Atlas Copco GA18, Instruction Book

Page 1: ...INSTRUCTION BOOK API451763 GA 18 ...

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Page 3: ...hereof 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 2017 09 www atlascopco com ...

Page 4: ...UCTION 12 2 2 AIR FLOW 14 2 3 OIL SYSTEM 16 2 4 COOLING SYSTEM 18 2 5 CONDENSATE SYSTEM 19 2 6 REGULATING SYSTEM 20 2 7 ELECTRICAL SYSTEM 21 2 8 ELECTRICAL DIAGRAMS 22 2 9 AIR DRYER 24 3 Elektronikon I regulator 26 3 1 ELEKTRONIKON I REGULATOR 26 3 2 CONTROL PANEL 27 3 3 DISPLAY 28 3 4 PICTOGRAPHS USED ON THE SCREEN 29 3 5 MAIN SCREEN 29 3 6 SHUT DOWN WARNING 30 3 7 SHUT DOWN 32 3 8 SERVICE WARNIN...

Page 5: ...SELECTION 44 3 21 CALLING UP MODIFYING SERVICE TIMER SETTING 45 3 22 CALLING UP MODIFYING UNIT OF TEMPERATURE 45 3 23 CALLING UP MODIFYING UNIT OF PRESSURE 46 3 24 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE 46 3 25 SELECTION BETWEEN Y D OR DOL STARTING 47 3 26 CALLING UP MODIFYING LOAD DELAY TIME 47 3 27 CALLING UP MODIFYING MINIMUM STOP TIME 48 3 28 ACTIVATING PASSWORD PROTECTION 49 3 29 ...

Page 6: ...PECIFICATIONS 71 6 3 STORAGE AFTER INSTALLATION 72 6 4 SERVICE KITS 72 6 5 DISPOSAL OF USED MATERIAL 72 7 Adjustments and servicing procedures 74 7 1 DRIVE MOTOR 74 7 2 AIR FILTER 74 7 3 OIL AND OIL FILTER CHANGE 75 7 4 OIL SEPARATOR CHANGE 77 7 5 COOLERS 77 7 6 SAFETY VALVES 78 7 7 DRYER MAINTENANCE INSTRUCTIONS 78 8 Problem solving 80 9 Technical data 83 9 1 READINGS ON DISPLAY 83 9 2 ELECTRIC C...

Page 7: ...CHES 85 9 5 REFERENCE CONDITIONS AND LIMITATIONS 85 9 6 COMPRESSOR DATA FOR GA 15 UP TO GA 22 85 10 Instructions for use 87 11 Guidelines for inspection 88 12 Pressure equipment directives 89 13 Declaration of conformity 90 Instruction book API451763 5 ...

Page 8: ...f the voltage Depressurize the machine Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work always disconnect and check ...

Page 9: ...siccant bags must be removed before connecting the pipes 5 Air hoses must be of correct size and suitable for the working pressure Never use frayed damaged or worn hoses Distribution pipes and connections must be of the correct size and suitable for the working pressure 6 In case the device is a compressor the aspirated air must be free of flammable fumes vapors and particles e g paint solvents th...

Page 10: ...ystem is present in the air net close to the dryer safety valves must be installed in the vessels of the dryer Also consult following safety precautions Safety precautions during operation and Safety precautions during maintenance These precautions apply to machinery processing or consuming air or inert gas Processing of any other gas requires additional safety precautions typical to the applicati...

Page 11: ... tamper with the sound damping material 12 Never remove or tamper with the safety devices guards or insulations fitted on the machine Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure relieving device or devices as required 13 Yearly inspect the air receiver Minimum wall thickness as specified in the instruct...

Page 12: ...ith open flame for inspecting the interior of a machine pressure vessel etc 14 Make sure that no tools loose parts or rags are left in or on the machine 15 All regulating and safety devices shall be maintained with due care to ensure that they function properly They may not be put out of action 16 Before clearing the machine for use after maintenance or overhaul check that operating pressures temp...

Page 13: ...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 and equipment hence some statements may not apply to your machine Instruction book API451763 11 ...

Page 14: ...ric cabinet comprising the motor starter is located behind this panel Floor mounted compressors are directly installed on the floor Front view GA 15 up to GA 22 Floor mounted Pack GA Full Feature GA Full Feature FF are controlled by the Atlas Copco Elektronikon I regulator They are provided with an air dryer integrated in the sound insulated bodywork The dryer removes condensate from the compresse...

