Atlas Copco GA110, Instruction Book

Page 1: ...GA 90 GA 110 GA 132 GA 160 GA 200 GA 250 GA 315 ...

Page 2: ......

Page 3: ...y 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 2010 03 No 2920 1475 06 www atlascopco com ...

Page 4: ...IR AND OIL SYSTEM 14 2 3 COOLING AND CONDENSATE SYSTEM 17 2 4 REGULATING SYSTEM 19 3 Elektronikon regulator 22 3 1 ELEKTRONIKON REGULATOR 22 3 2 CONTROL PANEL 24 3 3 FUNCTION KEYS 25 3 4 SCROLL KEYS 26 3 5 EMERGENCY STOP BUTTON 26 3 6 CONTROL PROGRAMS 27 3 7 CALLING UP MENUS 30 3 8 MAIN SCREEN MENU 31 3 9 STATUS DATA MENU 32 3 10 MEASURED DATA MENU 35 3 11 COUNTERS MENU 36 3 12 TEST MENU 37 3 13 M...

Page 5: ... 4 2 INSTALLATION PROPOSAL 61 4 3 ELECTRIC CABLE SIZE 67 4 4 PICTOGRAPHS 69 4 5 COOLING WATER REQUIREMENTS 70 5 Operating instructions 75 5 1 INITIAL START UP 75 5 2 BEFORE STARTING 81 5 3 STARTING 82 5 4 DURING OPERATION 84 5 5 CHECKING THE DISPLAY 85 5 6 MANUAL LOADING UNLOADING 86 5 7 STOPPING 87 5 8 TAKING OUT OF OPERATION 88 5 9 USE OF AIR RECEIVER 89 6 Maintenance 90 6 1 PREVENTIVE MAINTENAN...

Page 6: ...AFETY VALVE 106 8 Problem solving 108 8 1 PROBLEM SOLVING 108 9 Technical data 111 9 1 READINGS ON DISPLAY 111 9 2 REFERENCE CONDITIONS 112 9 3 LIMITS 112 9 4 SETTINGS OF SAFETY VALVE 113 9 5 SETTINGS FOR OVERLOAD RELAY AND FUSES 113 9 6 SETTINGS OF CIRCUIT BREAKERS 115 9 7 COMPRESSOR DATA 121 10 Pressure equipment directives 129 11 Documentation 130 Instruction book 4 2920 1475 06 ...

Page 7: ...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 8: ... 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 9: ...onments or rooms where the sound pressure level reaches or exceeds 80 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...

Page 10: ...e 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 press...

Page 11: ...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 12: ...2 General description 2 1 Introduction General General view of GA90 up to GA160 Instruction book 10 2920 1475 06 ...

Page 13: ...General view of GA90W up to GA160 W General view of GA200 GA250 and GA315 60 Hz Instruction book 2920 1475 06 11 ...

Page 14: ...vailing regulations Electronic drain The EWD Electronic Water Drain assures proper draining of condensate and prevents water from entering the compressed air net For any malfunction of the draining process the EWD generates a warning message on the display of the Elektronikon regulator Energy recovery The compressor is provided with an Atlas Copco energy recovery system to recover the major part o...

Page 15: ...talled in the motor two to measure the temperature of the bearings and three to measure the temperature of the windings The readings can be called up on the display of the Elektronikon regulator A message will appear on the display and the general alarm LED will light up if one of the temperatures exceeds the shut down warning setting Pipe connections This compressor can be equipped with ISO conne...

Page 16: ...2 2 Air and oil system Flow diagrams Flow diagram of GA90 up to GA160 Instruction book 14 2920 1475 06 ...

Page 17: ...Flow diagram of GA200 GA250 and GA315 60 Hz Instruction book 2920 1475 06 15 ...

Page 18: ...mum pressure valves Vp to air coolers Ca On GA Pack compressors the cooled air is discharged through condensate traps MTa and outlet AO towards the air net On GA Full Feature compressors the cooled air is discharged through condensate trap MTa and outlet AO towards the air net via the integrated air dryer Check valves CV prevent blow back of compressed air Minimum pressure valve Vp prevents the re...

Page 19: ...e compressor is stopped Valves BV by pass oil coolers Co when starting the compressor from a cold condition so ensuring rapid warming of the oil to normal working temperature In air receivers AR most of the oil is removed from the air centrifugally Almost all of the remaining oil is removed by the separator elements 2 3 Cooling and condensate system Condensate drain system Condensate drains of GA ...

Page 20: ...coolers to prevent condensate from entering the air outlet pipe The traps are provided with a float valve for automatically draining condensate and with a manual drain valve On Full Feature compressors a condensate trap is also installed downstream of the dryer This trap is also provided with a float valve for automatically draining condensate and with a manual drain valve Cooling system On air co...

Page 21: ...2 4 Regulating system Flow diagrams Flow diagram of GA 90 up to GA 160 Instruction book 2920 1475 06 19 ...

Page 22: ...tem The compressor is controlled by Elektronikon regulator 1 The regulator keeps the net pressure within programmable pressure limits by automatically loading and unloading the compressor depending on the air consumption It also protects the compressor and monitors components subject to service Instruction book 20 2920 1475 06 ...

Page 23: ...eceiver pressure through flexible 6 and channels 3 and 4 towards the air inlet 4 A small flow of air remains drawn in through hole 8 and channel 3 and is blown from receiver 10 via flexible 6 to the air inlet 5 Air delivery is stopped 0 the compressor runs unloaded Loading When the net pressure decreases to the lower limit of the working pressure loading pressure solenoid valve 5 is energised The ...

Page 24: ... 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 is kept running to prevent too short sta...

