. This option increases the total allowable pressure drop through the ducts without the need to install an additional external fan.
  • Page 60 Instruction book Air delivery pipe The pressure drop over the air delivery pipe can be calculated from: 1.85 Δp = (L x 450 x Q ) / (d x P) 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) = free air delivery of the compressor in l/s...
  • Page 61 Instruction book The air receiver must be fitted with a correctly sized and approved safety valve that is directly connected with the vessel. At the bottom of the vessel, a drain needs to be installed to collect the condensate. For normal air consumption, the volume of the air net (receiver and piping) can be calculated from: V = (0.25 x Q ) / (f x ΔP x T...

  • Page 62: Electrical Connections

    If the generator or transformer is smaller then this recommendation, contact your supplier to determine the optimal set-up for your specific installation. See below table to determine the apparent drive power. GA 22 VSD GA 26 VSD GA 30 VSD...
  • Page 63 Instruction book Electrical connections Reference Designation Customer's installation Power circuit Motor The complete electrical diagram can be found in the technical documentation, supplied with the unit. Description Note: You can find the correct position for the electrical connections in the section Dimension drawings.
  • Page 64 Instruction book 1. Provide an isolating switch. 2. Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals. 3. Check the fuses. See section Electric cable size and fuses. 4. Connect the power supply cables to the terminals on the EMC filter (Z1). 5.

  • Page 65: Pictographs

    Instruction book Pictographs Figure 18: Pictographs Reference Designation Lock out, tag out the compressor before starting maintenance or repairs Automatic condensate drain Manual condensate drain Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approximately half a turn) Automatic restart after voltage failure (ARAVF) Stop the compressor before cleaning the coolers...

  • Page 66: Energy Recovery

    Instruction book Energy recovery Energy recovery unit Description A large part of the energy required for any compression process is transformed into heat. The major part of the compression heat is dissipated through the oil system. Energy Recovery (ER) systems are designed to recover most of this heat by transforming it into warm or hot water without any adverse effects on compressor performance.

  • Page 67: Energy Recovery Systems

    Instruction book Reference Description Water outlet pipe Valve 1 Valve 2 Valve 3 Thermostatic bypass valve Overpressure valve Heat exchanger Oil drain valve Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor.

  • Page 68: Operation

    Instruction book Water requirements for open water circuits In open, non-recirculating water circuits, major problems that are usually encountered are related to deposit control, corrosion control, and microbiological growth control. To minimize these problems, the water that is being used should meet a number of requirements. Operation Description The compressor oil flow is controlled by two thermostatic bypass valves (BV1 and BV2), ensuring...
  • Page 69 Instruction book Reference Designation Oil/water heat exchanger Compressor element Oil filter Oil separator vessel Thermostatic bypass valve in oil filter housing Thermostatic bypass valve of ER unit Oil cooler Aftercooler Water inlet Water outet BV1 starts closing the bypass line over the oil cooling circuit at the lower limit of its temperature range.

  • Page 70: Maintenance

    Instruction book As soon as the oil temperature reaches the set point (opening temperature) of bypass valve (BV1), the valve starts closing off the bypass over the oil cooling system, gradually allowing the oil to flow through the heat exchanger (HE). As the oil temperature rises to approx. 75 ˚C (167 ˚F) , all the oil passes through the cooling system.

  • Page 71: Energy Recovery Cooling Water Requirements

    Instruction book Thermostatic bypass valves Change the thermostat (BV2) of the Energy Recovery (ER) system at the same interval as the thermostat (BV1) of the unit. Heat exchanger (HE) If the temperature rise over the Energy Recovery (ER) system declines over a period of time with the same basic working conditions, the heat exchanger should be inspected.
  • Page 72 Instruction book Type of cooling system Materials Standard Energy recovery Containing copper 6.8 - 9.3 6.8 - 9.3 Stainless steel with Single pass carbon steel and / or 6.8 - 9.3 6.8 - 9.3 cast iron Stainless steel only 6 - 9.3 6 - 9.3 Containing copper 6.8 - 9.3...
  • Page 73 Instruction book The Ryznar Stability Index is calculated as follows: RSI = 2*pH - pH, in which • pH = measured pH (at room temp) of the water sample • = pH at saturation is calculated from: = (9.3 + A + B) - (C + D), in which •...
  • Page 74 Instruction book Note: As a general rule, the RSI index should be between 5.6 and 7.5. If that is not the case, contact a specialist. 5. Free chlorine (Cl Disinfecting with chlorine is not done in closed systems, neither in energy recovery systems.