Page 15: ...rence Name AF Air filter AV Air outlet valve Ca Air cooler Co Oil cooler DR Dryer ER1 Elektronikon regulator M1 Motor MT Condensate trap GA Pack OF Oil filter OS Oil separator cartridge OT Oil separator tank S3 Emergency stop button Instruction book API451763 13 ...

Page 16: ...2 2 Air flow Flow diagrams Flow diagram GA Pack Instruction book 14 API451763 ...

Page 17: ...Flow diagram GA Full Feature Reference Description A Intake air B Air oil mixture C Oil D Wet compressed air E Condensate F Dried compressed air Instruction book API451763 15 ...

Page 18: ...imum value required for lubrication An integrated check valve prevents the compressed air downstream the valve from being vented to atmosphere during unloaded operation When the compressor is stopped inlet valve IV closes preventing compressed air and oil to be vented into the air filter A condensate trap MT downstream the air cooler is included On Full Feature compressors the air flows through ai...

Page 19: ... in the lower part of oil tank OT Air pressure forces the oil from oil tank OT through oil cooler Co and filter OF to compressor element E The oil system is provided with a thermostatic bypass valve BV When the oil temperature is below its set point bypass valve BV shuts off the supply to oil cooler Co and the oil cooler is bypassed Thermostatic bypass valve BV starts opening the supply from coole...

Page 20: ...ferences Description A Intake air B Air oil mixture C Oil D Wet compressed air Description The cooling system comprises air cooler Ca and oil cooler Co On air cooled compressors the cooling air flow is generated by fan FN Instruction book 18 API451763 ...

Page 21: ...s have a condensate trap MT downstream the air cooler The condensate trap is provided with a manual drain outlet Dm and an automatic drain outlet Da On Full Feature units the dryer is equipped with an electronic drain 1 The electronic drain is provided with an automatic drain outlet Da Instruction book API451763 19 ...

Page 22: ...air output of the compressor the net pressure increases When the net pressure reaches the unloading pressure solenoid valve Y1 is de energised Results The pressure above unloading valve blow off valve UV is released to atmosphere and the space above valve UV is no longer in connection with the oil separator tank pressure 1 Unloading valve blow off valve UV moves upwards connecting the oil separato...

Page 23: ...ts Electric cubicle on GA 15 up to GA 22 typical example Reference Designation F1 2 3 Fuses F4 5 6 Fuses F7 8 Fuses for dryer only on Full Feature compressors F21 Overload relay compressor motor K11 Auxiliary contactor for dryer only on Full Feature compressors K21 Line contactor K22 Star contactor K23 Delta contactor T1 T3 Transformers 1X0 Terminal strip voltage supply Instruction book API451763 ...

Page 24: ...erence Designation 1X1 Terminal strip motor X103 X108 Connectors PE Earth terminal 2 8 Electrical diagrams The complete electrical diagram can be found in the electric cubicle Instruction book 22 API451763 ...

Page 25: ...r delivery TT11 Temperature sensor element outlet TT90 Temperature sensor LAT dryer GA Full Feature only Y1 Solenoid valve Reference Starter cubicle E1 Elektronikon regulator F1 F2 Fuses F21 Overload relay compressor motor K11 Contactor for dryer supply GA Full Feature only K21 Line contactor K22 Star contactor K23 Delta contactor K5 Auxiliary relay motor protection S Remote pressure sensing S1 Re...

Page 26: ...ryer Air circuit Compressed air enters heat exchanger 10 and is cooled by the outgoing cold dried air Water vapor in the incoming air starts to condense The air then flows through heat exchanger evaporator 4 where the refrigerant evaporates causing the air to be cooled further to near the evaporating temperature of the refrigerant More water condenses The cold air then flows through separator 5 wh...

Page 27: ...id refrigerant flows through dryer filter 8 to capillary tube 7 The refrigerant leaves the capillary tube at evaporating pressure The refrigerant enters evaporator 4 where it withdraws heat from the compressed air by further evaporation at constant pressure The heated refrigerant leaves the evaporator and is sucked in by the compressor 1 Instruction book API451763 25 ...

Page 28: ... 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 Protecting the compressor Shut down If the compressor element outlet temperature exceeds the programmed shut down level the compressor will be stopped This will be indicated on dis...

