Atlas Copco GA11, Instruction Book

Page 1: ...Atlas Copco Oil injected rotary screw compressors GA 5 GA 7 GA 11 Instruction book ...

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Page 3: ...ontents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2009 12 No 2920 7090 51 Replaces No 2920 7090 50 www atlasc...

Page 4: ...IR FLOW 16 2 3 OIL SYSTEM 17 2 4 COOLING SYSTEM 18 2 5 CONDENSATE SYSTEM 19 2 6 REGULATING SYSTEM 20 2 7 ELECTRICAL SYSTEM 20 2 8 ELECTRICAL DIAGRAMS 21 2 9 AIR DRYER 24 3 Elektronikon controller 26 3 1 ELEKTRONIKON REGULATOR 26 3 2 CONTROL PANEL 27 3 3 ICONS USED ON THE DISPLAY 28 3 4 MAIN SCREEN 30 3 5 SHUT DOWN WARNING 30 3 6 SHUT DOWN 32 3 7 SERVICE WARNING 33 3 8 SCROLLING THROUGH ALL SCREENS...

Page 5: ...ICE TIMER SETTINGS 49 3 22 CALLING UP MODIFYING THE UNIT OF TEMPERATURE 49 3 23 CALLING UP MODIFYING UNIT OF PRESSURE 50 3 24 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE 50 3 25 SELECTION BETWEEN Y D OR DOL STARTING 50 3 26 CALLING UP MODIFYING LOAD DELAY TIME 51 3 27 CALLING UP MODIFYING MINIMUM STOP TIME 51 3 28 ACTIVATING PASSWORD PROTECTION 52 3 29 ACTIVATE LOAD UNLOAD REMOTE PRESSURE S...

Page 6: ...R PASSWORD MENU 100 4 17 WEB SERVER 101 4 18 PROGRAMMABLE SETTINGS 109 5 OSD oil condensate separator optional 113 5 1 OSD UNIT 113 5 2 OPERATING AND MAINTENANCE INSTRUCTIONS 114 5 3 PICTOGRAPHS 115 6 Installation 117 6 1 DIMENSION DRAWINGS 117 6 2 INSTALLATION PROPOSAL 123 6 3 ELECTRICAL CONNECTIONS 126 6 4 PICTOGRAPHS 131 7 Operating instructions 133 7 1 INITIAL START UP 133 7 2 BEFORE STARTING ...

Page 7: ...rocedures 148 9 1 DRIVE MOTOR 148 9 2 AIR FILTER 148 9 3 OIL AND OIL FILTER CHANGE 149 9 4 OIL SEPARATOR CHANGE 150 9 5 COOLERS 151 9 6 BELT TENSIONING AND REPLACEMENT 151 9 7 SAFETY VALVES 153 9 8 DRYER MAINTENANCE INSTRUCTIONS 154 10 Problem solving 156 11 Technical data 159 11 1 READINGS ON DISPLAY 159 11 2 ELECTRIC CABLE SIZE 160 11 3 SETTINGS FOR OVERLOAD RELAY AND FUSES 162 11 4 DRYER SWITCH...

Page 8: ... TECHNICAL DATA ELEKTRONIKON CONTROLLER 169 12 Instructions for use 171 13 Guidelines for inspection 172 14 Pressure equipment directives 173 15 Declaration of conformity 174 Instruction book 6 2920 7090 51 ...

Page 9: ...hecks stop the compressor press the emergency stop button switch off the voltage and depressurize the compressor In addition the power isolating switch must be opened and locked 6 Never play with compressed air Do not apply the air to your skin or direct an air stream at people Never use the air to clean dirt from your clothes When using the air to clean equipment do so with extreme caution and we...

Page 10: ... notice shall be affixed to the start equipment 10 Air cooled machines must be installed in such a way that an adequate flow of cooling air is available and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet 11 The electrical connections must correspond to the applicable codes The machines must be earthed and protected against short circuits by fuses in al...

Page 11: ... level reaches or exceeds 90 dB A shall wear ear protectors 8 Periodically check that All guards are in place and securely fastened All hoses and or pipes inside the machine are in good condition secure and not rubbing There are no leaks All fasteners are tight All electrical leads are secure and in good order Safety valves and other pressure relief devices are not obstructed by dirt or paint Air ...

Page 12: ... vessels 12 Whenever there is an indication or any suspicion that an internal part of a machine is overheated the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted 13 Never use a light source with open flame for inspecting the interior of a machine pressu...

Page 13: ...ical first aid Also consult following safety precautions Safety precautions during installation and Safety precautions during operation These precautions apply to machinery processing or consuming air or inert gas Processing of any other gas requires additional safety precautions typical to the application which are not included herein Some precautions are general and cover several machine types a...

Page 14: ...tegrated air dryer The basic version of GA 5 up to GA 11 is equipped with an Elektronikon controller see section Elektronikon controller The Elektronikon Graphic controller is available as option see section Elektronikon graphic controller The Elektronikon controller and the emergency stop button are integrated in the door panel of the electric cubicle An electric cabinet comprising the motor star...

Page 15: ...e AR Air receiver AV Air outlet valve Da Automatic condensate outlet Dc OSD drain outlet option Dm1 Manual condensate drain valve Dm2 Manual condensate drain valve ER1 Elektronikon controller S3 Emergency stop button 1 Electric cable entry Instruction book 2920 7090 51 13 ...

Page 16: ...pressors are installed directly on the floor GA 11 Pack Floor mounted Front view ER Elektronikon controller S3 Emergency stop button Dm1 Manual condensate drain valve Da Automatic condensate outlet Instruction book 14 2920 7090 51 ...

Page 17: ...Floor mounted Workplace Pack compressor rear view Ref Name AF Air filter AV Air outlet valve C Combicooler FN Fan motor M1 Drive motor Instruction book 2920 7090 51 15 ...

Page 18: ...2 2 Air flow Flow diagrams For Workplace units For Workplace Full Feature units References Ref Description A Intake air B Air oil mixture C Hot compressed air D Oil Instruction book 16 2920 7090 51 ...

Page 19: ... oil separator OT The air flows through minimum pressure valve Vp to air cooler Ca Minimum pressure valve Vp prevents the receiver pressure from dropping below a minimum pressure and includes a check valve which prevents blow back of compressed air from the net On Full Feature compressors the air flows through air dryer DR Air is discharged through outlet valve AV 2 3 Oil system Flow diagram Oil s...

Page 20: ... separator OT which serves as oil tank The remaining oil is removed by oil separator OS A small pipe returns the separated oil towards the compressor element Air pressure forces the oil from oil separator tank OT through oil cooler Co and filter OF towards compressor element E The system comprises a thermostatic bypass valve BV Only when the oil is warm the valve allows the oil to pass through the...

Page 21: ...t system The trap is equipped with a valve for automatic draining during operation and is connected to the automatic drain outlet Da and to a manually operated valve Dm1 for draining after stopping the compressor Tank mounted compressors are also provided with a manual condensate drain valve Dm2 for draining the condensate trapped in the receiver Full Feature versions are equipped with an electron...

