Atlas Copco GA 37 VSD, Instruction Book

Page 1: ...INSTRUCTION BOOK API480496 GA 37 VSD ...

Page 2: ......

Page 3: ... thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2019 10 www atlascopco com ...

Page 4: ...WITH SMARTBOX 10 2 General description 11 2 1 INTRODUCTION 11 2 2 AIR FLOW 14 2 3 OIL SYSTEM 15 2 4 COOLING SYSTEM 16 2 5 CONDENSATE SYSTEM 17 2 6 REGULATING SYSTEM 19 2 7 ELECTRICAL SYSTEM 20 2 8 AIR DRYER 21 3 Elektronikon Graphic controller 23 3 1 ELEKTRONIKON GRAPHIC CONTROLLER 23 3 2 CONTROL PANEL 25 3 3 ICONS USED 26 3 4 MAIN SCREEN 30 3 5 CALLING UP MENUS 34 3 6 INPUTS MENU 35 3 7 OUTPUTS M...

Page 5: ... 4 SMARTBOX and SMARTLINK 73 5 Installation 75 5 1 DIMENSION DRAWINGS 75 5 2 INSTALLATION PROPOSAL 76 5 3 ELECTRICAL CONNECTIONS 79 5 4 PICTOGRAPHS 81 6 Operating instructions 84 6 1 INITIAL START UP 84 6 2 BEFORE STARTING 87 6 3 STARTING 87 6 4 DURING OPERATION 88 6 5 CHECKING THE DISPLAY 90 6 6 STOPPING 91 6 7 TAKING OUT OF OPERATION 91 7 Maintenance 93 7 1 PREVENTIVE MAINTENANCE SCHEDULE 93 7 2...

Page 6: ...RIAL 104 8 Problem solving 105 9 Technical data 115 9 1 READINGS ON DISPLAY 115 9 2 ELECTRIC CABLE SIZE AND FUSES 116 9 3 PROTECTION SETTINGS 118 9 4 DRYER SWITCHES 118 9 5 REFERENCE CONDITIONS AND LIMITATIONS 118 9 6 COMPRESSOR DATA 119 9 7 TECHNICAL DATA CONTROLLER 119 10 Instructions for use 121 11 Guidelines for inspection 122 12 Pressure equipment directives 123 13 Declaration of conformity 1...

Page 7: ...f the voltage Depressurize the machine Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work always disconnect and check ...

Page 8: ...siccant bags must be removed before connecting the pipes 5 Air hoses must be of correct size and suitable for the working pressure Never use frayed damaged or worn hoses Distribution pipes and connections must be of the correct size and suitable for the working pressure 6 In case the device is a compressor the aspirated air must be free of flammable fumes vapors and particles e g paint solvents th...

Page 9: ...ystem is present in the air net close to the dryer safety valves must be installed in the vessels of the dryer Also consult following safety precautions Safety precautions during operation and Safety precautions during maintenance These precautions apply to machinery processing or consuming air or inert gas Processing of any other gas requires additional safety precautions typical to the applicati...

Page 10: ... tamper with the sound damping material 12 Never remove or tamper with the safety devices guards or insulations fitted on the machine Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure relieving device or devices as required 13 Yearly inspect the air receiver Minimum wall thickness as specified in the instruct...

Page 11: ...with open flame for inspecting the interior of a machine pressure vessel etc 14 Make sure that no tools loose parts or rags are left in or on the machine 15 All regulating and safety devices shall be maintained with due care to ensure that they function properly They may not be put out of action 16 Before clearing the machine for use after maintenance or overhaul check that operating pressures tem...

Page 12: ... of radio equipment in fuel depots chemical plants or other explosive environments Avoid SMARTBOX operation close to personal medical devices e g hearing aids and pacemakers Consult the manufacturers of the medical device to determine if it is adequately protected Avoid SMARTBOX operation close to other electronic equipment It may cause interference if the equipment is inadequately protected Obser...

Page 13: ...o monitor compressed air installations The electronic control module is fitted to the door at the right side An electric cabinet comprising fuses transformers relays etc is located behind this panel Atlas Copco s integrated VSD Variable Speed Drive technology mirrors air usage automatically adjusting the motor speed depending on the compressed air demand GA Workplace Full Feature The Workplace Ful...

Page 14: ...Front view GA 37 VSD up to GA 45 VSD Workplace Full Feature Instruction book 12 API480496 ...

Page 15: ...let valve Ca Air cooler Co Oil cooler CV Vs Check valve oil stop valve Da Automatic condensate outlet Da1 Automatic condensate outlet dryer DR Dryer E Compressor element ER Elektronikon Graphic controller FN Cooling fan M1 Drive motor OF Oil filter S3 Emergency stop button VP Vent plug Instruction book API480496 13 ...