Page 29: ...r was in the automatic operation mode the compressor will automatically restart when the supply voltage to the module is restored 3 2 Control panel Elektronikon I regulator Ref Name Function S3 Emergency stop button Push button to stop the compressor immediately in the event of an emergency After remedying the trouble unlock the button by pulling it out and press reset key 4 Only use S3 in case of...

Page 30: ...he compressor is loaded unloaded stopped and restarted depending on the air consumption and the limitations programmed in the regulator The LED is lit during automatic operation and flashes when the unit is remotely controlled 11 Pictograph Automatic operation 12 Downwards scroll key Key to scroll downwards through the screens or to decrease a setting 13 Upwards scroll key Key to scroll upwards th...

Page 31: ...shes Compressor status UNLOAD LOAD and UNLOAD indication Element outlet temperature Dew point temperature Motor or motor overload Emergency stop pressed Service pictograph LAN control or network setting 3 5 Main screen Procedure When the voltage is switched on the Main screen is shown automatically showing in short the operation status of the compressor and the outlet pressure Main screen typical ...

Page 32: ...vent of Too high a temperature at the outlet of the compressor element Too high a dew point temperature for Full Feature compressors Compressor element outlet temperature If the outlet temperature of the compressor element exceeds the shut down warning level 110 C 230 F alarm LED 4 will light up and the related pictograph will appear flashing Main screen with warning element outlet temperature fla...

Page 33: ...he dew point temperature exceeds the warning level not programmable alarm LED 4 will light up and the related pictograph will appear flashing Main screen with warning dew point temperature flashing bar 6 6 Press arrow key 3 until the actual dew point temperature appears Warning screen element outlet temperature flashing C 9 The screen shows that the dew point temperature is 9 C It remains possible...

Page 34: ...ompressor will be shut down alarm LED 4 will flash automatic operation LED 5 will go out and the following screen will appear Main screen with shut down indication element outlet temperature flashing bar 6 6 Press arrow key 3 until the actual compressor element temperature appears Shut down screen element outlet temperature flashing flashing C 122 The screen shows that the temperature at the outle...

Page 35: ... timer has reached the programmed time interval If the service timer exceeds the programmed time interval alarm LED 3 will light up Press arrow key 2 to scroll to d06 and the service symbol is shown Press key 1 the actual reading of the service timer appears and is shown in hrs or x1000 hrs if the service timer value is higer than 9999 Example of service timer screen d06 hrs 4002 The screen shows ...

Page 36: ...fter servicing reset the service timer See section Calling up resetting service timer 3 9 Scrolling through all screens Control panel Control panel Scroll keys 2 and 3 can be used to scroll through all screens The screens are divided into register screens measured data screens digital input screens numbered as d in d 01 parameter screens numbered as P 01 P 02 protections screens numbered as Pr 01 ...

Page 37: ... or LAN control See section Selection between local remote or LAN control P 02 Setting a node ID for LAN control See section Calling up modifying node ID P 03 Pressure band settings See section Calling up modifying pressure band settings P 04 Setting a pressure band selection See section Modifying pressure band selection P 05 Modifying a service timer See section Calling up modifying service timer...

Page 38: ...Protections screens See section Calling up modifying protection settings Test screen Designation Related topic t 01 Display test See sections Test screens t 02 Safety valve test See sections Test screens Menu flow Simplified menu flow Instruction book 36 API451763 ...

Page 39: ...emperature will be shown C 83 The screen shows that the outlet temperature is 83 C For Full Feature compressors Press arrow key 2 the dew point temperature will be shown C 3 The screen shows that the dew point temperature is 3 C Press arrow keys 2 and 3 to scroll downwards or upwards through the screens Instruction book API451763 37 ...

Page 40: ...rrow key 2 until d 01 is shown and then press enter key 1 x 1000 hrs 11 25 The screen shows the unit used x1000 hrs and the value 11 25 the running hours of the compressor are 11250 hours 3 12 Calling up motor starts Control panel Starting from the Main screen Instruction book 38 API451763 ...

Page 41: ... if x1000 lits up times 1000 The number of motor starts is 10100 3 13 Calling up module hours Control panel Starting from the Main screen bar 6 6 Press arrow key 2 until d 03 is shown and then press enter key 1 hrs 5000 The screen shows the unit used hrs and the value 5000 the module hours of the compressor are 5000 hours Instruction book API451763 39 ...