Page 25: ...The regulator has a built in function to automatically restart the compressor if the voltage is restored after voltage failure For compressors leaving the factory this function is made inactive If desired the function can be activated Consult the Atlas Copco Customer Centre If activated and provided the regulator was in the automatic operation mode the compressor will automatically restart if the ...

Page 26: ...the right can be modified 5 Function keys Keys to control and program the compressor 6 Voltage on LED Indicates that the voltage is switched on 7 General alarm LED Is lit if a shut down warning condition exists or maintenance is required 7 General alarm LED Flashes if a shut down condition exists if an important sensor is out of order or after an emergency stop 8 Automatic operation LED Indicates ...

Page 27: ...reviously shown option or menu Cancel To cancel a programmed setting when programming parameters Delete To delete compressor start stop commands Help To find the Atlas Copco internet address Limits To show limits for a programmable setting Load To load the compressor manually Mainscreen To return from a menu to the main screen Menu Starting from the main screen to have access to the submenus Menu ...

Page 28: ...scroll key with the same symbol can be used to see the previous item When the scroll key is kept pressed the scrolling is continued 3 5 Emergency stop button Control panel In case of emergency press button S2 to stop the compressor immediately At the occurrence of an emergency stop the compressor element is stopped immediately and the solenoid valve will be deactivated by Elektronikon regulator No...

Page 29: ...the voltage to the compressor Close the air outlet valve and open the manual condensate drain valves to depressurize the air system Apply all relevant Safety precautions 3 6 Control programs Function In order to facilitate programming and controlling menu driven control programs have been implemented in the regulator Instruction book 2920 1475 06 27 ...

Page 30: ...Menu flow for GA 90 up to GA 315 simplified example Instruction book 28 2920 1475 06 ...

Page 31: ...pressor Is the gateway to all functions Status Data Calls up the status of the compressor protection functions shut down shut down warning and service warning Resets a shut down motor overload and service condition Measured Data Calls up the data currently measured and the status of a number of inputs Instruction book 2920 1475 06 29 ...

Page 32: ...commands Configuration time date display language Service Calls up service plans and resets the timers after carrying out the service actions in a service plan Saved Data Calls up the saved data last shut down last emergency stop data Unload Load Loads and unloads the compressor manually 3 7 Calling up menus Description Control panel When the voltage is switched on the Main screen is shown automat...

Page 33: ...enu shows the status of the compressor operation and is the gateway to all functions implemented in the regulator Procedure The Main screen is shown automatically when the voltage is switched on If the function or arrow keys 1 2 and 3 are not used for some minutes the regulator will automatically return to the Main screen Whenever displayed on a submenu screen press the Mainscreen F1 key to return...

Page 34: ...t valve and depressurize the air system Function Control panel The Status data submenu gives information regarding the status of the compressor protection functions shut down shut down warning and service warning and allows resetting of a shut down motor overload and service condition Procedure Starting from the Main screen see Main screen menu Press the key Menu F1 the option Status Data will be ...

Page 35: ...Switch off the voltage and remedy the trouble After remedying and when the shut down condition has disappeared switch on the voltage and press the key Reset F3 Press the keys Menu and Mainscreen to return to the Main screen and restart the compressor by means of start button 3 A shut down warning message exists A shut down warning level is a programmable level below the shut down level If a shut d...

Page 36: ...appears Press the key Menu F1 and the tabulator key 2 to select the Status data menu the option Service is blinking Scroll to this option and select it by pressing the tabulator key 2 two options may blink Inputs if the programmed service level of a component is exceeded e g the maximum pressure drop of the air filter Plan if a service plan interval is exceeded Stop the compressor and switch off t...

Page 37: ...een menu Press the key Menu F1 Press the arrow down key 1 until Measured Data is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 By pressing the scroll keys 1 a number of actually measured data can be found If one of the sensors is linked to a shut down service or warning function both the actually measured value as well as the corresponding shut down warning or se...

Page 38: ...rocedure Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Counters is followed by a horizontal arrow Press the tabulator key 2 to activate the menu By pressing the arrow key 1 the above mentioned data can be found Example of a Counters screen Running Hours 2455 hrs Loaded Hours 1973 hrs Motor Starts 945 Menu F1 F2 F3 Instruction book 36 2920...

Page 39: ... 2 During testing the regulator will generate a series of patterns on the display which enable the operator to check that each pixel still functions normally the LEDs are lit at the same time Press the Menu key F1 to return to the submenu 3 13 Modify parameters menu Function To modify a number of programmable settings Parameters see section Modifying parameters Protections see section Modifying pr...

Page 40: ...etpoint If desired the operator can program two pressure bands Loading pressure Unloading pressure and Loading pressure 2 Unloading pressure 2 Consult the section Procedure to select Loading Pressure The screen shows the current setting To modify this setting press the key Modify F2 the setting will blink The key Limits F2 can be used to find out the limitations for the parameter Use the scroll ke...

Page 41: ... a horizontal arrow Press the tabulator key 2 the first items will appear Press the arrow down key 1 until the item to be modified is followed by a horizontal arrow and press the tabulator key 2 Modifying settings for the compressor element temperature Consult the section Procedure above to select the parameter Element 1 outlet The screen see example below shows the current temperature on the firs...

Page 42: ...mable settings for the most important settings 3 16 Modifying service plans Function To modify the hour intervals for the service levels Service plans The service actions to be carried out are grouped in plans called Service level A B C or D When reaching an interval a message will appear on the screen indicating which Service plans are to be carried out Always consult your Atlas Copco Customer Ce...

Page 43: ... to pressure band 2 On Saturday at 18 00 stopping Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Modify Parameters is followed by a horizontal arrow Activate the menu by pressing tabulator key 2 Use the arrow down key 1 to scroll until the option Clock Function is followed by a horizontal arrow Activate the menu by pressing tabulator key 2...