Page 16: ...le 2 2 Air flow Flow diagrams GA 37 VSD and GA 45 VSD Workplace Full Feature Reference Description A Air inlet B Air oil mixture C Oil D Wet compressed air E Condensate F Dry compressed air Full Feature Instruction book 14 API480496 ...

Page 17: ...which prevents blow back of compressed air from the net Full Feature compressors are provided with a dryer DR 2 3 Oil system Flow diagram Reference Description A Air inlet B Air oil mixture C Oil D Wet compressed air 1 To the dryer in case of a Workplace Full Feature version Note The cooling fan FN is not provided on water cooled compressors Description In air receiver AR most of the oil is remove...

Page 18: ...o 40 C 104 F bypass valve BV starts opening the supply from oil cooler Co At approx 55 C 131 F all the oil flows through the oil cooler 2 4 Cooling system Air cooled compressors References Description A Intake air B Air oil mixture C Oil D Wet compressed air E Condensate Description The cooling system on air cooled compressors comprises air cooler Ca and oil cooler Co The cooling air flow is gener...

Page 19: ...vel it is discharged through the automatic drain outlet Da On Full Feature compressors an additional electronic water drain EWD1 is provided The condensate trap of the heat exchanger is drained by EWD1 and discharged through automatic drain outlet Da1 See also section Air flow Testing the electronic water drain can be done by briefly pressing the test button 1 on top of the device Condensate drain...

Page 20: ...he collector of the drain When the condensate reaches a certain level it is discharged through the automatic drain outlet Da The Test button on top of the drain can be used in three different ways according the situation When pressed during normal operation it starts the manual drain test When pressed during an alarm it resets the control logic By pressing the Test button for at least 5 seconds th...

Page 21: ...tine is unsuccessful a second routine will be started Causes Filter mesh clogged Not enough pressure on drain Internal problem with the drain Checks Is the filter clean and in good condition Is there a minimum pressure of 0 2 bar 2 8 psi in the drain Press the test button T for at least 5 seconds to reset the drain Red LED blinking fast If cleaning routine 1 is completed after 30 cycles but still ...

Page 22: ... Electrical system Electric components The electrical system comprises the frequency converter Neos or Control Technics optional with the following components Electric cabinet for GA 37 VSD and GA 45 VSD typical example Reference Designation T1 Transformer Q15 Circuit breaker Q1 Circuit breaker K15 Contactor F15 Overload relay Z1 L1 EMC filter and choke U1 Frequency converter PE Earthing terminal ...

Page 23: ...chine 2 8 Air dryer On compressors with integrated dryer only Flow diagram Air dryer Reference Name AI Air inlet AO Air outlet 1 Air air heat exchanger 2 Air refrigerant heat exchanger evaporator 3 Condensate separator 4 Automatic drain condensate outlet 5 Refrigerant compressor 6 Refrigerant condenser 7 Liquid refrigerant dryer filter 8 Capillary 9 Bypass valve 10 Condenser cooling fan Instructio...

Page 24: ...ried air flows through heat exchanger 1 where it is warmed up by the incoming air 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 capillary tube 8 The refrigerant leaves the capillary tube at about evaporating pressure The ref...

Page 25: ...with frequency converter A number of programmable settings e g the unloading and loading pressures for fixed speed compressors the setpoint for compressors with frequency converter the minimum stop time and the maximum number of motor starts and several other parameters are hereby taken into account The controller stops the compressor whenever possible to reduce the power consumption and restarts ...

Page 26: ...s Warning A warning message will appear if on Full Feature compressors the dew point temperature is too high in relation to the ambient temperature Service warning A number of service operations are grouped called Service Plans Each Service Plan has a programmed time interval If a time interval is exceeded a message will appear on display 1 to warn the operator to carry out the service actions bel...

Page 27: ...if service is needed 7 Automatic operation LED Indicates that the regulator is automatically controlling the compressor 8 Voltage on LED Indicates that the voltage is switched on 9 Pictograph Voltage 10 Enter key Use this button to confirm the last action 11 Escape key Use this button to go to previous screen or to end the current action 12 Scroll keys Keys to scroll through the menu 13 Stop butto...

Page 28: ...mpressor is running the icon is rotating Compressor status Motor stopped Running unloaded Running loaded Machine control mode or Local start stop Remote start stop Network control Automatic restart after voltage failure Automatic restart after voltage failure is active Week timer Week timer is active Instruction book 26 API480496 ...

Page 29: ...down 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 Instruction book API480496 27 ...

Page 30: ...mpressor element LP HP Dryer Fan Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Menu icons Icon Description Inputs Outputs Alarms Warnings shutdowns Counters Instruction book 28 API480496 ...

Page 31: ...Icon Description or Test Settings Service Event history saved data Access key User password Network Setpoint Info Navigation arrows Icon Description Up Down Instruction book API480496 29 ...