Page 22: ...A The pressure in the oil separator vessel stabilises at low value A reduced amount of air is compressed to guarantee a minimal pressure required for lubrication during unloaded operation Air output is stopped 0 the compressor runs unloaded Loading When the net pressure decreases to the loading pressure solenoid valve Y1 is energised Control pressure is fed from the oil separator vessel via soleno...

Page 23: ...ne contactor T1 Transformer PE Earth terminal 2 8 Electrical diagrams The service diagram and the explanatory designations below are given as typical example only Some of the texts may not be applicable to a specific case The applicable service diagram is situated in the electric cubicle of the compressor Instruction book 2920 7090 51 21 ...

Page 24: ...Service diagram Designations Instruction book 22 2920 7090 51 ...

Page 25: ...l Feature KL Line contactor KY Star contactor KD Delta contactor T1 Transformer KA Auxiliary relay for heaters and auxiliary fan S1 Remote Start programmed stop S2 Remote Load unload S3 Emergency stop S3 Remote emergency stop Reference Control module I Start button 0 Stop button K01 Blocking relay K02 Auxiliary relay star contactor K03 Auxiliary relay delta contactor K04 Auxiliary relay loading un...

Page 26: ... for ES100 S10 Main power isolating switch Y2 Solenoid valve for modulating control 2 9 Air dryer 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 Instruction book 24 2920 7090 51 ...

Page 27: ...through outlet 4 The cold dried 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 refrigerant enters evaporator 2 where it withdraws heat from the compressed air by further evaporation at constant pressure The heated refr...

Page 28: ...t The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases If the expected unloading period is to short the compressor is kept running to prevent too short stand still periods Protecting the compressor Shut down If the compressor element outlet temperature exceeds the programmed shut down level the compressor...

Page 29: ...pco Customer Centre If activated and if the regulator was in the automatic operation mode the compressor will automatically restart when the supply voltage to the module is restored 3 2 Control panel Detailed description Control panel of the Elektronikon with standard display Reference Designation Function 1 Display Shows icons and operating conditions 2 Automatic operation symbol 3 LED Automatic ...

Page 30: ...confirm the last action 14 Escape button Use this button to go to previous screen or to end the current action 3 3 Icons used on the display Function Icon Description Compressor status When the compressor is stopped the icon stands still When the compressor is running the icon is rotating Motor stopped Running unloaded Running loaded Machine control mode Remote start stop LAN control Automatic res...

Page 31: ...shown together with seconds Percent The value shown must be multiplied by 10 to get the actual value The value shown must be multiplied by 100 to get the actual value The value shown must be multiplied by 1000 to get the actual value Motor overload Element outlet temperature Filter Drain Energy saving dryer Ambient temperature Instruction book 2920 7090 51 29 ...

Page 32: ...onsult Atlas Copco if the pressure on the display is preceded by a t 3 5 Shut down warning Description A shut down warning will appear in the event of Too high a temperature at the outlet of the compressor element Too high a dewpoint temperature Full Feature compressors Compressor element outlet temperature If the outlet temperature of the compressor element exceeds the shut down warning level fac...

Page 33: ...he compressor has stopped Switch off the voltage inspect the compressor and remedy The warning message will disappear as soon if the warning condition disappears Dewpoint temperature On compressors with integrated dryer alarm LED 5 will light up and the related pictograph will appear flashing if the dewpoint temperature exceeds the warning level programmable Main screen with the dewpoint temperatu...

Page 34: ...hut down In case the temperature at the outlet of the compressor element exceeds the shut down level In case of error of the outlet pressure sensor In case of overload of the drive motor In case of overload of the fan motor on air cooled compressors Compressor element outlet temperature If the outlet temperature of the compressor element exceeds the shut down level factory setting 120 C 248 F prog...

Page 35: ...e compressor Motor overload In the event of motor overload the compressor will be shut down alarm LED 5 will flash automatic operation LED 3 will go out and the following screen will appear Main screen with shut down indication motor overload Switch off the voltage and remedy the trouble After remedying and when the shut down condition has disappeared switch on the voltage and restart the compress...

Page 36: ...actual reading of the service timer appears and is shown in hrs or x1000 hrs if the service timer value is higher than 9999 Example of running hours screen Stop the compressor switch off the voltage and carry out the required service actions See section Preventive Maintenance The longer interval service actions must also include the shorter interval actions In the example above carry out all servi...

Page 37: ...e numbers of the screens appear consecutively For most screens the unit of measurement and the related pictograph are shown together with the screen number Example The screen shows the screen number d 1 the unit used hrs and the related symbol for running hours Press Enter key 13 to call up the actual running hours Overview of the screens Digital input screens Designation Related topic d in Digita...

Page 38: ... See section Modifying pressure band selection P 06 Modifying a service timer See section Calling up modifying service timer settings P 07 Setting of unit for temperature See section Calling up modifying unit of temperature P 08 Setting of unit for pressure See section Calling up modifying unit of pressure P 09 Selection for function Automatic restart after voltage failure active or not only for A...

Page 39: ...tion Related topic t 01 Display test See sections Test screens t 02 Safety valve test See sections Test screens t 03 Production test See sections Test screens Menu flow Simplified menu flow Instruction book 2920 7090 51 37 ...

Page 40: ...ours 22 Load delay time 8 Loading hours 23 Minimum stop time 9 Load relay 24 Password settings 10 Service timer reading 25 Remote pressure sensing 11 Actual program version 26 Protections 12 LAN selection 27 Display test 13 Settings node ID 28 Safety valve test 14 IP settings 29 Production test 15 Pressure band selection 3 9 Calling up outlet and dewpoint temperatures Control panel Starting from t...

Page 41: ...ture will be shown The screen shows that the dewpoint temperature is 3 C Press Scroll button 12 to scroll downwards or upwards through the screens 3 10 Calling up running hours Control panel Starting from the Main screen Press Scroll button 12 until d 1 is shown and then press Enter button 13 Instruction book 2920 7090 51 39 ...

Page 42: ... 3 11 Calling up motor starts Control panel Starting from the Main screen Press Scroll button 12 until d 2 is shown and then press Enter button 13 This screen shows the number of motor starts x 1 or if x1000 lights up x 1000 In the above example the number of motor starts is 10100 Instruction book 40 2920 7090 51 ...

Page 43: ...lue 5000 the regulator module has been in service during 5000 hours 3 13 Calling up loading hours Starting from the Main screen Press Scroll button 12 until d 4 is shown and then press Enter button 13 The screen shows the unit used hrs or x1000 hrs and the value 1755 the compressor has been running loaded during 1755 hours 3 14 Calling up load relay Starting from the Main screen Instruction book 2...