Page 44: ...nd modify this line in a similar way to the following command 06 15 Pressure Band 1 Press the key Menu F1 and scroll to Friday Thursday Friday Saturday Menu Delete F1 F2 F3 Programming the command to change over at 18 o clock to Pressure Band2 is carried out in a similar way as described above Press the key Menu F1 and scroll to Saturday Programming the command 18 00 Compressor Stop is carried out...

Page 45: ...fying a command Suppose the command to stop the compressor on Saturday 18 00 is to be modified i e stopping at 17 o clock instead of 18 o clock Starting from the Main screen press the key Menu F1 press the arrow down key 1 until the option Modify Parameters is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 Use the arrow down key 1 to scroll until the option Clock ...

Page 46: ...lowing screen appears Monday Tuesday Wednesday Menu Delete F1 F2 F3 Scroll through the display until Monday is followed by a horizontal arrow Press the tabulator key 2 Scroll through the compressor start stop pressure band commands until the first empty command line is indicated by the horizontal arrow Press the key Modify the first two digits start blinking Enter 18 00 Compressor Stop using the s...

Page 47: ...g screen appears Clock Function Not Activated Menu Modify Delete F1 F2 F3 Deleting all commands Press the key Delete in the screen above A question to confirm the deleting operation will appear Deleting all commands of a specific day Scroll through the display until the desired day is followed by a horizontal arrow Press the key Delete a question to confirm the deleting operation will appear Delet...

Page 48: ...ey Modify F2 the first field 14 will blink Use the scroll keys 1 to change the setting then press the tabulator key 2 to go to the next field 30 The setting of this field can now be modified using the scroll keys 1 Press the key Program F1 to program the new value or the key Cancel F3 to cancel the modification operation the original value will be retained The procedure to modify other parameters ...

Page 49: ...he Elektronikon regulator When a service plan interval is reached a message will appear on the screen see section Status data After carrying out the service actions related to the indicated levels the timers are to be reset Example Service plans Intervals Service plan A Every 4000 running hours Service plan B Every 8000 running hours Service plan C Every 16000 running hours Service actions accordi...

Page 50: ...rs Press the arrow down key 1 to find out which service plans were carried out previously following screen appears Previous Timer Level A 4008 hrs Back F1 F2 F3 The screen shows that plan A was carried out at 4008 running hours Stop the compressor switch off the voltage and carry out the service operations related to the indicated service plans see section Preventive maintenance schedule Switch on...

Page 51: ...t shutdown 1 Press the tabulator key 2 to find out the date time and other data reflecting the status of the compressor at the last shut down If desired scroll through the other items 3 21 Programmable settings for GA90 up to GA500 Regulation settings On GA90 up to GA250 and GA315 60 Hz Full Feature compressors the maximum working pressure is 0 25 bar 3 6 psi lower than stated below On GA90 up to ...

Page 52: ...r psig 65 3 137 8 145 Unloading pressure 13 bar compressor bar e 4 5 12 5 13 005 Unloading pressure 190 psi compressor psig 65 3 181 3 188 5 Unloading pressure 6 9 bar compressor bar e 4 5 6 9 7 405 Unloading pressure 100 psi compressor psig 65 3 100 1 107 3 Unloading pressure 8 6 bar compressor bar e 4 5 8 6 9 105 Unloading pressure 125 psi compressor psig 65 3 124 7 132 Unloading pressure 10 4 b...

Page 53: ... 5 Oil injection pressure element start protection bar 2 0 2 5 13 2 Oil injection pressure element start protection psi 29 36 2 191 4 Compressor outlet temperature without DD filter shut down warning level C 0 66 120 Compressor outlet temperature without DD filter shut down warning level F 32 150 8 248 Compressor outlet temperature without DD filter shut down level C 0 80 120 Compressor outlet tem...

Page 54: ...8 Delay at shut down signal sec 5 5 5 Oil separator temperature C 0 120 120 Oil separator temperature F 32 248 248 Delay at start motor overload sec 0 1 1 Delay at signal motor overload sec 0 1 1 Delay at start fan motor overload sec 0 1 3 Delay at signal fan motor overload sec 0 1 3 Delay at start starter feedback contact open sec 0 13 60 Delay at signal starter feedback contact closed sec 0 2 3 ...

Page 55: ...as automatically stopped it will remain stopped for the minimum stop time approx 20 seconds whatever the net air pressure In automatic operation the compressor will not be stopped by the regulator until a standstill period of at least the sum of the minimum stop time and required stop period is expected However if the decrease in air net pressure should require a new start of the compressor the re...

Page 56: ...4 Installation 4 1 Dimension drawing Compressor dimensions Dimension drawing of GA90 110 air cooled Instruction book 54 2920 1475 06 ...

Page 57: ...Dimension drawing of GA90 110 water cooled Instruction book 2920 1475 06 55 ...

Page 58: ...Dimension drawing of GA132 160 and GR110 up to GR200 air cooled Instruction book 56 2920 1475 06 ...

Page 59: ...Dimension drawing of GA132 160 and GR110 up to GR200 water cooled Instruction book 2920 1475 06 57 ...

Page 60: ...Dimension drawing of GA200 250 and GA315 60 Hz air cooled Instruction book 58 2920 1475 06 ...

Page 61: ...n drawing of GA200 250 and GA315 60 Hz water cooled Text on drawing Reference Designation 1 Compressed air outlet 2 Cooling air outlet 3 Air inlet 4 Cooling air inlet 5 Water in Instruction book 2920 1475 06 59 ...