Page 32: ...shed It is switched off automatically after a few minutes when no keys are pushed Typically 5 different main screen views can be chosen 1 Two value lines 2 Four value lines 3 Chart High resolution 4 Chart Medium resolution 5 Chart Low resolution Two and four value lines screens This type of Main screen shows the value of 2 or 4 parameters see section Inputs menu Instruction book 30 API480496 ...

Page 33: ...gures 1 Compressor Outlet 2 Flow 3 Off Shutdown text varies upon the compressors actual condition 4 Menu 5 Running hours 6 Element outlet 7 Load Unload text varies upon the compressors actual condition Section A shows information regarding the compressor operation e g the outlet pressure or the temperature at the compressor outlet On compressors with a frequency converter the load degree flow is g...

Page 34: ...hows the Action buttons These buttons are used To call up or program settings To reset a motor overload service message or emergency stop To have access to all data collected by the regulator The function of the buttons depends on the displayed menu The most common functions are Designation Function Menu To go to the menu Modify To modify programmable settings Reset To reset a timer or message To ...

Page 35: ...the chart shows the variation of the selected input per day The screen shows the evolution over the last 10 days Selection of a main screen view To change between the different screen layouts select the far right icon in the control icons line see value lines display icon or chart display icon in section Icons used and press the Enter key A screen similar to the one below opens Select the layout r...

Page 36: ...cription 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 Press the Enter key to select the menu Following screen appears Instruction book 34 API480496 ...

Page 37: ...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 Move the cursor to the action button Menu and press the Enter key Following screen appears Text on image 1 Menu 2 Regulation Using the Scroll keys ...

Page 38: ... in the list means this input signal is shown on the chart at the main screen Any analog input can be selected Selecting another input signal as main chart signal With the Modify button active light grey background in above screen press the Enter button on the controller A screen similar to the one below appears The first item in the list is highlighted In this example the Net Pressure is selected...

Page 39: ...7 Outputs menu Menu icon Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact on air cooled compressors the Emergency stop contact etc Procedure Starting from the Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Instruction book API480496 37 ...

Page 40: ...o the one below appears Outputs screen typical Text on image 1 Outputs 2 Fan motor 3 Blowoff 4 General shutdown 5 Automatic operation The screen shows a list of all outputs with their corresponding icons and readings If an output is in warning or shutdown the original icon is replaced by the warning or shutdown icon respectively Instruction book 38 API480496 ...

Page 41: ...of motor starts The number of hours that the regulator has been powered The number of load cycles The number of recirculation cycles The number of recirculation cycle failures Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Instruction book API480496 39 ...

Page 42: ... key Following screen appears Text on figure 1 Counters 2 Running Hours 3 Motor Starts 4 Load Relay 5 VSD 1 20 rpm in the percentage of the time during which the motor speed was between 1 and 20 6 Recirculation Cycles 7 Recirculation Failures The screen shows a list of all counters with their actual readings Instruction book 40 API480496 ...

Page 43: ...rol 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 Instruction book API480496 41 ...

Page 44: ...ns used for the meaning of the icons 3 10 Service menu Menu icon Service Function To reset the service plans which are carried out To check when the next service plans are to be carried out To find out which service plans were carried out in the past To modify the programmed service intervals Procedure Starting from the Main screen Move the cursor to the action button Menu and press the Enter key ...

Page 45: ...lowing screen appears Text on image 1 Service 2 Overview 3 Service Plan 4 Next Service 5 History Scroll through the items to select the desired item and press the Enter key to see the details as explained below Overview Text on image 1 Overview 2 Running Hours 3 Real Time Hours 4 Reset Example for service level A Instruction book API480496 43 ...

Page 46: ... hours or 8280 hours to go before the next Service intervention Service plans A number of service operations are grouped called Level A Level B etc Each level stands for a number of service actions to be carried out at the time intervals programmed in the Elektronikon controller When a service plan interval is reached a message will appear on the screen After carrying out the service actions relat...

Page 47: ...Next Service Text on image 1 Next service 2 Level 3 Running Hours 4 Actual In the example above the A Service level is programmed at 4000 running hours of which 0 hours have passed History The History screen shows a list of all service actions done in the past sorted by date The date at the top is the most recent service action To see the details of a completed service action e g Instruction book ...

Page 48: ...ter key 3 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 Highlight the action key Menu using the Scroll keys and press the Enter key Following screen appears Instruction book 46 API480496 ...

Page 49: ... 4 Direct stop level 1 5 Setpoint 2 6 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 The first line of the screen is highlighted Use the Scroll keys 1 to highlight the setting to be modified and press the Enter key 2 Following screen appears Instruction book API480496 47 ...

Page 50: ...e to minimum speed and the compressor will switch to unloaded condition Direct stop occurs when the compressor runs at a speed between minimum and maximum and the net pressure rises above the direct stop setpoint setpoint plus Direct stop level Both settings Indirect stop level and Direct stop level are programmable see section Programmable settings 3 12 Event history menu Menu icon Event History ...