Page 44: ...ad actions x 1 or if x1000 lights up x 1000 In the above example the number of unload to load actions is 10100 3 15 Calling up resetting the service timer Calling up the service timer Starting from the Main screen Press Scroll button 12 until d 6 is shown and then press Enter button 13 Instruction book 42 2920 7090 51 ...

Page 45: ...button 14 to cancel the operation 3 16 Selection between local remote or LAN control Starting from the Main screen Press Scroll button 12 until P 01 is shown and then press Enter button 13 The actually used control mode is shown LOC for local control rE for remote control or LAn for LAN control Press Enter button 13 and if necessary enter the password The actually used control mode is blinking Use...

Page 46: ...he Enter button 13 to program the new node ID or press the Escape button 14 to leave this screen or to cancel this operation Modifying the Node ID The Node ID can be changed use a value between 1 and 31 When the function is ON the parameters cannot be modified Change the function to OFF to change the node ID It is also possible to change the channels The controller has 4 channels When changing the...

Page 47: ...creen may look as follows 3 18 Calling up modifying IP Gateway and Subnetmask Calling up Starting from the Main screen Press the Scroll button 12 until P 03 is shown and then press Enter button 13 The next screen shows either OFF or ON If ON press the Enter button 13 to modify it to OFF Use the Scroll buttons Up or Down 12 to scroll between the items in this list IP for IP address SUB for Subnetma...

Page 48: ...enter the password The first digits are blinking Use the Scroll buttons Up or Down 12 to modify the settings and press Enter 13 to confirm Modify the next digits the same way The standard IP address is set as 192 168 100 100 Instruction book 46 2920 7090 51 ...

Page 49: ...P 04 is shown and then press Enter button 13 Pressure band 1 Pb 1 is shown on the display Button 12 can be used to scroll to pressure band 2 Pb 2 Press Enter button 13 on the desired pressure band The load level of the selected pressure band appears Button 12 can be used to scroll to the unload level Instruction book 2920 7090 51 47 ...

Page 50: ...el value starts blinking A password may be required Use Scroll buttons 12 to change the loading pressure Press Enter button 13 to program the new values or press the Escape button 14 to cancel 3 20 Modifying the pressure band selection Control panel Instruction book 48 2920 7090 51 ...

Page 51: ...he service timer is shown in hrs hours or x1000 hrs hours x 1000 Example 4000 hrs means the timer is set at 4000 running hours Press Enter button 13 to modify this value a password may be required the value blinks Use the Scroll buttons 12 to modify the setting Press Enter button 13 to program the new value 3 22 Calling up modifying the unit of temperature Control panel Starting from the Main scre...

Page 52: ...nit of pressure Press the escape button 14 to return to the parameter screens 3 24 Activating automatic restart after voltage failure Description This parameter accessible in screen P 09 can only be modified after entering a code Consult Atlas Copco if this function is to be activated 3 25 Selection between Y D or DOL starting Control panel Starting from the Main screen Press Scroll button 12 unti...

Page 53: ...is shown and press the Enter button 13 This screen shows the load delay time 10 and the unit s seconds To modify this value press the Enter button 13 a password may be required The value starts blinking and Scroll buttons 12 can be used to modify the value Press the Enter button 13 to program the new value The minimum and maximum value depends on the parameters 3 27 Calling up modifying minimum st...

Page 54: ...by a password Starting from the Main screen Press Scroll buttons 12 until P 13 is shown and press Enter button 13 Password PASS appears on the screen Press the Enter button 13 The screen shows the password status ON On or OFF OFF Press Enter button 13 to modify Change the value with Scroll buttons 12 Select On and press Enter button 13 Enter the new password and press Enter button 13 to confirm En...

Page 55: ...protection screens are labelled Pr The pictograph shown with the protection screen indicates the purpose of the protection Possible combinations are Pr followed by a number and one of the next pictographs Pictograph Designation Pr shown with the pressure pictograph shows the pressure protections Pr shown with the element outlet temperature pictograph shows the element outlet temperature protection...

Page 56: ...ress Scroll buttons 12 until Pr followed by a number and the element outlet temperature pictograph is shown and press Enter button 13 The warning level for the high temperature warning level AL H and the high temperature shut down level Sd H become visible Use Scroll keys 12 to move between the warning level AL and the shut down level Sd press the Enter button 13 to modify the value An optional pa...

Page 57: ...sted after entering a code Consult Atlas Copco if the safety valves are to be tested Production test Test screen t 03 is only intended for production test If the Main screen shows following screen the controller is in production test mode How to solve Use the Scroll buttons 12 and scroll to menu t 03 The screen shows Press the Enter button 13 the text starts blinking Press enter again and the menu...

Page 58: ...ia the PC instead of via the display of the controller Getting started Make sure you are logged in as administrator Use the internal network card from your computer or an USB to LAN adapter see picture below USB to LAN adapter Use an UTP cable CAT 5e to connect to the controller see picture below Configuration of the network card Go to My Network places 1 Instruction book 56 2920 7090 51 ...

Page 59: ... Click on View Network connections 1 Select the Local Area connection 1 which is connected to the controller Click with the right button and select properties 1 Instruction book 2920 7090 51 57 ...

Page 60: ...f the web server Configure the web interface The internal web server is designed and tested for Microsoft Internet Explorer 6 7 and 8 Other web browsers like Opera and Firefox do not support this internal web server When using Opera or Firefox a redirect page opens Click on the hyperlink to connect to the download server from Microsoft to download the latest version of Internet Explorer and instal...

Page 61: ... Click on the Connections tab 1 and then click on the LAN settings button 2 In the Proxy server Group box click on the Advanced button 1 Instruction book 2920 7090 51 59 ...

Page 62: ... addresses 192 168 100 1 and 192 168 100 2 Now you add 192 168 100 100 and separate the 3 IP addresses by putting semicolons between them 1 see picture Click OK 2 to close the window Viewing the controller data 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 Instruction book 60 2920 7090 51 ...

Page 63: ... controller On the left site of the interface you can find the navigation menu see picture below If a license for ESi is foreseen the menu contains 3 buttons Compressor shows all compressor settings Es shows the ESi status if a license is provided Preferences allows to change temperature and pressure unit Instruction book 2920 7090 51 61 ...

Page 64: ...ain screen Analog inputs The units of measure can be changed in the preference button from the navigation menu Counters Counters give an overview of all actual counters from controller and compressor Info status Machine status is always shown on the web interface Digital inputs Gives an overview of all Digital inputs and status Instruction book 62 2920 7090 51 ...

Page 65: ...Shows all levels of the service plan and status This screen only shows the running hours It is also possible to show the actual status of the service interval ES screen controller If a ESi license is provided the button ES is shown in the navigation menu At the left all compressors in the ES and at the right the ES status is shown Instruction book 2920 7090 51 63 ...