Page 62: ...holes for horizontally pulling unit out of container 25 Net mass approximately 26 For units without dryer 27 For units with dryer 28 Cooling air outlet for units with dryer 29 Centre of gravity with dryer 30 Cooling air inlet for units with dryer 31 Centre of gravity without dryer 32 Only for units with dryer 33 Only for units with OSD 34 Only for units with DD filter 35 Outlet motor cables medium...

Page 63: ...4 2 Installation proposal Compressor room example Compressor room example of GA 90 up to GA 160 air cooled Instruction book 2920 1475 06 61 ...

Page 64: ...Compressor room example of GA 90 up to GA 160 water cooled Instruction book 62 2920 1475 06 ...

Page 65: ...Compressor room example of GA 200 GA 250 and GA 315 60 Hz air cooled Instruction book 2920 1475 06 63 ...

Page 66: ...ompressor room example of GA 200 GA 250 and GA 315 60 Hz water cooled Text on drawing Reference Designation 1 Minimum free area 2 Ventilation proposals 3 Cooling systems Instruction book 64 2920 1475 06 ...

Page 67: ... pipe in m p Absolute pressure at the compressor outlet in bar a Qc Free air delivery of the compressor in l s It is recommended that the connection of the compressor air outlet pipe is made on top of the main air net pipe in order to minimise carry over of possible condensate residue As a rule of thumb the following formula can be used to calculate the recommended volume of the air net V 30 x C x...

Page 68: ...ves are installed a safety device with set pressure according to the maximum cooling water inlet pressure has to be installed between the compressor water outlet pipe and the shut off valve When operating the unit the operator must ensure that the cooling water system cannot be blocked The above mentioned also applies for the energy recovery cooling system Remove the plastic plugs if provided from...

Page 69: ... up to GA 250 and GA 315 60 Hz compressors Cable size GA 90 up to GA 250 50 Hz and GR 50 Hz compressors Compressor Supply voltage Cable size GA 90 230 V 2x 3x120 mm2 70 mm2 GA 90 400 V 2x 3x50 mm2 25 mm2 GA 90 500 V 2x 3x35 mm2 20 mm2 GA 110 230 V 2x 3x150 mm2 70 mm2 Instruction book 2920 1475 06 67 ...

Page 70: ...2 35 mm2 GA 90 440 460V 2x 3x50 mm2 25 mm2 GA 110 220 230 V 2x 3x185 mm2 95 mm2 GA 110 380 V 2x 3x95 mm2 50 mm2 GA 110 440 460V 2x 3x70 mm2 35 mm2 GA 160 380 V 2x 3x120 mm2 70 mm2 GA 160 440 460V 2x 3x95 mm2 50 mm2 GA 200 380 V 2x 3x185 mm2 95 mm2 GA 200 440 460V 2x 3x150 mm2 70 mm2 GA 250 380 V 2x 3x240 mm2 120 mm2 GA 250 440 460V 2x 3x185 mm2 95 mm2 GA 315 380 V 4x 3x95 mm2 50 mm2 GA 315 440 460...

Page 71: ...3xMCM350 AWG0 GA 315 440 460V 4x 3xAWG4 0 AWG3 GA 315 575 V 4x 3xAWG2 0 AWG4 4 4 Pictographs Control panel Pictographs of control panel Reference Description 1 Start 2 Keys to scroll through display 3 Key to go to next field on display 4 Voltage on 5 Alarm 6 Automatic operation 7 Stop Instruction book 2920 1475 06 69 ...

Page 72: ...brass CuZn bolts 22 Consult the Instruction book before greasing 23 Switch off the voltage before removing the protecting cover inside the electric cabinet 24 Oil the gaskets screw on the filters and tighten by hand approx one half turn 25 Consult the Instruction book before maintenance or repair 26 Cooling water inlet 27 Cooling water outlet 28 Oil outlet 4 5 Cooling water requirements Recommenda...

Page 73: ... scaling or corrosive is only determined by its actual pH value and by the saturation pH value pHs The saturation pH value is determined by the relationship between the calcium hardness the total alkalinity the total solids concentration and the temperature The Ryznar Index is calculated as follows RSI 2 pHs pH Symbol Explanation pH Measured pH at room temperature of water sample pHs pH at saturat...

Page 74: ... Occasional inspection recommended 6 3 RSI 6 8 Neutral water Water treatment not necessary Occasional inspection recommended 6 9 RSI 7 5 Slight corrosion at higher temperature Water treatment not necessary Occasional inspection recommended 7 6 RSI 9 0 Strong corrosion Regular inspection necessary use of corrosion inhibitor recommended 9 1 RSI 11 Very strong corrosion Regular inspection necessary u...

Page 75: ...uld be limited Closed cooling system chlorides 500 ppm Open cooling system chlorides 150 ppm However if the water is scaling lower limits should be used See The Ryznar stability index RSI Free chlorine Cl2 A level of 0 5 ppm should not be exceeded for long periods For shock treatments a maximum limit of 2 ppm for maximum 30 minutes day applies Sulphates SO4 Closed cooling system sulphates 400 ppm ...

Page 76: ...Suspended solids Non soluble particles size 1 mm 10 ppm Instruction book 74 2920 1475 06 ...

Page 77: ... Copco Moving lifting The compressor can be moved by a lift truck using the slots in the frame Make sure that the forks protrude from the other side of the frame The compressor can also be lifted after inserting beams in the slots Make sure that the beams cannot slide and that they protrude from the frame equally The chains must be held parallel to the bodywork by chain spreaders in order not to d...

Page 78: ... Plugs to fill compressor elements of GA 90 up to GA 160 and GR 110 up to GR 200 at initial start up Plugs to fill compressor elements of GA 200 GA 250 and GA3 15 60 Hz at initial start up Instruction book 76 2920 1475 06 ...