  • Page 75: Energy Recovery Data

    Instruction book 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 76 Data for low temperature rise/high water flow systems In the tables below, typical values are given for the above mentioned type of water flow system. Parameter Unit GA 22 VSD GA 26 VSD GA 30 VSD GA 37 VSD Recoverable 20.9...
  • Page 77 Instruction book Parameter Unit GA 22 VSD GA 26 VSD GA 30 VSD GA 37 VSD Pressure drop* WC Temperature ˚C at inlet Temperature ˚F at inlet Temperature ˚C at outlet Temperature ˚F at outlet Input power, 26.5 32.9 37.4 45.6...

  • Page 78: Operating Instructions

    Instruction book Operating instructions Initial start-up Warning: The operator must apply all relevant safety precautions. Also consult section Problem solving. Note: For the location of the air outlet valve and the drain connections, see sections Introduction and Condensate system. 1. Remove the canopy panel(s) in order to get access to the internal components. Remove the red transport spacers (1), transport brackets (2) and the related bolts under the motor.
  • Page 79 Instruction book Close the valve. 6. Check the oil level. The oil level should reach the bottom of the oil filler neck (FC). Minimum level should reach the oil sight glass (GI) when the compressor is stopped. If needed, top up the oil. Take care that no dirt drops into the oil system.

  • Page 80: Starting

    Instruction book The dryer will become damaged when operating in the wrong direction! Rotation arrows, visible through the grating in the roof, are provided on the plate below the fan to indicate the correct rotation direction of the fan motor. 9.
  • Page 81 Instruction book Regularly check the oil level. A few minutes after stopping, the oil level should reach the bottom of the oil filler neck (FC). If the oil level is too low, wait until the compressor has depressurized. Push the emergency stop button to avoid the compressor to start unexpectedly.

  • Page 82: Stopping

    Instruction book Regularly check the controller display. Check the display (1) 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 (see section Problem solving) if alarm LED (2) is lit or flashes, see section Icons used.

  • Page 83: Taking Out Of Operation

    Instruction book Taking out of operation 1. Disconnect the compressor from the mains. 2. Unscrew the oil filler plug only one turn to permit any pressure in the system to escape. 3. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net.

  • Page 84: Maintenance

    Instruction book Maintenance Preventive maintenance schedule Warning: Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Close the air outlet valve. • Wait 10 minutes for the vessel to depressurize. • Press the emergency stop button. •...
  • Page 85 Instruction book Service plans Besides the daily and 3-monthly checks, preventive maintenance actions are specified in the schedule below. Each plan has a programmed time interval at which all service actions belonging to that plan are to be carried out. When reaching the interval, a message will appear on the screen indicating which service plans are to be carried out.
  • Page 86 Instruction book A-service every 4000 B-service every 8000 D-Service every running hours (1) running hours (2) 24000 running hours Check for water leakages Change the air filter Check the prefilters Change the drain(s) filter mesh Change the oil x (4)(7) x (7) Change the oil filter x (4)(7)

  • Page 87: Oil Specifications

    Instruction book Oils In order to achieve the best machine performance and guarantee the reliability, it is required to use genuine lubricants. Their tailor made formulation is the result of years of field experience, research and in-house development. Consult the Spare Parts list for part number information. Danger: Avoid mixing lubricants of different brands or types as they may not be compatible and the oil mix may have inferior properties.