Page 66: ...re 100 psi compressors bar e 5 5 6 9 7 4 Unloading pressure 100 psi compressors psig 80 100 107 3 Unloading pressure 125 psi compressors bar e 5 5 8 6 9 1 Unloading pressure 125 psi compressors psig 80 125 132 Unloading pressure 150 psi compressors bar e 5 5 10 3 10 8 Unloading pressure 150 psi compressors psig 80 150 156 6 Unloading pressure 175 psi compressors bar e 5 5 12 12 5 Unloading pressur...

Page 67: ...9 5 9 7 Unloading pressure 10 bar compressors psig 80 137 8 140 7 Unloading pressure 13 bar compressors bar e 5 5 12 5 12 7 Unloading pressure 13 bar compressors psig 80 181 3 184 2 Unloading pressure 100 psi compressors bar e 5 5 6 9 7 1 Unloading pressure 100 psi compressors psig 80 100 103 Unloading pressure 125 psi compressors bar e 5 5 8 6 8 8 Unloading pressure 125 psi compressors psig 80 12...

Page 68: ... time sec 0 3 20 Power recovery time ARAVF sec 10 10 3600 Restart delay sec 0 0 1200 Communication time out sec 10 30 60 Protections Minimum setting Factory setting Maximum setting Compressor element outlet temperature shut down warning level C 50 110 119 Compressor element outlet temperature shut down warning level F 122 230 246 Compressor element outlet temperature shut down level C 111 120 120 ...

Page 69: ...own level changes to 96 C 204 F The recommended difference between the warning level and shut down level is 10 C 18 F Delay at shut down signal Is the time for which the signal must exist before the compressor is shut down If it is required to program this setting to another value consult Atlas Copco Minimum stop time Once the compressor has automatically stopped it will remain stopped for the min...

Page 70: ...nd unloading the compressor A number of programmable settings e g the unloading and loading pressures the minimum stop time and the maximum number of motor starts are taken into account The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases In case the expected unloading period is too short the compressor i...

Page 71: ...appears Warning A warning message will appear if on full Feature compressors the Dewpoint 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 action...

Page 72: ...icates that the regulator is automatically controlling the compressor 8 Voltage on LED Indicates that the voltage is switched on 9 Pictograph Voltage on 10 Enter key Key to select the parameter indicated by the horizontal arrow Only the parameters followed by an arrow pointing to the right can be modified 11 Escape key To go to previous screen or to end the current action 12 Scroll keys Keys to sc...

Page 73: ...ompressor status Motor stopped Running unloaded Running loaded Machine control mode 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 Active protection functions Emergency stop Shutdown Warning Service Service required Instruction book 2920 7090 51 71 ...

Page 74: ...e temperature Digital input Special protection System icons Icon Description Compressor element LP HP Dryer Fan Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Instruction book 72 2920 7090 51 ...

Page 75: ...tion Inputs Outputs Alarms Warnings shutdowns Counters Test Settings Service Event history saved data Access key User password Network Setpoint Info Navigation arrows Icon Description Up Down Instruction book 2920 7090 51 73 ...

Page 76: ... to all functions implemented in the controller The Main screen is shown automatically when the voltage is switched on and one of the keys is pushed It is switched off automatically after a few minutes when no keys are pushed Typical Main screen fixed speed compressors Typical Main screen compressors with frequency converter Instruction book 74 2920 7090 51 ...

Page 77: ... corresponding function is activated e g week timer automatic restart after voltage failure etc Pop up icons These icons pop up if an abnormal condition occurs warnings shutdowns service To call up more information about the icons shown select the icon using the scroll keys and press the enter key Section C is called the Status bar This bar shows the text that corresponds to the selected icon Sect...

Page 78: ...e Menu screen highlight the Menu button 3 using the Scroll keys Press the Enter key to select the menu Following screen appears The screen shows a number of icons Each icon indicates a menu item By default the Pressure Settings Regulation icon is selected The status bar shows the name of the menu that corresponds with the selected icon Use the Scroll keys to select an icon Instruction book 76 2920...

Page 79: ...nputs Function To call up information regarding the actually measured data and the status of some inputs such as the emergency stop switch Procedure Starting from the main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on figure Instruction book 2920 7090 51 77 ...

Page 80: ...t 3 Element outlet 4 Ambient air 5 Emergency stop The screen shows a list of all inputs with their corresponding icons and readings If an input is in warning or shutdown the original icon is replaced by the warning or shutdown icon respectively i c the Stop icon and the Warning icon in the screen shown above 4 7 Outputs menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Instruction book 78 ...

Page 81: ...ollowing screen appears Text on figure 1 Menu 2 Regulation Move the cursor to the Outputs icon see above section Menu icon using the Scroll keys Press the Enter key A screen similar to the one below appears 1 Outputs 2 Fan motor contact 3 Blow off contact 4 General shutdown 5 Automatic operation The screen shows a list of all outputs with their corresponding icons and readings If an input is in wa...

Page 82: ...s The loaded hours The number of motor starts The number of hours that the regulator has been powered The number of load cycles Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Text on figure Instruction book 80 2920 7090 51 ...

Page 83: ... rpm in the percentage of the time during which the motor speed was between 1 and 20 compressors with frequency converter The screen shows a list of all counters with their actual readings Note the example above is for a frequency converter driven compressor For a fixed speed compressor the actual screen will be somewhat different 4 9 Service menu Control panel 1 Scroll keys 2 Enter key 3 Escape k...

Page 84: ...in screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Using the Scroll keys move the cursor to the Service icon see above section Menu icon Press the Enter key Following screen appears Text on figure 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 ...

Page 85: ...ler is not powered The figures within the bars are the number of hours to go till the next service intervention In the example above the compressor was just started up which means it still has 4000 running hours or 8280 hours to go before the next Service intervention Service plans A number of service operations are grouped called Level A Level B etc Each level stands for a number of service actio...

Page 86: ... the Scroll keys to select the value to be modified A screen similar to the one below appears Press the Enter key Following screen appears Modify the value as required using the or scroll key and press the Enter key to confirm Note Running hours can be modified in steps of 100 hours real time hours can be modified in steps of 1 hour Next Service Text on figure Instruction book 84 2920 7090 51 ...

Page 87: ...ction e g Service level Running hours or Real time hours use the Scroll keys to select the desired action and press the Enter key 4 10 Setpoint menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Setpoint Function On fixed speed compressors the operator can program two different pressure bands This menu is also used to select the active pressure band Procedure Starting from the Mai...

Page 88: ...ading pressure 2 5 Loading pressure 2 6 Modify The screen shows the actual unloading and loading pressure settings for both pressure bands To modify the settings move the cursor to the action button Modify and press the Enter key Following screen appears The first line of the screen is highlighted in red Use the Scroll keys to highlight the setting to be modified and press the Enter key Following ...

Page 89: ...ge the other settings as required in the same way as described above 4 11 Event history menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Event History Function To call up the last shut down and last emergency stop data Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Instruction boo...

Page 90: ...other data reflecting the status of the compressor when that shut down or emergency stop occurred 4 12 Modifying general settings Control panel 1 Scroll keys 2 Enter key 3 Escape key Menu icon Settings Function To display and modify a number of general settings e g Time Date Date format Language units Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu...