Page 51: ...t 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 3 13 Modifying general settings Menu icon Settings Function To display and modify a number of settings Procedure Starting from the Main screen Move the cursor to the action button Menu and press the Enter key F...

Page 52: ...eneral Automatic restart after voltage failure ARAVF Network Regulation For adapting certain parameters a password may be necessary Example Selecting the General Settings icon gives the possibility to change e g the language the date the date format etc Text on image 1 General 2 Language in Use 3 Time 4 Date 5 Date Format 6 Modify To modify select the Modify button using the Scroll keys and press ...

Page 53: ...internet address Procedure Starting from the Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on image 1 Menu 2 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 Instruction book API480496 51 ...

Page 54: ...week in the cycle one of the four programmed week schemes can be chosen Important remark In the Elektronikon you can select different timers on one day up to 8 actions It is however not possible to program 2 actions at the same time The solution leave at least 1 minute in between 2 actions Example Start Compressor 5 00 AM Pressure Setpoint 2 5 01 AM or later Procedure Starting from the Main screen...

Page 55: ...maining 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 Programming week schemes Select Week action schemes and press Enter A new window opens The first item in the list is highlighted in red Press the Enter key on the controller to modify Week Action Scheme 1 Instruction book API480496 53 ...

Page 56: ...tomatically selected and highlighted in red Press the Enter key on the controller to set an action for this day 1 Week Action Scheme 1 2 Monday 3 Tuesday 4 Wednesday 5 Thursday 6 Friday 7 Saturday 8 Sunday A new window opens The Modify action button is selected Press the enter button on the controller to create an action Instruction book 54 API480496 ...

Page 57: ...is list by using the Scroll keys on the controller When ready press the Enter key to confirm 1 Monday 2 Actions 3 Remove 4 Start 5 Stop 6 Pressure Setpoint 1 7 Modify A new window opens The action is now visible in the first day of the week Instruction book API480496 55 ...

Page 58: ...2 Start 3 Save 4 Modify A pop up window opens Use the or key of Scroll keys to modify the values of the hours Use the or Scroll keys to go to the minutes 1 Monday 2 Time 3 Save 4 Modify Press the Escape key on the controller The action button Modify is selected Use the Scroll keys to select the action Save Instruction book 56 API480496 ...

Page 59: ... on the controller to select the correct actions Press the Enter key to confirm 1 Monday 3 Are you sure 4 No 5 Yes 6 Save 7 Modify Press the Escape key to leave this window The action is shown below the day the action is planned 1 Week Action Scheme 1 Instruction book API480496 57 ...

Page 60: ... 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 Select Week Cycle from the main Week Timer menu list 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Week Timer Inactive 6 Remaining Running Time A list of 10 weeks is shown 1 Week Cycle 2 Week 1 3 Week 2 Instruction book 58 API480496 ...

Page 61: ...eme 1 4 Week Action Scheme 2 5 Week Action Scheme 3 6 Modify Check the status of the Week Timer Use the Escape key on the controller to go back to the main Week Timer menu Select the status of the Week Timer 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Week Timer Inactive 6 Remaining Running Time A new window opens Select Week 1 to set the Week Timer active Instruction book API480496...

Page 62: ... status shows that week 1 is active 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Remaining Running Time 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 Instruction book 60 API480496 ...

Page 63: ...e set in this screen This timer is prior to the Week Timer action 1 Week Timer 2 Week action schemes 3 Remaining Running Time 3 16 Test menu Menu icon Test or Function To carry out a display test i e to check whether the display and LED s are still intact Procedure Starting from the Main screen Move the cursor to the action button Menu and press the enter key 2 following screen appears Instruction...

Page 64: ...rotected by a security code Select the item display test and press the enter key A screen is shown to inspect the display at the same time all LED s are lit 3 17 User password menu 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 section Main screen Move the cursor to Menu a...

Page 65: ...ve a built in web server that allows direct connection to the company network or to a dedicated PC via a local area network LAN This allows to consult certain data and settings via a PC instead of the display of the controller Getting started Make sure you are logged in as administrator Use the internal network card from your computer or a USB to LAN adapter Use a UTP cable CAT 5e to connect to th...

Page 66: ...oller Click with the right button and select Properties 1 Use the check box Internet Protocol version 4 TCP IPv4 1 see picture To avoid conflicts uncheck other properties if they are checked After selecting TCP IPv4 click on the Properties button 2 to change the settings Instruction book 64 API480496 ...

Page 67: ...o generate a fixed IP address in your company s network That IP address will be excluded from the DNS server so it will be reserved for the controller Also get the correct Gateway and Subnet mask settings For example IP 10 25 43 200 Gateway 10 25 42 250 Subnet mask 255 255 254 0 Connect the controller to the company s network LAN by using a UTP cable min CAT 5e Instruction book API480496 65 ...