Page 79: ...ay be remotely controlled 3 A number of VCI Volatile Corrosion Inhibitor plates are provided inside the bodywork to protect the compressor against corrosion Remove the plates 4 Remove filler plugs 1 On GA90 up to GA250 and GA315 60 Hz and GR110 up to GR200 pour approx 1 l 0 26 US gal 0 22 Imp gal of oil into the compressor elements Refit the plugs 5 Check that the compressor is filled with oil the...

Page 80: ...rts motor support and air receiver supports are secured to the frame immobilising the vibration dampers during transport 2 Remove the bushes 1 from the gear casing supports and the motor support 3 Remove the brackets fitted next to the air receiver supports Instruction book 78 2920 1475 06 ...

Page 81: ...Electric cabinet Example of a cubicle with starter Example of a cubicle without starter Instruction book 2920 1475 06 79 ...

Page 82: ...Check that overload relay F21 is set for automatic resetting and check its setting see the section Setting of overload relay and fuses Water circuit Step Action 1 Check that the cooling water drain valves customer s installation in the inlet and outlet lines are closed 2 Check that the water shut off valves customer s installation are open 3 Open the water regulating valve and check for water flow...

Page 83: ...sting to a stop 4 If the rotation direction is wrong press the emergency stop button switch off the voltage and reverse two incoming electric lines The correct direction of rotation is indicated for the drive motor by an arrow on the gear casing and for the fan motors by arrows on the motor housings 4 Run the compressor for a few minutes and check that it is operating normally 5 2 Before starting ...

Page 84: ...ge range 5 On compressors with integrated dryer check that the by pass valve is closed and that the inlet and outlet valves of the dryer are open see the section Initial start up Open the water shut off valves and the water regulating valve 5 3 Starting Warning The operator must apply all relevant Safety precautions On Full Feature compressors switch on the voltage 4 hours before starting in order...

Page 85: ...oaded The message on display 2 changes from Automatically unloaded to Automatically loaded 3 On water cooled compressors regulate the cooling water flow with the compressor running loaded Adjust the water flow to obtain the most suitable air temperature at the outlet of the compressor elements The temperature must be between 2 and approx 7 C 4 and approx 13 F above the relevant temperature in the ...

Page 86: ...V regulator 1 When the automatic operation LED 8 is lit the starting and stopping of the motor is controlled automatically 2 Check the readings on display 2 3 To unload the compressor manually press the Unload key 5 To put the compressor back into automatic operation press the Load key 5 4 Regularly check that the vessel of the OSD is filled if necessary gently top up with water to the level of th...

Page 87: ...s shown indicating the compressor outlet pressure the status of the compressor and the functions of the keys below the display 2 Always check the display and remedy the problem if alarm LED 7 is lit or flashing 3 The display will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded Carry out the service actions of the...

Page 88: ...he main display Main display of GA compressors Compressor outlet 7 5 bar Automatically loaded Menu Unload F1 F2 F3 5 6 Manual loading unloading Control panel Control panel of Elektronikon MkIV regulator Example of the main display Main display of GA compressors Instruction book 86 2920 1475 06 ...

Page 89: ...mand Load does not force the compressor into loaded condition but it will switch the compressor to automatic operation again the compressor will be loaded if the air net pressure drops below the programmed level 5 7 Stopping Important After pressing stop button 9 the compressor will run unloaded for 30 seconds The compressor stops after this period A start command during this period is ignored Aft...

Page 90: ...d compressors close the water shut off valves 7 On water cooled compressors if the compressor is installed in a room where freezing temperatures are expected drain the cooling system by opening the drain valves in the water inlet and outlet pipes customer s installation 5 8 Taking out of operation Disconnecting the compressor At the end of the service life of the compressor proceed as follows Step...

Page 91: ...r and must be operated within the specified limits as mentioned on the dataplate 3 No alterations shall be made to this vessel by welding drilling or other methods of mechanical working without written permission of the manufacturer 4 Original bolts have to be used after opening for inside inspection Maximum torque has to be taken into consideration 5 Devices for pressure and temperature control m...

Page 92: ...eplace all removed gaskets O rings and washers Preventive maintenance schedule Period Running hours Operation Daily 8 Check readings on display Daily 8 Check that condensate is discharged during loading Daily 8 Check oil level Before starting the level should be in the middle of the sight glass Weekly Drain condensate from the air receiver if installed Weekly 50 On compressors equipped with an OSD...

Page 93: ...n Inspection Plan A Preventive Maintenance Plan A Total Responsibility Plan Contact your Customer Centre to set up a tailor made service agreement It will ensure optimum operational efficiency minimise downtime and reduce the total life cycle costs Service plan A number of service operations are grouped called Level A Level B Level C Each level stands for a number of service actions to be carried ...

Page 94: ...h 90 gr 3 15 oz WEG drive motor WEG motors must be greased with Polyrex EM 60 Hz Compressor type Interval D end Amount D end Interval N end Amount N end GA 90 8000 h 45 gr 1 58 oz 8000 h 35 gr 1 23 oz GA 110 8000 h 45 gr 1 58 oz 8000 h 35 gr 1 23 oz GA 160 8000 h 45 gr 1 58 oz 8000 h 35 gr 1 23 oz GA 200 8000 h 45 gr 1 58 oz 8000 h 35 gr 1 23 oz GA 250 4000 h 60 gr 2 1 oz 4000 h 45 gr 3 15 oz GA 3...

Page 95: ...or in excellent condition Roto Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 C 32 F and 46 C 115 F see section Service kits Important Never mix oils of different brands or types 6 4 Oil change Warning The operator must apply all relevant Safety precautions Control panel Control panel of MkIV regulator Instruction book 2920 1475 06 93 ...