  • Page 88: Drive Motor

    Instruction book Roto Synthetic Fluid XTEND DUTY Atlas Copco's Roto Synthetic Fluid XTEND DUTY is a high quality synthetic lubricant for oil injected screw compressors which keeps the compressor in excellent condition. Because of its excellent oxidation stability, Roto Synthetic Fluid XTEND DUTY can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F).

  • Page 89: Air Filter

    Instruction book Air filter Procedure 1. Stop the compressor. Switch off the voltage. 2. Remove the cover of the air filter (AF) by opening the clip system. Remove the filter element. 3. Fit the new element and the cover. Oil, oil filter and oil separator change Warning: The operator must apply all relevant safety precautions.
  • Page 90 Instruction book Procedure 1. Run the compressor until warm and stop the compressor. • Close the air outlet valve. • Wait 5 minutes for the compressor to depressurize the vessel. • Open the condensate drain valve to depressurize the cooler (see condensate system) and close again.
  • Page 91 Instruction book • With the collector in place, open the drivetrain top cover. • Rotate the motor in counter-clockwise direction for 5 rotations. Do this with an Allen key via the top cover as shown on picture below. • Close the drivetrain top cover. •...

  • Page 92: Coolers

    Instruction book Take care that no dirt drops into the system. Refit and tighten filler plug (FC). 9. Run the compressor loaded for a few minutes. 10. Stop the compressor. 11. Close the air outlet valve and switch off the voltage. •...
  • Page 93 Instruction book 4. Remove dirt from the coolers with a fibre brush. Brush in the direction of the cooling fins. 5. Remove dirt from the fan with a fibre brush. 6. Clean with an air jet in the direction of the normal flow. 7.

  • Page 94: Air Dryer

    Instruction book Air dryer Safety precautions Danger: Refrigeration dryers of ID type contain refrigerant HFC. When handling refrigerant, all applicable Safety precautions must be observed. Please be specifically aware of the following points: • Contact of refrigerant with the skin will cause freezing. Special gloves must be worn. If contacted with the skin, the skin should be rinsed with water.

  • Page 95: Rh Sensor

    Instruction book RH sensor Cleaning Reference Designation Relative humidity sensor 1. Remove the front service panel with the key delivered with the compressor. 2. Disconnect the RH sensor and remove it from the panel by loosening the bolt. 3. Clean the RH sensor with isopropanol (fast solution) or demineralised water and let it dry. 4.

  • Page 96: Filters

    Instruction book Testing Warning: The safety valve (SV) test can only be performed by authorized personnel and is protected by a security code. If the safety valve does not open at the set pressure stamped on the valve, it needs to be replaced. 7.10 Filters UD+ filters...

  • Page 97: Drain Replacement

    Instruction book 7.12 Drain replacement The easiest way to replace a drain is through the CAN Troubleshooting menu. Replacing drains should be done one by one. Removing multiple devices at the same time is not recommended. 1. In the CAN Troubleshooting menu press Make Inoperative and confirm. Make sure that the compressor is off and in local control.