Page 68: ... Adapt the network settings in the controller Go to Main Menu Go to Settings 1 Go to Network 1 Instruction book 66 API480496 ...

Page 69: ... Ethernet 1 Switch Off 1 the Ethernet communication to allow editing the settings Adapt IP Address 1 Adapt Gateway IP 2 Adapt Subnet Mask 3 Switch On 4 the Ethernet communication Instruction book API480496 67 ...

Page 70: ... Also Opera Mozilla Firefox Safari and Chrome should work Viewing the controller data All screen shots are indicative The number of displayed fields depends on the selected options Open your browser and type the IP address of the controller you want to view in your browser in this example http 192 168 100 100 The interface opens Screen shot example Instruction book 68 API480496 ...

Page 71: ... if a license is provided Preferences allows to change temperature and pressure unit Unit settings All unit settings can be displayed or hidden Put a check mark in front of each point of interest and it will be displayed Only the machine status is fixed and can not be removed from the main screen Analog inputs Lists all current analog input values The measurement units can be changed in the prefer...

Page 72: ...ts Lists all digital outputs and their status Special protections Lists all special protections of the unit Service plan Displays all levels of the service plan and their status This screen shot underneath only shows the running hours It is also possible to show the current status of the service interval Instruction book 70 API480496 ...

Page 73: ...tting Factory setting Maximum setting Minimum stop time sec 5 5 30 Power recovery time sec 10 10 3600 Restart delay sec 0 0 1200 Communication time out sec 10 30 60 Fan motor starts per day air cooled compressors 1 240 240 Protections Minimum setting Factory setting Maximum setting Compressor element outlet temperature shut down warning level C 50 110 119 Compressor element outlet temperature shut...

Page 74: ...e after a power failure ARAVF active Compressor element outlet The recommended minimum setting is 70 C 158 F For testing the temperature sensor the setting can be decreased to 50 C 122 F Reset the value after testing The regulator does not accept inconsistent settings e g if the warning level is programmed at 95 C 203 F the minimum limit for the shut down level changes to 96 C 204 F The recommende...

Page 75: ...unted on the outside of the machine SMARTLINK In case SMARTLINK access is desired at least one machine SMARTLINK ready machine is required Follow the next steps Take the information about the SMARTLINK ready machine s e g picture of the data plate invoice Go to the SMARTLINK web site http www atlascopco com smartlink Click on the left button in the screen below Use the data of the SMARTLINK ready ...

Page 76: ... 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 Instruction book 74 API480496 ...

Page 77: ...g water outlet connection Cooling water inlet Cooling water inlet connection Prepared for manual drain Prepared for manual drain Dryer cooling air inlet Dryer cooling air inlet Dryer cooling air outlet Dryer cooling air outlet Centre of gravity Centre of gravity Mass Mass of the machine Type Machine type Water outlet Energy recovery option Water outlet Energy recovery option Water inlet Energy rec...

Page 78: ... Compressor room example 1 Air cooling 2 Water cooling 3 The direction of the cooling flows may never be inverted Description 1 Compressor Install the compressor unit on a solid level floor suitable for taking its weight Instruction book 76 API480496 ...

Page 79: ...n C For ventilation alternatives 2 and 4 the fan capacity should match the compressor fan capacity at a pressure head equal to the pressure drop over the air ducts Apply separate outlet ducts for the compressor and the dryer 5 The drain pipes to the drain collector must not dip into the water of the drain collector Atlas Copco has oil water separators type OSD or OSCi to separate the oil from the ...

Page 80: ...luding those mentioned in this book Outdoor altitude operation Fix speed compressors can be sold with option rain protection With this option this compressor can be installed outside under a shelter in frost free conditions If frost might occur the appropriate measures 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...

Page 81: ... for use in TT TN networks and are intended for industrial environments where the electrical supply is separated from the residential commercial supply network To use the machine in light industrial commercial or residential environments with a shared supply network or in an IT network extra measures can be required Contact Atlas Copco Set the switch S on I for use in a TT TN network and set the s...

Page 82: ...CD supplied with the machine Description 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 terminals 1 3 and 5 on contactor K21 of the Control Technics converter Connect the power supply cables to terminals 1 3 and 5 o...

Page 83: ...Stop the compressor and switch off the voltage before connecting external equipment Consult Atlas Copco Compressor control modes See also section Control mode selection The following control modes can be selected Local control The compressor will react to commands entered by means of the buttons on the control panel Compressor start stop commands via Clock function are active if programmed Remote ...

Page 84: ...12 15 16 17 Reference Designation 1 Warning Always read the manual switch off the voltage depressurise compressor and lock out tag out before repairing 2 Keep the doors closed during operation Instruction book 82 API480496 ...