Page 42: ...s arrow key 2 until d 04 is shown and then press enter key 1 hrs 1755 The screen shows the unit used hrs or x1000 hrs and the value 1755 the loading hours of the compressor are 1755 hours 3 15 Calling up load relay Control panel Starting from the Main screen Instruction book 40 API451763 ...

Page 43: ... The number of unload to load actions is 10100 3 16 Calling up resetting service timer Control panel Starting from the Main screen bar 6 6 Press arrow key 3 until d 06 is shown and then press enter key 2 hrs 1191 This screen shows the unit used hrs or x1000 hours x 1000 and the value 1191 the compressor has run 1191 hours since the previous service Instruction book API451763 41 ...

Page 44: ...s reset key 1 to cancel the operation 3 17 Selection between local remote or LAN control Control panel Starting from the Main screen bar 6 6 Press arrow key 2 until P 01 is shown and then press enter key 1 The actually used control mode is shown LOC for local control rE for remote control or LAn for LAN control Press enter key 1 and if necessary enter the password The actually control mode is blin...

Page 45: ...ssword The actually used node ID is blinking Use keys 2 and 3 to change the node ID Press enter key 1 to program the new node ID or press reset key to cancel 3 19 Calling up modifying pressure band settings Control panel Starting from the Main screen bar 6 6 Press arrow key 2 until P 03 is shown and then press enter key 1 Pressure band 1 Pb 1 is shown on the display key 2 can be used to scroll to ...

Page 46: ...d Use keys 2 and 3 to change the load pressue Press enter key 1 to program the new values or press reset key to cancel 3 20 Modifying pressure band selection Control panel Starting from the Main screen bar 6 6 Press arrow key 2 until P 04 is shown and then press enter key 1 The active pressure band 1 Pb 1 is shown on the display Press enter key 1 to modify the pressure band selection a password ma...

Page 47: ...s enter key 1 the setting of the 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 key 1 to modify this value a password may be required the value blinks Use arrow keys 2 and 3 to modify this setting Press enter key 1 to program the new value and to return to the parameter screens 3 22 Calling up modifying unit o...

Page 48: ...tarting from the Main screen bar 6 6 Press arrow key 2 until P 07 and the possible settings are shown Mpa psi and bar press enter key 1 and the actually used unit is shown Press enter key 1 unit starts blinking and use arrow keys 2 and 3 to select another unit of pressure Press enter key 1 to program the new unit of pressure and press reset key to return to the parameter screens 3 24 Activating au...

Page 49: ...rting mode is shown Y d for Y D star delta or doL for DOL direct on line This parameter can only be modified after entering a code Consult Atlas Copco if the parameter is to be changed 3 26 Calling up modifying load delay time Control panel Starting from the Main screen bar 6 6 Press arrow key 2 until P 10 and the compressor load pictograph is shown and then press enter key 1 Instruction book API4...

Page 50: ...ess reset key to cancel 3 27 Calling up modifying minimum stop time Control panel Starting from the Main screen bar 6 6 Press arrow key 2 until P 11 and the motor pictograph is shown and then press enter key 1 s 20 This screen shows the minimum stop time 10 and the unit s seconds To modify this value press enter key 1 The value starts blinking and arrow keys 2 and 3 can be used to modify this valu...

Page 51: ...rd PASS appears on the screen Press enter key 1 The screen shows the password status on On or off OFF Press enter key 1 to modify Change the value with scroll keys 2 and 3 Select On and press enter key 1 Enter the new password and press enter key 1 to confirm Enter the password again and press enter key 1 to confirm On appears on the display Press reset key to return to the parameter screen Lost p...

Page 52: ...wn with the element outlet temperature pictograph shows the element outlet temperature protections Pr shown with the dewpoint temperature pictograph shows the dewpoint temperature protections Pr shown with the ambient temperature pictograph shows the ambient temperature protections Four protection settings are possible A low warning level shown on the display as AL L A high warning level shown on ...

Page 53: ...rning level to the shut down level press enter key 1 to modify the value The value appears on the display Press enter key 1 to modify the value An optional password may be required the value starts blinking and arrow keys 2 and 3 can be use to modify the value Press enter key 1 to program the new value press reset key to cancel Programmable settings can only be modified within allowed limits 3 30 ...