  • Page 98: Problem Solving

    Instruction book Problem solving Warning: Before carrying out any maintenance, repair work or adjustment, stop compressor, wait 3 minutes and close the air outlet valve. Press the emergency stop button and switch off the voltage. Lock out, tag out the electrical supply.
  • Page 99 Oil separator clogged Have element replaced. pressure below normal Air leakage Have leaks repaired. Safety valve leaking Have valve replaced. Compressor element out of Consult Atlas Copco. order Condition Fault Remedy Minimum pressure valve Check and have defective malfunctioning parts replaced.
  • Page 100 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description 0x2000 Check motor, oil, valves and Overcurrent Main Motor element. If the 8978 0x2312 detected at motor overcurrent error returns, side. contact your supplier. Check for shortcircuits or High common line-to-ground Main Motor 8979...
  • Page 101 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description Check which Pt1000 temperature Drive Temperature 16385 0x4001 measurement is overtemperature measurements too high in the exceed 130°C. controller. Overtemperature Let the drive cool Drive 16913 0x4211 detected in fan off.
  • Page 102 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description Overtemperature Drive 17184 0x4320 detected on overtemperature powerboard PCB. Let the drive cool off. Check for Overtemperature excessive Drive detected on 17185 0x4321 ambient overtemperature control board temperature. PCB. Clean the heat Overtemperature sink with...
  • Page 103 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description Drive Main motor Check for 17220 0x4344 overtemperature overload. overloads. 0x5000 Emergency off Check the 20512 0x5020 (STO) emergency stop Emergency stop button. Check for circuit opened. loose connectors Emergency off 20513 0x5021...
  • Page 104 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description Failed temperature Drive failure reading of power 24834 0x6102 (hardware) board. Time-out communication at Try to reset the initialization. error. If the error Internal returns, contact Drive failure 24840 0x6108 communication your supplier.
  • Page 105 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description BB MCU did not jump into Drive failure bootloader state 24854 0x6116 (software) during the initialization phase. BB MCU did not jump into Drive failure application state 24855 0x6117 (software) during the initialization...
  • Page 106 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description CB hardware Drive failure revision is not 24862 0x611E (software) recognized by CB MCU. BB FW Boot Reboot the Drive failure version is not 24863 0x611F system or turn off (software) recognized by CB the unit and then...
  • Page 107 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description First ADC regular Drive failure acquisition Try to reset the 24873 0x6129 (software) sequence not error. If the error executed in time. returns, contact your supplier. Drive failure Foreground part 1 24874 0x612A (software)
  • Page 108 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description Negative value obtained for the Drive failure rotor time during 24885 0x6135 Reset the error (software) IM parameters and repeat the identification procedure. If the procedure. error returns, The identification contact your procedure was supplier.
  • Page 109 Instruction book Code Detailed Code (Decimal) Fault description Actions (Hexadecimal) description Drive failure 33025 0x8101 (software) Check the CAN- Drive failure 33041 0x8111 cable connection (software) between the Drive failure 33042 0x8112 controller and the (software) converter. Check Drive failure 33057 0x8121 communication...
  • Page 110 Instruction book Faults and remedies, dryer For all references hereafter, consult section Air dryer. Condition Fault Remedy Air inlet temperature too Check and correct; if necessary, clean high the aftercooler of the compressor. Check and correct; if necessary, draw Ambient temperature too cooling air via a duct from a cooler high place or relocate the compressor.

  • Page 111: Technical Data

    Instruction book Technical data Readings on display Figure 23: Elektronikon Touch controller Note: The data is valid under the reference conditions. See section Reference conditions and limitations. Reference Reading Air outlet pressure Depends on the setpoint (desired net pressure). Compressor element Approx.
  • Page 112 RCM or RCD Type B (according to IEC/EN 60755) with a sufficient trip level. Currents and fuses (1) Max fuse (1) (2) Max fuse (2) Type gL/gG gL/gG 50/60 50/60 GA 22 VSD Table 11: IEC approval (1) Max fuse (1) (2) Max fuse (2) Type gL/gG gL/gG 50/60 50/60...
  • Page 113 GA 37 VSD Table 14: IEC approval (1) Max fuse (1) (2) Max fuse (2) Class Class Type 50/60 50/60 GA 22 VSD Table 15: UL/cUL approval (1) Max fuse (1) (2) Max fuse (2) Class Class Type 50/60 50/60...
  • Page 114 EN 60204-1 section 828). Motor cables Cable assembly Model Size Quantity Wire ends number GA 22 VSD 1649 8102 35 M8 Type B GA 26 VSD 1649 8102 34 M8 Type B GA 30 VSD 1649 8102 34 M8 Type B...
  • Page 115 Instruction book Max Current IEC 90°C 22 kW 63 A (16mm²) 26 kW 75 A (25mm²) 30 kW 84 A (25mm²) 37 kW 103 A (35mm²) Table 19: Maximum allowed current in function of the ambient temperature for installation method B2, conductor temperature 90°C Installation method B2 according table B.52.1.
  • Page 116 Instruction book • I = 424 A + 10 % = 424 x 1.1 = 466 A • The table for method F 90° C conductor and ambient temperature = 45 ° C allows a maximum current of 386 A for a 150mm² cable. •...
  • Page 117 Instruction book AWG or kcmil Maximum current < 85 A < 100 A < 115 A < 130 A < 150 A < 175 A < 200 A Table 20: Maximum allowed current in function of the wire size Calculation method for UL: •...