Page 85: ...ighten by hand approx half a turn 8 Before connecting the compressor electrically consult the Instruction book for the motor rotation direction 9 Compressor remains pressurized for 180 seconds after switching off the voltage 10 Torques for steel Fe or brass CuZn bolts 11 Switch off the voltage and wait at least 6 minutes before removing the screen 12 Oil outlet option DD PD filters 17 Automatic Re...

Page 86: ...parator vessel 1 Bolts and bushes under the gear casing 2 Supports under motor 3 Transport fixtures of GA 37 VSD and GA 45 VSD 3 Check that the electrical connections correspond to the local codes and that all wires are clamped tight to their terminals The installation must be earthed and protected against short circuits by fuses of the inert type in all phases An isolating switch must be installe...

Page 87: ...ust 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 If the pipes have been fitted outside the room where freezing is possible they must be insulated 8 For compressors with a DD or a DD and PD filter connect the automatic drain of the filters to a suitable drain collector 9 Pro...

Page 88: ...let hose 3 2 Remove the unloader 1 3 Pour 0 75 l 0 20 US gal 0 17 Imp gal of compressor oil into the inlet arrestor 1 For oil specifications see section Oil specifications 4 Reinstall the inlet hose Make sure that all connections are tight Position of arrestor on GA 37 VSD and GA 45 VSD 1 Check the oil level The oil level should be between the oil filler neck FC and the top in the sight glass Gl I...

Page 89: ...otation direction of the fan motor 4 Check the programmed settings 5 Start and run the compressor for a few minutes Check that the compressor operates normally 6 2 Before starting Procedure 1 If the compressor has not run for the past 6 months it is strongly recommended to improve the lubrication of the compressor element before starting See section Initial start 2 Check the oil level Top up if ne...

Page 90: ...otor switches over from star to delta and the compressor starts running loaded 6 4 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 automatic operation is alight the motors may start automatica...

Page 91: ... and open the manual drain valve Dm until the air system between oil separator air receiver vessel and outlet valve is fully depressurized See section Condensate system for location of the outlet valve and water drain 5 Unscrew oil filler plug FC one turn to permit any pressure left in the system to escape Wait a few minutes 6 Remove the plug and add oil until the level reaches the filler opening ...

Page 92: ...ondensate depends on environmental and working conditions 6 5 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 a...

Page 93: ...LED flashes 7 On compressors with an Elektronikon Graphic controller Remedy the problem cause and unlock the button by pulling it out Navigate to the Stop icon on the display by means of the navigation keys 3 4 and press the Select key Press Reset Do not use the emergency stop button for normal stopping Close the air outlet valve Press the test button on top of the electronic water drain s if supp...

Page 94: ...ltage and disconnect the compressor from the mains Unscrew the oil filler plug only one turn to permit any pressure in the system to escape Consult section Oil and oil filter change to locate the filler plug 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 Drain the oil Drain the condensate circuit a...

Page 95: ...al repairs as dangerous high voltage remains on the capacitors of the start and speed regulation unit during some minutes after switching off the voltage Always switch off the voltage Only pressing the emergency stop button is not sufficient to make the compressor voltage free If the machine is equipped with an automatic restart after voltage failure function and if this function is active be awar...

Page 96: ...ection of the normal flow Use low pressure air Keep the compressed air nozzle more than 30 cm away from the condenser to avoid damaging the of condenser fins Remove dust from inside the dryer e g with a vacuum cleaner Do not use water or solvents to clean the condenser 3 monthly 1 Check coolers clean if necessary Remove the air filter element and inspect If necessary clean using an air jet Replace...

Page 97: ...re equipment directives 1 or when the real time counter indicates the service plan whichever comes first 2 or when the real time counter indicates the service plan whichever comes first The indicated oil exchange intervals are valid for standard operating conditions see section Reference conditions and limitations and nominal operating pressure see section Compressor data Exposure of the compresso...

Page 98: ...to use Roto Synthetic Fluid ULTRA or Roto Synthetic Fluid XTEND DUTY See the table below for recommended oil exchange intervals Ambient temperature Element outlet temperature Exchange interval Maximum time interval up to 30 C 86 F up to 95 C 203 F 4000 1 year from 30 C 86 F up to 35 C 95 F see note from 95 C 203 F up to 100 C 212 F 3000 1 year from 35 C 95 F up to 40 C 104 F see note from 100 C 21...

Page 99: ...eratures between 0 C 32 F and 46 C 115 F See the table below for oil exchange intervals Ambient temperature Element outlet temperature Exchange interval Maximum time interval up to 35 C 95 F up to 100 C 212 F 8000 2 years from 35 C 95 F up to 40 C 104 F see note from 100 C 212 F up to 105 C 221 F 6000 2 years above 40 C 104 F above 105 C 221 F 5000 2 years Note the presence of dust and or high hum...