Page 91: ...ct the Modify button using the Scroll keys and press the Enter key A screen similar to the one above is shown a red selection bar is covering the first item Language Use the key of the Scroll keys to select the setting to be modified and press the Enter key A pop up screen appears Use the or key to select the required parameter and press the Enter key to confirm 4 13 Info menu Control panel Instru...

Page 92: ...screen see Main screen Move the cursor to the action button Menu and press the Enter key Following screen appears Using the Scroll keys move the cursor to the Info icon see above section Menu icon Press the Enter key The Atlas Copco internet address appears on the screen 4 14 Week timer menu Control panel Instruction book 90 2920 7090 51 ...

Page 93: ...week cycle can be programmed 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 Procedure Starting from the Main screen see Main screen Move the cursor to the action button Menu and press the Enter key Use the Scroll buttons to select the Timer icon Text on figure 1 Menu 2 Week Timer Press the Enter key on the controller Followin...

Page 94: ...ter 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 1 Week Action Schemes 2 Week Action Scheme 1 3 Week Action Scheme 2 4 Week Action Scheme 3 5 Week Action Scheme 4 A weekly list is shown Monday is automatically selected and highlighted in red Press the Enter key on the controller to set an action for this da...

Page 95: ...ion 1 Monday 2 Modify A new pop up window opens Select an action from this list by using the Scroll keys on the controller When ready press the Enter key to confirm 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 2920 7090 51 93 ...

Page 96: ...the controller and press the Enter key to confirm 1 Monday 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 modify the minutes 1 Monday 2 Time 3 Save 4 Modify Instruction book 94 2920 7090 51 ...

Page 97: ...y 2 Start 3 Save 4 Modify A new pop up window opens Use the Scroll keys on the controller to select the correct actions Press the Enter key to confirm 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 Instruction book 2920 7090 51 95 ...

Page 98: ...the week cycle A week cycle is a sequence of 10 weeks For each week in the cycle one of the four programmed week schemes can be chosen 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 Instruction book 96 2920 7090 51 ...

Page 99: ...Scheme 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 2920 7...

Page 100: ...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 98 2920 7090 51 ...

Page 101: ...compressor must continue working for example 1 hour it can be set in this screen This timer is prior to the Week Timer action 1 Week Timer 2 Week action schemes 3 Remaining Running Time 4 15 Test menu Control panel Menu icon Test Function To carry out a display test i e to check whether the display and LEDs are still intact Instruction book 2920 7090 51 99 ...

Page 102: ...bove section Menu icon Press the enter key 2 following screen appears The safety valve test can only be performed by authorized personnel and is protected 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 4 16 User password menu Control panel 1 Scroll keys 2 Enter key 3 Escape key Instruction book 100...

Page 103: ...ton using the Scroll keys and press the Enter key Next modify the password as required 4 17 Web server All Elektronikon controllers have a built in web server that allows direct connection to a PC via a local area network LAN This allows to consult certain data and settings via the PC instead of via the display of the controller Getting started Make sure you are logged in as administrator Use the ...

Page 104: ...Configuration of the network card Go to My Network places 1 Click on View Network connections 1 Select the Local Area connection 1 which is connected to the controller Instruction book 102 2920 7090 51 ...

Page 105: ...k 255 255 255 0 Click OK and close network connections Configuration of the web server Configure the web interface The internal web server is designed and tested for Microsoft Internet Explorer 6 7 and 8 Other web browsers like Opera and Firefox do not support this internal web server When using Opera or Firefox a redirect page opens Click on the hyperlink to connect to the download server from Mi...

Page 106: ... Open Internet Explorer and click on Tools Internet options 2 Click on the Connections tab 1 and then click on the LAN settings button 2 In the Proxy server Group box click on the Advanced button 1 Instruction book 104 2920 7090 51 ...

Page 107: ... addresses 192 168 100 1 and 192 168 100 2 Now you add 192 168 100 100 and separate the 3 IP addresses by putting semicolons between them 1 see picture Click OK 2 to close the window Viewing the controller data 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 Instruction book 2920 7090 51 105 ...

Page 108: ... controller On the left site of the interface you can find the navigation menu see picture below If a license for ESi is foreseen the menu contains 3 buttons Compressor shows all compressor settings Es shows the ESi status if a license is provided Preferences allows to change temperature and pressure unit Instruction book 106 2920 7090 51 ...

Page 109: ...ain screen Analog inputs The units of measure can be changed in the preference button from the navigation menu Counters Counters give an overview of all actual counters from controller and compressor Info status Machine status is always shown on the web interface Digital inputs Gives an overview of all Digital inputs and status Instruction book 2920 7090 51 107 ...

Page 110: ...Shows all levels of the service plan and status This screen only shows the running hours It is also possible to show the actual status of the service interval ES screen controller If a ESi license is provided the button ES is shown in the navigation menu At the left all compressors in the ES and at the right the ES status is shown Instruction book 108 2920 7090 51 ...

Page 111: ...sure 100 psi compressors bar e 5 5 6 9 7 4 Unloading pressure 100 psi compressors psig 80 100 107 3 Unloading pressure 125 psi compressors bar e 5 5 8 6 9 1 Unloading pressure 125 psi compressors psig 80 125 132 Unloading pressure 150 psi compressors bar e 5 5 10 3 10 8 Unloading pressure 150 psi compressors psig 80 150 156 6 Unloading pressure 175 psi compressors bar e 5 5 12 12 5 Unloading press...

Page 112: ...9 5 9 7 Unloading pressure 10 bar compressors psig 80 137 8 140 7 Unloading pressure 13 bar compressors bar e 5 5 12 5 12 7 Unloading pressure 13 bar compressors psig 80 181 3 184 2 Unloading pressure 100 psi compressors bar e 5 5 6 9 7 1 Unloading pressure 100 psi compressors psig 80 100 103 Unloading pressure 125 psi compressors bar e 5 5 8 6 8 8 Unloading pressure 125 psi compressors psig 80 12...

Page 113: ... Programmed stop time sec 0 3 20 Power recovery time ARAVF sec 10 10 3600 Restart delay sec 0 0 1200 Communication time out sec 10 30 60 Protections Minimum setting Factory setting Maximum setting Compressor element outlet temperature shut down warning level C 50 110 119 Compressor element outlet temperature shut down warning level F 122 230 246 Compressor element outlet temperature shut down leve...

Page 114: ...changes to 96 C 204 F The recommended difference between the warning level and shut down level is 10 C 18 F Delay at shut down signal Is the time for which the signal must exist before the compressor is shut down If it is required to program this setting to another value consult Atlas Copco Oil separator Use only Atlas Copco oil separators The recommended maximum pressure drop over the oil separat...