Page 96: ...rain plugs on GA 90 up to GA 250 GA 315 60 Hz and GA 132 VSD up to GA 315 VSD compressor elements Vent filler and drain plugs on air cooled GA 90 up to GA 160 and GA 132 VSD up to GA 315 VSD compressors Instruction book 94 2920 1475 06 ...

Page 97: ...t filler and drain plugs on air cooled GA 200 up to GA 315 compressors Filler and drain plugs on water cooled GA 90 up to GA 160 and GA 132 VSD up to GA 315 VSD compressors Instruction book 2920 1475 06 95 ...

Page 98: ...Filler and drain plugs on GA 200 up to GA 500 compressors Instruction book 96 2920 1475 06 ...

Page 99: ...r housing and oil coolers of water cooled compressors On air cooled GA 315 50 Hz and air cooled GA 355 up to GA 500 loosen the clip fixing the flexible to the frame Lift the flexible until all the oil is drained Tighten the plugs after draining 4 Remove filler plug 8 Fill the air receiver with oil until the level reaches the filler opening Refit and tighten plug 8 Tighten the vent plug of the oil ...

Page 100: ... Activate the menu by pressing key 2 Press key 1 until the related Service Plan is followed by an arrow pointing to the right and activate by pressing key 2 Press the Reset key 3 the timer is reset to 0 6 5 Oil filter change Warning Stop the compressor and switch off the voltage The operator must apply all relevant Safety precautions Control panel Control panel MkIII regulator Instruction book 98 ...

Page 101: ...Position of oil filters Position of oil filter on GA 90 up to GA 160 GA 132 VSD up to GA 315 VSD and GR 110 up to 200 Instruction book 2920 1475 06 99 ...

Page 102: ...Position of oil filter on GA 200 up to GA 500 Instruction book 100 2920 1475 06 ...

Page 103: ... key 2 Press key 1 until Oil filter is followed by an arrow pointing to the right Activate the menu by pressing key 2 Press the Reset key 3 the timer is reset to 0 6 6 Storage after installation Procedure Run the compressor e g twice a week until warm Load and unload the compressor a few times to operate the components of the unloading loading system If the compressor is going to be stored without...

Page 104: ... Xtend Duty Fluid Roto Xtend Duty Fluid can be ordered in the following quantities 5 litre can 2901 1700 00 20 litre can 2901 1701 00 209 litre drum 2901 1702 00 See Oil specifications Instruction book 102 2920 1475 06 ...

Page 105: ...p the compressor close the air outlet valve press the emergency stop button and switch off the voltage The operator must apply all relevant Safety precautions Position of air filters Air filters GA90 up to GA160 and GR110 up to GR200 Instruction book 2920 1475 06 103 ...

Page 106: ...Air filters GA200 GA250 and GA315 60 Hz Control panel of MkIII regulator Control panel of MkIV regulator Instruction book 104 2920 1475 06 ...

Page 107: ...ssing key 2 Press key 1 until Air filters is followed by an arrow pointing to the right Activate the menu by pressing key 2 Press Reset key 3 the timer is reset to 0 7 2 Coolers Warning Stop the compressor press the emergency stop button and switch off the voltage The operator must apply all relevant Safety precautions Procedure Cooler block of air cooled GA 90 up to GA 250 GA 315 60 Hz and GR com...

Page 108: ...ith 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 4 If it is necessary to clean the coolers with a cleaning agent consult Atlas Copco 5 Reposition and fix the fan Make sure that the fan rotates freely On water cooled compressors consult the Atlas Copco Customer Centre if it is necessary to clean the coolers ...

Page 109: ... valve on water cooled GA 90 up to GA 250 GA 315 60 Hz and GA 132 VSD up to GA 315 VSD compressors The valve can be tested on a separate compressed air line Consult the Atlas Copco Customer Centre if the valve does not open at the correct pressure see the section Settings of safety valve Instruction book 2920 1475 06 107 ...

Page 110: ...remedies A service message appears on the display Stop the compressor and carry out the indicated service actions Reset the message Press the Menu key 3 Press key 1 until Service is followed by an arrow pointing to the right Activate the menu by pressing key 2 Press the Reset key 3 the timer is reset to 0 A shut down warning message appears on the display The alarm LED will light up indicating tha...

Page 111: ...mpressor air delivery or pressure below normal Air consumption exceeds air delivery of compressor Check equipment connected Choked air filters Replace filters Air leakage Check and correct Condition Fault Remedy Compressor element outlet temperature or delivery air temperature above normal Oil level too low Check and correct Oil coolers clogged Consult the section Coolers Air cooler clogged Consul...

Page 112: ...arged through OSD outlets Strainer restrictors at the inlets of the separator vessels clogged Clean the strainer restrictors Consult Atlas Copco Flexibles between condensate traps and OSD clogged Replace flexibles Instruction book 110 2920 1475 06 ...

Page 113: ...g and loading pressures Compressor outlet temperature air cooled Pack compressors C Approx 29 Compressor outlet temperature air cooled Pack compressors F Approx 84 Compressor outlet temperature air cooled Full Feature compressors C Approx 26 Compressor outlet temperature air cooled Full Feature compressors F Approx 79 Compressor outlet temperature water cooled GA90 up to GA250 and GA315 60 Hz Pack...

Page 114: ... water inlet temperature C 20 Cooling water inlet temperature F 68 9 3 Limits Limits Maximum air inlet ambient temperature C 40 Maximum air inlet ambient temperature F 104 Minimum air inlet ambient temperature C 0 Minimum air inletambient temperature F 32 Maximum cooling air temperature C 40 Maximum cooling air temperature F 104 Minimum cooling air temperature C 0 Minimum cooling air temperature F...