Page 100: ... knob in the extremity of the body 5 Reset the air filter service warning For compressors equipped with an Elektronikon Graphic regulator see section Service menu 7 5 Oil and oil filter change Warning The operator must apply all relevant Safety precautions Always drain the compressor oil at all drain points Used oil left in the compressor can contaminate the oil system and can shorten the lifetime...

Page 101: ...Procedure Oil drain and filler plug on the oil separator vessel Oil drain plugs check valve and gear casing Instruction book API480496 99 ...

Page 102: ...n Clean the seat on the manifold Oil the gasket of the new filter and screw it into place Tighten firmly by hand Remove filler plug FC Fill the air receiver AR with oil until the level reaches the filler neck Take care that no dirt drops into the system Refit and tighten filler plug FC Run the compressor loaded for a few minutes Stop the compressor and wait a few minutes to allow the oil to settle...

Page 103: ...ecessary to wash the coolers with a cleaning agent consult Atlas Copco Remove the cover used during cleaning Mount the service plates 1 at the fan compartment Instructions for compressors with dryer Stop the compressor close the air outlet valve and switch off the voltage Remove any dirt on the condenser inlet with a vacuum cleaner Next clean with an air jet in the reverse direction to normal flow...

Page 104: ... valve SV can be tested on a separate air line If the valve does not open at the set pressure stamped on the valve it needs to be replaced Warning No adjustments are allowed Never run the compressor without safety valve 7 8 Dryer maintenance instructions Safety precautions Refrigeration dryers of ID type contain refrigerant HFC When handling refrigerant all applicable safety precautions must be ob...

Page 105: ...nt which influences its function must be undertaken by an authorised control body The installation should be checked once a year by an authorised control body General For all references see section Introduction The following remarks should be kept in mind Keep the dryer clean Brush or blow off the finned surface of condenser monthly Inspect and clean the electronic condensate drain monthly 7 9 Ser...

Page 106: ...sposed of in an environmentally friendly and safe manner and in line with the local recommendations and environmental legislation Electronic components are subject to the EU Directive 2012 19 EC for Waste Electrical and Electronic Equipment WEEE As such these parts must not be disposed of at a municipal waste collection point Refer to local regulations for directions on how to dispose of this prod...

Page 107: ...til the slot of the handle fits over the blocking edge on the valve body Fit the screw Before electrical maintenance Wait for at least 10 minutes before starting any electrical repairs as dangerous high voltage remains on the capacitors of the start and speed regulation unit during some minutes after switching off the voltage Always switch off the voltage Only pressing the emergency stop button is...

Page 108: ...ment out of order Consult Atlas Copco Safety valve blows Minimum pressure valve malfunctioning Check and have defective parts replaced Oil separator element clogged Have element replaced Safety valve out of order Have valve checked Replace if necessary On Full Feature compressors dryer piping clogged due to formation of ice Have system checked by Atlas Copco Customer Centre Compressor element outl...

Page 109: ...w Condenser pressure too high or too low Fan control switch out of order Replace Fan blades or fan motor out of order Have checked fan fan motor if necessary replace Ambient temperature too high Check and correct if necessary draw cooling air via a duct from a cooler place or relocate the compressor Condenser externally clogged Clean condenser Compressor stops or does not start Electric power supp...

Page 110: ...e converter a specific code Main motor converter alarm will appear on the Elektronikon display together with a fault code Typical display when the compressor is stopped by a shutdown 1 Shutdown Navigate to the Stop icon or to the Protections icon and press Enter 1 Protections 1 General The display shows the problem Main Motor Converter Alarm and a fault code 31 in this case Instruction book 108 AP...

Page 111: ...re 3 in this case Below table lists the most important error codes If another code appears please contact Atlas Copco Fault code Fault description Cause Actions 0x1111 Undervoltage Main Power supply voltage too low or missing links in the control panel Check if main supply voltage is within specs Check main fuses Check for loose connectors at the control unit of the converter and Elektronikon Chec...

Page 112: ...ture Let drive cool off Check for excessive ambient temperature Clean heatsink with compressed air Clean inlet filter cubicle Ensure proper flow of cooling air in compressor room Check if supply voltage is within specs 0x3225 Undervoltage Undervoltage detected Check if main supply voltage is within specs Check main fuses 0x3226 Overvoltage Overvoltage or overtemperature detected in IGBT U phase Le...

Page 113: ...junction VL 0x4318 Drive overtemperature Overtemperature detected in IGBT junction WH 0x4319 Drive overtemperature Overtemperature detected in IGBT junction WL 0x4320 Drive overtemperature Overtemperature detected in powerboard 0x4321 Drive overtemperature Overtemperature detected in control board 0x4322 Drive overtemperature Overtemperature detected in IGBT board U phase 0x4323 Drive overtemperat...