Page 115: ...igned to separate the major part of this oil from the condensate and to catch the oil in a collector The condensate meets the requirements of the environmental codes General view of OSD 22 typical example Reference Designation 1 Condensate vessel 2 Pressure gauge 3 Oil removal filter 4 Oil collector 5 Condensate inlet 6 Dp of filter 7 Clean condensate outlet 8 Oil outlet 9 Cover Instruction book 2...

Page 116: ...e air system between air receiver and outlet valve is fully depressurized Press the emergency stop button Switch off the voltage For detailed instructions see Problem solving The operator must apply all relevant Safety precautions Operating instructions Inside of OSD Before starting check that vessel 1 is filled If necessary gently pour water into filler pipe 2 or vessel 1 until it flows through t...

Page 117: ... on and tighten by hand approx half a turn Check strainer 5 if necessary clean it Monthly 200 Check the oil level in collector 4 If nearly full disconnect oil tube 8 and deliver the oil to the local oil collection service Reinstall an empty collector 5 3 Pictographs Pictographs shown on OSD Reference Description 1 Oil 2 Oil outlet 3 Condensate outlet 4 Pressure 5 Inlet 6 Service point drain 7 Sepa...

Page 118: ...Reference Description 9 Consult instruction book before maintenance or repair Instruction book 116 2920 7090 51 ...

Page 119: ...6 Installation 6 1 Dimension drawings Drawings GA 5 up to GA 11 Pack Floor mounted Instruction book 2920 7090 51 117 ...

Page 120: ...GA 5 up to GA 11 Pack on 270 l air receiver Instruction book 118 2920 7090 51 ...

Page 121: ...GA 5 up to GA 11 Full Feature Floor mounted Instruction book 2920 7090 51 119 ...

Page 122: ...GA 5 up to GA 11 Full Feature on 270 l air receiver Instruction book 120 2920 7090 51 ...

Page 123: ...GA 5 up to GA 11 Pack on 500 l air receiver Instruction book 2920 7090 51 121 ...

Page 124: ...ll Feature on 500 l air receiver Reference Designation 1 Compressor and motor cooling air inlet 2 Dryer cooling air outlet 3 Dryer air inlet 4 Compressed air outlet 5 Compressor air inlet Instruction book 122 2920 7090 51 ...

Page 125: ...ion proposal Outdoor altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below 0 C 32 F precautions must be taken In this case and also if operating above 1000 m 3300 ft consult Atlas Copco Moving lifting To transport the compressor with a forklift truck use the openings in the frame Move the compressor smoothly Instruction book 2920 7090 51 123 ...

Page 126: ...tallation proposal Compressor room example Text on drawing Reference Designation 1 Ventilation proposals 2 Minimum free area to be reserved for the compressor installation Instruction book 124 2920 7090 51 ...

Page 127: ... maximum allowable pressure drop over the cooling air ducts is 30 Pa 0 12 in water column If it is greater than this value a fan is needed at the outlet of the ducts Consult Atlas Copco For alternatives 1 and 3 the required ventilation capacity to limit the compressor room temperature can be calculated as follows Qv 1 16 N ΔT for units without optional dryer Qv 1 16 N 0 6 ΔT for units with optiona...

Page 128: ...ers in order to isolate the filters during maintenance without disturbing the compressor 6 3 Electrical connections Important remark When connecting to electric supply leave 2 m 6 5 ft of loose cable to allow easy removal of back panel Always disconnect the power supply before working on the electrical circuit General instructions IEC CE cubicle Instruction book 126 2920 7090 51 ...

Page 129: ...rminals L1 L2 and L3 1X0 and the neutral conductor if applicable to terminal N Connect the earth conductor Specific instructions for GA 5 up to GA 11 with 208 V 230 V 460 V cubicle Always disconnect the power supply before working on the electrical circuit The standard voltage configuration for the compressor is mentioned on the data plate of the machine When the compressors leave the factory the ...

Page 130: ...ee further 4 Modify the motor terminal bridge configuration in the main cubicle for the desired voltage 5 Replace the voltage sticker by the appropriate voltage sticker provided 6 On FF units replace the power fuses F10 in the main cubicle with the CC type 6 A fuses provided 7 Modify the power transformer terminal bridge configuration in the transformer cubicle for the desired voltage To adjust th...

Page 131: ...the transformer to the terminal marked with the desired voltage 208 V 230 V or 460 V Replace the two fuses marked F1 by opening the fuse holder Use the 4 A fuses for 208 230 V and the 2 A fuses for 460 V supplied with the compressor Fuses Fuse rating V 208 V 230 V 460 V Class F1 600 V AC 4 A 4 A 2 A UL class JDYX or JDYX2 10 3 x 38 mm F2 250 V AC 3 A 3 A 3 A UL class JDYX or JDYX2 5 x 20 mm Instru...

Page 132: ...e factory standard Locate the yellow voltage labels provided with the compressor Replace the existing label with the appropriate voltage label 200 208 V 230 V or 460 V Compressor status indication on compressors equipped with an Elektronikon controller The Elektronikon regulator is provided with an auxiliary relay K05 for remote indication of a shutdown Maximum load for the contacts 10 A 250 V AC ...

Page 133: ...sulting in loading and unloading of the compressor at the pressures programmed in the Elektronikon regulator If the mentioned terminals are not bridged the compressor is switched out of automatic load unload operation and remains running unloaded For remote loading unloading via external pressure switch Compressors with an Elektronikon Graphic controller can also be wired to load and unload depend...

Page 134: ...rically consult Instruction book for motor rotation direction 6 Torques for steel Fe or brass CuZn bolts 7 Consult instruction book before greasing 8 Lightly oil gasket of oil filter screw it on and tighten by hand approx half a turn Instruction book 132 2920 7090 51 ...

Page 135: ...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 installed near the compressor 3 Check transformer T1 for correct connection Check the settings of drive motor overload relay F21 Check that the motor overload relay is set for manual resetting Electric cubicle typical example 4 Fit the air outlet valv...

Page 136: ...stall an oil water separator which is available from Atlas Copco as an option See section OSD unit 7 Check the oil level The oil level sight glass should be between 1 4 and 3 4 full Position of oil level sight glass 8 Provide labels warning the operator that The compressor may automatically restart after voltage failure if activated consult Atlas Copco The compressor is automatically controlled an...

Page 137: ...ins in place the rotation direction is incorrect see the pictographs on the label If the rotation direction is incorrect switch off the voltage open the isolating switch and reverse two incoming supply lines 10 Check the programmed settings Consult section Programmable settings 11 Start and run the compressor for a few minutes Check that the compressor operates normally 7 2 Before starting Procedu...

Page 138: ...raphic controller Step Action Switch on the voltage Check that voltage on LED 6 lights up Open the air outlet valve Close the condensate drain valve s Dm Press start button 1 on the control panel The compressor starts running and the automatic operation LED 8 lights up Ten seconds after starting the drive motor switches over from star to delta and the compressor starts running loaded Instruction b...

Page 139: ...7 4 During operation Procedure Control panel of the Elektronikon controller Control panel of the Elektronikon Graphic controller Instruction book 2920 7090 51 137 ...