  • Page 118: Reference Conditions And Limitations

    Maximum air inlet temperature ˚F Minimum ambient temperature ˚C Minimum ambient temperature ˚F Compressor data Note: The data is valid under the reference conditions. See section Reference conditions and limitations. GA 22 VSD Normal effective bar(e) 12.5 working pressure Maximum effective bar(e)
  • Page 119 Instruction book Minimum motor shaft 1300 1300 1300 1300 speed Nominal motor power Total amount of refrigerant, Full-Feature Oil capacity 18.7 18.7 18.7 18.7 Sound pressure level (according to dB(A) ISO 2151 (2004)) GA 26 VSD Normal effective bar(e) 12.5 working pressure Maximum...
  • Page 120 Instruction book GA 30 VSD Normal effective bar(e) 12.5 working pressure Maximum effective bar(e) working pressure, Pack Maximum effective working bar(e) 12.75 12.75 12.75 12.75 pressure, Full- Feature Maximum motor shaft 7300 7300 6463 5447 speed Minimum motor shaft 1300 1300 1300 1300...

  • Page 121: Technical Data Controller

    Instruction book Maximum motor shaft 8680 8680 7735 6600 speed Minimum motor shaft 1300 1300 1300 1300 speed Nominal motor power Total amount of refrigerant, Full-Feature Oil capacity 20.4 20.4 20.4 20.4 Sound pressure level (according to dB(A) ISO 2151 (2004)) Technical data controller General...

  • Page 122: Inputs And Outputs

    Instruction book Inputs and outputs Digital input Strip Description DI01 Remote start/stop DI02 Remote pressure selection DI03 Remote pressure sensing Empty DI05 Empty Empty DI06 Empty Empty DI07 Empty Empty DI08 Empty Empty DI09 Empty Empty DI10 Empty Empty Digital output Strip Description Potential free contacts...
  • Page 123 Instruction book Digital out Strip Description DO01 Empty General warning DO02 Empty General shutdown DO03 Empty Automatic operation DO04 Empty Empty DO05 Empty Empty DO06 Empty Empty DO07 Dryer (GND) Dryer (24V) DO08 Empty Empty DO09 Y1 Blow-off Solenoid Valve DO10 Y2 recirculation Solenoid Valve (CPC)
  • Page 124 Instruction book Analog input pressure Strip Description PT20 - Outlet pressure PT12 - Vessel pressure (option*) Empty MT01/TT01 - Humidity temperature sensor (ambient temperature) Empty MT01/TT01 - Humidity temperature sensor (relative humidity) *These options are not released as standard options. Additional programming needs to be done in controller database to activate these.

  • Page 125: Instructions For Use

    Instruction book Instructions for use Air/oil separator vessel This vessel can contain pressurised air; this can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator and must be operated within the limits specified on the data plate.

  • Page 126: Guidelines For Inspection

    Instruction book Guidelines for inspection On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.

  • Page 127: Pressure Equipment Directives

    (1) frequency frequency thickness 2204 1070 Vessel 2 x 10 3.9mm 1 year 10 years GA 22 VSD up to GA 37 0830 1010 Safety valve - Minimum Compresso Design maximum Component Description Volume PED Class r type...

  • Page 128: Declaration Of Conformity

    Instruction book Declaration of conformity Figure 24: Typical example of a Declaration of Conformity document Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium Applicable directives Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
  • Page 130 atlascopco.com...

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