Page 114: ... 0x6106 Drive failure hardware Internal checksum error detected 0x6107 Drive failure hardware Internal communication timeout 0x6108 Drive failure hardware Internal communication timeout 0x6109 Drive failure hardware Internal checksum error detected 0x610A Drive failure hardware Internal communication overload 0x610B Drive failure hardware Internal control overload 0x610C Drive failure hardware CAN...

Page 115: ...Check for loose connectors at the control unit of the converter 0x8401 Overvoltage Motor maximum speed exceeded Try to reset the error If error returns contact Atlas Copco 0x8402 Overvoltage Motor startup unsuccessful requested speed not reached Wait until the vessel depressurizes by blow off by not resetting the fault immediately If the problem persists contact Atlas Copco 0x9001 Hardware run ena...

Page 116: ... thermistor Check the ambient temperature Clean the motor cooling fins Contact Atlas Copco 27 O ht3 Converter overheating thermal model Check the ambient temperature Check the cubicle cooling Contact Atlas Copco 32 PH High input voltage phase imbalance or input phase loss Check supply phases Contact Atlas Copco 102 O ht4 Converter overheating Power module Check the ambient temperature Check the cu...

Page 117: ...e reference conditions see section Reference conditions and limitations Reference Reading Air outlet pressure Depends on the setpoint desired net pressure Compressor element outlet temperature Approx 60 C 108 F above ambient temperature Dewpoint temperature on Full Feature compressors Approx 4 C 39 F Instruction book API480496 115 ...

Page 118: ...han the values proposed below Currents are calculated with the full service factor but we suggest to add 10 due to over and under voltage Fuses are maximum allowed values calculated for full service factor and 10 over and under voltage Caution Always double check the fuse size versus the calculated cable size If required reduce fuse size or enlarge cable size Cable length should not exceed the max...

Page 119: ...e of the recommended maximum fuse size on each cable Size PE cable For supply cables up to AWG8 same size as the supply cables For supply cables larger than AWG8 use maximum allowed ampacity of the selected supply cables and compare with value in table below see CEC Part 1 table 17 100 A use AWG8 200 A use AWG6 300 A use AWG4 Always check the voltage drop over the cable less than 5 of the nominal ...

Page 120: ...nditions and limitations Reference conditions Air inlet pressure absolute bar 1 Air inlet temperature C 20 Relative humidity 0 Working pressure See section Compressor data Limits Maximum working pressure See section Compressor data Minimum working pressure bar e 4 Maximum air inlet temperature C 46 Minimum ambient temperature C 0 Maximum altitude operation 1 m 1000 m above sea level Maximum altitu...

Page 121: ...1172 Temperature of air leaving the outlet valve approx Workplace Full Feature C 23 23 23 Nominal motor power kW 37 37 37 Dryer power at full load Workplace Full Feature units kW 50 Hz 60 Hz 1 34 1 62 1 34 1 62 1 34 1 62 Refrigerant type Workplace Full Feature R410A R410A R410A Refrigerant quantity Workplace Full Feature kg 50 Hz 60 Hz 0 97 1 01 0 97 1 01 0 97 1 01 Oil capacity air cooled l 21 21 ...

Page 122: ...pe 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 Graphic controller p n 1900 5200 10 1900 5200 19 Supply by controller 24 V DC Supply protection Short circuit protected to ground Input protection Not isolated Analog inputs Number of pressure inputs 2 Elektronikon Graphic controller p n 1900 5200 10 1...

Page 123: ...tten permission of the manufacturer The pressure and temperature of this vessel must be clearly indicated The safety valve must correspond with pressure surges of 1 1 times the maximum allowable operating pressure It should guarantee that the pressure will not permanently exceed the maximum allowable operating pressure of the vessel Use only oil as specified by the manufacturer Original bolts have...

Page 124: ...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 Local legal requirements and or use outside the limits and or conditions as specified by the manufacturer may require other inspection periods as mentioned below Instruction book 122 API480496 ...

Page 125: ...25 5641 99 Vessel 43 1 l 15 bar e 10 C 120 C II 0830 1008 39 Safety valve IV 0830 1008 40 Safety valve IV 0832 1000 78 Safety valve IV 0832 1000 79 Safety valve IV Compressor type Component Description Number of cycles 1 Minimum wall thickness Inspection frequency 2 GA 37 VSD and GA 45 VSD 1625 5641 99 Vessel 2 x 106 8 mm 10 years 0830 1000 38 Safety valve 0830 1000 40 Safety valve 0832 1000 78 Sa...

Page 126: ...gium 2 Applicable directives 3 Standards used On the Declaration of Conformity Declaration by the Manufacturer the harmonized and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this device Instruction book 124 API480496 ...

Page 127: ......

Page 128: ...stomers towards the environment and the people around us We make performance stand the test of time This is what we call Sustainable Productivity www atlascopco com Atlas Copco Airpower NV All rights reserved Designs and specifications are subject to change without notice or obligation ...