Page 140: ... up oil until the sight glass is full Fit and tighten the plug FC When automatic operation LED 8 is lit the regulator is automatically controlling the compressor i e loading unloading stopping of the motors and restarting If provided regularly check that condensate is discharged by the automatic drain s during operation See section Condensate system The amount of condensate depends on environmenta...

Page 141: ...nent has been exceeded Carry out the service actions of the indicated plans or replace the component and reset the relevant timer see section Service warning Compressors with Elektronikon Graphic controller Check the display 2 regularly for readings and messages The display normally shows the compressor outlet pressure while the status of the compressor is indicated by means of a number of icons R...

Page 142: ...7 6 Stopping Elektronikon regulator Control panel of the Elektronikon controller Control panel of the Elektronikon Graphic controller Air outlet valve Instruction book 140 2920 7090 51 ...

Page 143: ...ton 10 for normal stopping Close the air outlet valve AV Open the condensate drain valve Dm See section Condensate system The air dryer and air receiver remain under pressure The DD and PD filters if installed remain under pressure If maintenance or repair work is necessary consult Problem solving for all relevant safety precautions 7 7 Taking out of operation Procedure Step Action Stop the compre...

Page 144: ...ep Action Drain the condensate circuit and disconnect the condensate piping from the condensate net Air outlet valve Condensate drain valve Tank mounted GA 5 up to GA 11 Instruction book 142 2920 7090 51 ...

Page 145: ...ork Consult your Atlas Copco Customer Centre General When servicing replace all removed gaskets O rings and washers Intervals The local Atlas Copco Customer Centre may overrule the maintenance schedule especially the service intervals depending on the environmental and working conditions of the compressor The longer interval actions and checks must also include the shorter interval actions and che...

Page 146: ...Check readings on display Check that condensate is discharged during loaded operation Drain condensate compressed air receiver Check the pressure dew point temperature compressors with integrated dryer Monthly For units with built in dryer Inspect condenser of dryer and clean if necessary Press the test button on top of the electronic water drain EWD Open the manual drain valve s Dm Dm1 to clean t...

Page 147: ... leakages If provided remove dismantle and clean float valve of condensate trap See section Condensate system Clean the condenser of the dryer Full Feature compressors yearly Test temperature shut down function Test safety valve s 8000 2 If Atlas Copco Roto Xtend Duty Fluid is used change oil Replace V belts Have air inlet valve and minimum pressure valve inspected by Atlas Copco 1 or yearly which...

Page 148: ...tween 40 C and 46 C 115 F oil lifetime is reduced significantly In such case it is recommended to use Roto Xtend Duty Fluid Roto Xtend Duty Fluid Atlas Copco s Roto Xtend Duty Fluid 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 Xtend Duty Fluid can be used for compressors ...

Page 149: ...o a full range of extensively tested lubricants suitable for your specific needs is available to keep the compressor in excellent condition Consult the Spare Parts List for part numbers 8 5 Disposal of used material Used filters or any other used material e g desiccant lubricants cleaning rags machine parts etc must be disposed of in an environmentally friendly and safe manner and in line with the...

Page 150: ...r is running 2 For minimum downtime replace the dirty element by a new one 3 Discard the element when damaged Procedure 1 Stop the compressor Switch off the voltage 2 Remove the cover of air filter AF by turning it anti clockwise Remove the filter element If necessary clean the cover 3 Fit the new element and the cover 4 Reset the air filter service warning For compressors equipped with an Elektro...

Page 151: ...l and deliver it to the local collection service Refit and tighten the drain and vent plugs after draining 4 Remove the oil filter OF Clean the seat on the manifold Oil the gasket of the new filter and screw it into place Tighten firmly by hand 5 Remove filler plug FC Fill the oil tank OT with oil until the level reaches the middle of sight glass Gl Take care that no dirt drops into the system Ref...

Page 152: ...mponents 1 Run the compressor until warm Stop the compressor close the air outlet valve and switch off the voltage Wait a few minutes and depressurise by unscrewing oil filler plug FC just one turn to permit any pressure in the system to escape 2 Wait 5 minutes and remove the oil separator OS Clean the seat on the manifold Oil the gasket of the new separator and screw it into place Tighten firmly ...

Page 153: ... compressor close the air outlet valve and switch off the voltage Cover all parts under the coolers Remove any dirt from the coolers with a fibre brush Never use a wire brush or metal objects Next clean with an air jet in the reverse direction to normal flow Use low pressure air If necessary the pressure may be increased up to 6 bar e 87 psig If it is necessary to wash the coolers with a cleaning ...

Page 154: ...ch off the voltage 2 Remove the front panel and the right panel 3 Loosen bolts 2 by one turn 4 Adjust the belt tension by turning nuts 1 5 The tension is correct when the force F needed to create a deflection of 5 mm 0 2 in corresponds to the data in the table above 6 Tighten bolts 2 7 Refit the bodywork panels Replacing the belts The belts must always be replaced as a set even if only one of the ...

Page 155: ...rk panels 9 Check the belt tension after 50 running hours and adjust if necessary 9 7 Safety valves Location of safety valve Safety valve on oil separator vessel Safety valve on oil separator vessel Instruction book 2920 7090 51 153 ...

Page 156: ...rigerant 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 On no account may clothing be removed Fluid refrigerant will also cause freezing of the eyes always wear saf...

Page 157: ...t in mind Keep the dryer clean Brush or blow off the finned surface of condenser monthly Switch off the voltage and close the air outlet valve Remove the panel where the condenser is situated see the picture below Clean the condenser fins with compressed air Do not use water or solvents Close the panel Inspect and clean the electronic condensate drain monthly Functioning of the drains can be check...

Page 158: ... out of order Replace valve Inlet valve stuck in closed position Have valve checked Leak in control air flexibles Replace leaking flexible Minimum pressure valve leaking when net is depressurised Have valve checked Condition Fault Remedy Compressor does not unload safety valve blows Solenoid valve out of order Replace valve Inlet valve does not close Have valve checked Condition Fault Remedy Conde...

Page 159: ...valve out of order Have valve replaced Compressor element out of order Consult Atlas Copco Oil separator element clogged Have element replaced Condition Fault Remedy Compressor element outlet temperature or delivery air temperature above normal Oil level too low Check and correct On air cooled compressors insufficient cooling air or cooling air temperature too high Check for cooling air restrictio...

Page 160: ...denser externally clogged Clean condenser 3 Compressor stops or does not start Electric power supply to compressor is interrupted Check and correct as necessary Thermal protection of refrigerant compressor motor has tripped Motor will restart when motor windings have cooled down 4 Electronic condensate drain remains inoperative Electronic drain system clogged Have system inspected Clean the filter...

Page 161: ...readings mentioned below are valid under the reference conditions see section Reference conditions and limitations Reference Reading Air outlet pressure Modulates between programmed unloading and loading pressures Compressor element outlet temperature Approx 60 C 108 F above cooling air temperature Dewpoint See section Compressor data Instruction book 2920 7090 51 159 ...