Page 115: ...50 Hz IEC compressors with ABB motors GA 90 up to GA 250 and GR 110 up to GR 200 Compressor type Supply voltage V Overload relay A Fuses Class gL gG Type 2 A 2X3 fuses 2X3 cables to contactor Fuses Class gL gG Type 2 A 3 fuses 2X3 cables to contactor Fuses Class gL gG Type 2 A 3 fuses 3 cables to contactor bridges to be installed by customer GA 90 230 197 2x 3x250 3x400 GA 90 400 110 2x 3x160 3x22...

Page 116: ...tor Fuses Class gL gG Type 1 A 3 fuses 2X3 cables to contactor Fuses Class gL gG Type 1 A 3 fuses 3 cables to contactor bridges to be installed by customer GA 90 220 230 208 2x 3x300 GA 90 380 122 2x 3x160 3x250 GA 90 440 460 104 2x 3x160 3x224 GA GR 110 220 230 257 2x 3x355 GA GR 110 380 149 2x 3x200 3x300 GA GR 110 440 460 129 2x 3x160 3x300 GA GR 160 380 195 2x 3x250 3x400 GA GR 160 440 460 169...

Page 117: ...0 440 460 245 2x 3x300 3x500 GA 250 575 187 2x 3x250 3x400 GA 315 440 460 274 2x 3x350 3x600 GA 315 575 209 2x 3x250 3x400 9 6 Settings of circuit breakers For cooler cooling fan air cooled 50 Hz Compressor type Supply voltage V Circuit breakers Setting A GA 90 230 Q25 Q26 12 4 GA 90 400 Q25 Q26 7 2 GA 90 500 Q25 Q26 5 7 GA GR 110 230 Q25 Q26 12 4 GA GR 110 400 Q25 Q26 7 2 GA GR 110 500 Q25 Q26 5 ...

Page 118: ...460 Q25 Q26 7 2 GA GR 160 575 Q25 Q26 5 7 GA GR 200 220 230 Q25 Q26 20 2 GA GR 200 380 Q25 Q26 11 7 GA GR 200 440 460 Q25 Q26 9 9 GA GR 200 575 Q25 Q26 7 7 GA 250 220 230 Q25 Q26 20 2 GA 250 380 Q25 Q26 11 7 GA 250 440 460 Q25 Q26 9 9 GA 250 575 Q25 Q26 7 7 GA 315 220 230 Q25 Q26 20 2 GA 315 380 Q25 Q26 11 7 GA 315 440 460 Q25 Q26 9 9 GA 315 575 Q25 Q26 7 7 For bodywork ventilation fan water coole...

Page 119: ...ing A GA 90 220 230 Q25 2 1 GA 90 380 Q25 1 4 GA 90 440 460 Q25 1 1 GA 90 575 Q25 1 1 GA GR 110 220 230 Q25 2 1 GA GR 110 380 Q25 1 4 GA GR 110 440 460 Q25 1 1 GA GR 110 575 Q25 1 1 GA GR 160 220 230 Q25 2 1 GA GR 160 380 Q25 1 4 GA GR 160 440 460 Q25 1 1 GA GR 160 575 Q25 1 1 GA GR 200 220 230 Q25 2 1 GA GR 200 380 Q25 1 4 GA GR 200 440 460 Q25 1 1 GA GR 200 575 Q25 1 1 GA 250 220 230 Q25 2 1 GA ...

Page 120: ...00 500 Q40 22 GA 250 400 Q40 27 GA 250 500 Q40 22 For dryer motor 60 Hz Compressor type Supply voltage V Circuit breakers Setting A GA 90 220 230 Q40 25 GA 90 380 Q40 15 GA 90 440 460 Q40 13 GA 90 575 Q40 10 GA 110 220 230 Q40 25 GA 110 380 Q40 15 GA 110 440 460 Q40 13 GA 110 575 Q40 10 GA GR 160 380 Q40 22 GA GR 160 440 460 Q40 19 GA GR 160 575 Q40 15 GA 200 380 Q40 38 GA 200 440 460 Q40 33 GA 20...

Page 121: ... 400 Q41 1 4 GA GR 160 500 Q41 1 1 GR 200 500 Q41 1 1 GA 200 400 Q41 6 2 GA 200 500 Q41 5 1 GA 250 400 Q41 6 2 GA 250 500 Q41 5 1 For dryer cooling fan motor 60 Hz Compressor type Supply voltage V Circuit breakers Setting A GA 90 220 230 Q41 3 6 GA 90 380 Q41 2 2 GA 90 440 460 Q41 1 9 GA 90 575 Q41 1 4 GA GR 110 220 230 Q41 3 6 GA GR 110 380 Q41 2 2 GA GR 110 440 460 Q41 1 9 GA GR 110 575 Q41 1 4 ...

Page 122: ... 6 4 5 GA GR 132 400 Q1 0 9 1 4 2 2 2 8 GA GR 132 500 Q1 0 7 1 1 1 8 2 2 GA GR 160 230 Q1 1 5 2 4 3 6 4 5 GA GR 160 400 Q1 0 9 1 4 2 2 2 8 GA GR 160 500 Q1 0 7 1 1 1 8 2 2 GA GR 200 400 Q1 0 9 1 4 2 2 2 8 GA GR 200 500 Q1 0 7 1 1 1 8 2 2 GA 250 400 Q1 0 9 1 4 2 2 2 8 GA 250 500 Q1 0 7 1 1 1 8 2 2 For control circuit 60 Hz Compressor type Supply voltage V Circuit breakers Transforme r T1 250 VA Tra...