Page 162: ...ted cable sections are calculated according to 60364 5 52 electrical installations of buildings part 5 selection and erection equipment section 52 current carrying capacities in wiring systems Standard conditions refer to loose copper conductors or multicore cable with 70 C PVC insulation in free air or on open cable trays installation method C at 30 C ambient temperature and operating at nominal ...

Page 163: ...ize in order to protect the motor against short circuit For cUL fuse HRC form II for UL fuse class RK5 If the local conditions are more severe then the described standard conditions the cables and fuses for worst case conditions should be used Cable size Type V Approval Recommended wire section mm2 Pack Full Feature GA 5 200 IEC 4 x 6 4 x 10 GA 5 230 IEC 4 x 6 4 x 10 GA 5 380 IEC 4 x 2 5 4 x 4 GA ...

Page 164: ...rload Relay Pack Overload Relay Full Feature MAX Setting A MAX Setting A GA 5 200 IEC 40 32 40 39 GA 5 230 IEC 28 28 40 32 GA 5 380 IEC 20 16 25 19 GA 5 400 IEC 20 16 25 19 GA 5 400 N IEC 20 16 25 21 GA 5 460 IEC 20 15 20 17 GA 5 500 IEC 16 14 20 16 GA 7 200 IEC 50 42 50 48 GA 7 230 IEC 40 36 50 41 GA 7 380 IEC 25 21 32 24 GA 7 400 IEC 25 21 32 24 GA 7 400 N IEC 25 21 32 26 GA 7 460 IEC 25 19 25 2...

Page 165: ...39 19 60 60 30 60 60 30 GA 7 575 CSA UL 15 5 20 25 GA 11 200 CSA UL 63 5 80 80 GA 11 200 230 460 CSA UL 61 55 27 5 80 80 40 80 80 40 GA 11 575 CSA UL 22 30 35 11 4 Dryer switches General The regulating and safety devices are factory adjusted to give optimum performance of the dryer Do not alter the setting of any of the devices 11 5 Reference conditions and limitations Reference conditions Air inl...

Page 166: ...100 psi 125 psi 150 psi 175 psi Frequency Hz 50 50 50 50 60 60 60 60 Maximum unloading pressure units without dryer bar e 7 5 8 5 10 13 7 4 9 1 10 8 12 5 Maximum unloading pressure units without dryer psig 109 123 145 189 107 132 157 181 Maximum unloading pressure Full Feature units bar e 7 25 8 25 9 75 12 75 7 15 8 85 10 55 12 25 Maximum unloading pressure Full Feature units psig 105 120 141 185 ...

Page 167: ...75 75 75 75 75 75 75 75 Dew point Full Feature units C 3 3 3 3 3 3 3 3 Dew point Full Feature units F 37 4 37 4 37 4 37 4 37 4 37 4 37 4 37 4 Nominal motor rating kW 5 5 5 5 5 5 5 5 Nominal motor rating hp 6 7 6 7 6 7 6 7 6 7 6 7 6 7 6 7 Power consumption dryer at full load Full Feature units kW 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 Power consumption dryer at full load Full Feature units hp 0 54 0 54 0 ...

Page 168: ...5 8 25 9 75 12 75 7 15 8 85 10 55 12 25 Maximum unloading pressure Full Feature units psig 105 120 141 185 104 128 153 178 Nominal working pressure bar e 7 8 9 5 12 5 6 9 8 6 10 3 12 Nominal working pressure psig 102 116 138 181 100 125 150 175 Pressure drop over dryer Full Feature units bar e 0 12 0 1 0 08 0 05 0 12 0 1 0 08 0 05 Pressure drop over dryer Full Feature units psig 1 74 1 45 1 16 0 7...

Page 169: ...ure units hp 0 67 0 67 0 67 0 67 0 67 0 67 0 67 0 67 Power consumption dryer at no load Full Feature units kW 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 Power consumption dryer at no load Full Feature units hp 0 54 0 54 0 54 0 54 0 54 0 54 0 54 0 54 Refrigerant type Full Feature units R134a R134a R134a R134a R134a R134a R134a R134a Refrigerant quantity Full Feature units kg 0 48 0 48 0 48 0 48 0 44 0 44 0 44...

Page 170: ...0 04 0 02 0 12 0 08 0 04 0 02 Pressure drop over dryer Full Feature units psig 1 74 1 16 0 6 0 3 1 74 1 16 0 6 0 3 Motor shaft speed r min 2935 2935 2935 2935 3535 3535 3535 3535 Thermostatic valve closing opening temperature C 71 84 71 84 71 84 71 84 71 84 71 84 71 84 71 84 Thermostatic valve closing opening temperature F 160 183 160 183 160 183 160 183 160 183 160 183 160 183 160 183 Temperature...

Page 171: ...Feature units R134a R134a R134a R134a R134a R134a R134a R134a Refrigerant quantity Full Feature units kg 0 37 0 37 0 37 0 37 0 37 0 37 0 37 0 37 Refrigerant quantity Full Feature units lb 0 81 0 81 0 81 0 81 0 81 0 81 0 81 0 81 Oil capacity l 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 Oil capacity US gal 1 35 1 35 1 35 1 35 1 35 1 35 1 35 1 35 Oil capacity Imp gal 1 12 1 12 1 12 1 12 1 12 1 12 1 12 1 12 Soun...

Page 172: ... 4 Elektronikon controller p n 1900 5200 00 1900 5200 09 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 Parameter Value Pressure inputs 1 Elektronikon controller p n 1900 5200 00 1900 5200 09 2 Elektronikon Graphic controller p n 1900 5200 10 1900 5200 19 T...

Page 173: ...slation may require an internal inspection Air receiver on tank mounted units 1 Corrosion must be prevented depending on the conditions of use condensate may accumulate inside the tank and must be drained every day This may be done manually by opening the drain valve or by means of the automatic drain if fitted to the tank Nevertheless a weekly check of correct functioning of the automatic valve i...

Page 174: ...r 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 172 2920 7090 51 ...

Page 175: ...nd higher according to the Pressure Equipment Directive 97 23 EC and all pressure equipment according to the Simple Pressure Vessel Directive 87 404 EEC Compressor type Part number Description PED Class GA 5 up to GA 11 2202 8891 01 Safety valve IV 2202 8891 03 Safety valve IV 2202 8891 02 Safety valve IV Overall rating The compressors conform to PED smaller than category I Instruction book 2920 7...

Page 176: ...15 Declaration of conformity Typical example of a Declaration of Conformity document Instruction book 174 2920 7090 51 ...

Page 177: ......

Page 178: ...s the products and services that help to increase your business efficiency and profitability Atlas Copco s pursuit of innovation never ceases driven by our need for reliability and efficiency Always working with you we are committed to providing you the customized quality air solution that is the driving force behind your business www atlascopco com ...