Page 123: ...he nominal working pressure is 0 1 bar 1 45 psi lower than the nominal pressure stated below Data for GA 7 5 bar 109 psi 50 Hz compressors Units GA90 GA110 GA132 GA160 GA200 GA250 Maximum working pressure GA Pack bar e 7 5 7 5 7 5 7 5 7 5 7 5 Maximum working pressure GA Pack psig 109 109 109 109 109 109 Maximum working pressure GA Full feature bar e 7 25 7 25 7 25 7 25 7 25 7 25 Maximum working pr...

Page 124: ...32 GA160 GA200 GA250 Maximum working pressure GA Pack bar e 8 5 8 5 8 5 8 5 8 5 8 5 Maximum working pressure GA Pack psig 123 123 123 123 123 123 Maximum working pressure GA Full Feature bar e 8 25 8 25 8 25 8 25 8 25 8 25 Maximum working pressure GA Full Feature psig 120 120 120 120 120 120 Nominal working pressure bar e 8 0 8 0 8 0 8 0 8 0 8 0 Nominal working pressure psig 116 116 116 116 116 11...

Page 125: ...pressure psig 138 138 138 138 138 138 Motor shaft speed r min 1490 1490 1490 1490 1490 1490 Power input GA Pack kW 102 124 146 178 224 273 Power input GA Pack hp 137 166 196 239 300 366 Power input GA Full Feature kW 108 131 155 187 240 290 Power input GA Full Feature hp 145 176 208 251 322 389 Power input GA W Pack kW 99 121 141 173 216 265 Power input GA W Pack hp 133 162 189 232 290 355 Power i...

Page 126: ... W Pack kW 101 121 144 177 233 281 Power input GA W Pack hp 135 162 193 237 312 377 Power input GA W Full Feature kW 106 126 152 185 250 298 Power input GA W Full Feature hp 142 169 204 248 335 400 Oil capacity GA l 69 75 93 100 130 130 Oil capacity GA US gal 18 2 19 8 24 6 26 4 34 3 34 3 Oil capacity GA Imp gal 15 2 16 5 20 5 22 28 6 28 6 Oil capacity GA cu ft 2 42 2 63 3 26 3 5 4 55 4 55 Oil cap...

Page 127: ...l capacity GA Imp gal 15 2 16 5 22 28 6 28 6 28 6 Oil capacity GA cu ft 2 42 2 63 3 5 4 55 4 55 4 55 Oil capacity GA W l 63 63 85 113 113 113 Oil capacity GA W US gal 16 6 16 6 22 4 29 8 29 8 29 8 Oil capacity GA W Imp gal 13 9 13 9 18 7 24 9 24 9 24 9 Oil capacity GA W cu ft 2 21 2 21 2 98 3 96 3 96 3 96 Sound pressure level GA dB A 76 76 78 76 76 76 Sound pressure level GA W dB A 71 71 71 72 72 ...

Page 128: ... 76 76 Sound pressure level GA W dB A 71 71 71 72 72 72 Maximum cooling water flow l s 2 0 2 5 3 6 4 2 5 6 6 9 Maximum cooling water flow cfm 4 2 5 3 7 6 8 9 11 9 14 6 Minimum cooling water flow l s 0 7 0 8 1 1 1 3 1 6 1 8 Minimum cooling water flow cfm 1 5 1 7 2 3 2 8 3 4 3 8 Data for GA 10 4 bar 150 psi 60 Hz compressors Units GA90 GA110 GA160 GA200 GA250 GA315 Maximum working pressure GA Pack b...

Page 129: ... 2 8 3 4 3 8 Data for GA 13 8 bar 200 psi 60 Hz compressors Units GA90 GA110 GA160 GA250 GA315 Maximum working pressure GA Pack bar e 13 8 13 8 13 8 13 8 13 8 Maximum working pressure GA Pack psig 200 200 200 200 200 Maximum working pressure GA Full Feature bar e 13 55 13 55 13 55 13 55 13 55 Maximum working pressure GA Full Feature psig 197 197 197 197 197 Nominal working pressure bar e 13 3 13 3...

Page 130: ... 13 9 18 7 24 9 24 9 Oil capacity GA W cu ft 2 21 2 21 2 98 3 96 3 96 Sound pressure level GA dB A 76 76 78 76 76 Sound pressure level GA W dB A 71 71 71 72 72 Maximum cooling water flow l s 2 0 2 5 3 6 5 6 6 9 Maximum cooling water flow cfm 4 2 5 3 7 6 11 9 14 6 Minimum cooling water flow l s 0 7 0 8 1 1 1 6 1 8 Minimum cooling water flow cfm 1 5 1 7 2 3 3 4 3 8 Instruction book 128 2920 1475 06 ...

Page 131: ...essure 15 bar e content 189 l Design standard ASME section VIII div 1 Safety valve Cat IV Design code AD Merkblätter A2 PED instructions GA200 up to GA500 Product GA 200 500 This machine is a pressure assembly of cat IV according to 97 23 EC Parts of article 3 3 of 97 23 EC are subject to good engineering practice Parts of category I according to 97 23 EC are integrated into the machine and fall u...

Page 132: ...ntation Declaration of conformity Typical example of a Declaration of Conformity document Declaration of incorporation Typical example of a Declaration of Incorporation document Instruction book 130 2920 1475 06 ...

Page 133: ...Instruction book 2920 1475 06 131 ...

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Page 136: ...ans having the flexibility to adapt to the diverse demands of the people we cater for It s the commitment to our customers business that drives our effort towards increasing their productivity through better solutions It starts with fully supporting existing products and continuously doing things better but it goes much further creating advances in technology through innovation Not for the sake of...

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