Page 54: ...essors bar e 4 1 8 6 9 1 Loading pressures Loading pressure 125 psi compressors bar e 4 8 9 Parameters unloading loading pressures for compressors with built in refrigeration dryer Minimum setting Factory setting Maximum setting Unloading pressures Unloading pressure 125 psi compressors bar e 4 1 8 6 8 8 Loading pressures Loading pressure 125 psi compressors bar e 4 8 8 7 Parameters Minimum settin...

Page 55: ...l 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 Power recovery time Is the period within which the voltage must be restored to have an automatic restart Is accessible if the automatic restart is activated See Elektronikon I regulator To activate the...

Page 56: ...4 Installation 4 1 Dimension drawings GA 15 up to GA 22 Floor mounted Pack Instruction book 54 API451763 ...

Page 57: ...Floor mounted Full Feature Type GA 18 Pack GA 18 Full Feature Weight of Floor mounted version kg 395 470 Ref Name 1 Compressor air inlet 2 Motor and cooling air inlet 3 Compressed air outlet Instruction book API451763 55 ...

Page 58: ...otor and compressor cooling air outlet 5 Electrical cable entry 6 Dryer cooling air inlet 7 Dryer cooling air outlet 8 Automatic drain 4 2 Installation proposal Compressor room example Instruction book 56 API451763 ...

Page 59: ...allowed The maximum air temperature at the compressor intake is 46 C 115 F minimum 0 C 32 F The ventilation capacity required to limit the compressor room temperature can be calculated from Qv 0 92 N ΔT Qv Required ventilation capacity in m3 s N Shaft input of compressor in kW ΔT Temperature increase in the compressor room in C 5 Mains cable entry To preserve the protection degree of the electric ...

Page 60: ...ferent from 3 x 400 V plus neutral and 3 x 230 V the dryer is powered by a transformer Compressor control modes on compressors equipped with an Elektronikon I regulator Consult section Selection between local remote or LAN control if it is desired to switch to another control mode The following control modes can be selected Local control The compressor will react to commands entered by means of th...

Page 61: ...struction book before carrying out maintenance 6 Warning voltage 7 Warning hot parts 8 Lock all doors of the bodywork before starting If the sheet is pulled downwards stop the compressor and switch off the voltage Reverse two incoming lines Repeat the previous step If the sheet is blown away the motor rotation is correct 9 Manual condensate drain 10 Automatic condensate drain 11 Warning switch off...

Page 62: ... book Drain the condensate to reduce the risk of corrosion 2 Drain the vessel daily by opening the manual drain valve 3 Inspect the vessel wall thickness yearly and note down the inspection date Instruction book 60 API451763 ...

Page 63: ...y The operator must apply all relevant Safety precautions Procedure For the location of the air outlet valve and the drain connections see sections Introduction and Condensate system Motor and gear casing transport fixtures Instruction book API451763 61 ...

Page 64: ...Position of oil level sight glass Electric cubicle Instruction book 62 API451763 ...

Page 65: ... filter connect the automatic drain of the filters to a suitable drain collector Check the oil level See section Oil and oil filter change Provide labels warning the operator that The compressor may automatically restart after voltage failure if activated consult Atlas Copco The compressor is automatically controlled and may be restarted automatically Affix sheet 5 explaining the procedure for che...

Page 66: ...air outlet valve Switch on the voltage Check that voltage on LED 6 lights up 5 4 During operation Warnings The operator must apply all relevant Safety precautions Also consult section Problem solving Removing the front panel service panel during operation will lead to an automatic shutdown of the unit after a certain time depending of the compressor version When the motors are stopped and LED 8 au...

Page 67: ...oo low press the emergency stop button 10 close the air outlet valve and open if provided the manual condensate drains See section Introduction and section Condensate system for location of the outlet valve and the water drain Next depressurise the oil system by unscrewing oil filler plug FC one turn and wait a few minutes Remove the plug and top up oil until the sight glass is full Fit and tighte...

Page 68: ... See section Condensate system The amount of condensate depends on environmental and working conditions 5 5 Checking the display Procedure Control panel Elektronikon I On compressors equipped with an Elektronikon I regulator check the display 2 regularly the compressor status is indicated by pictographs see section Pictographs used on the screen Remedy the trouble if alarm LED 7 is lit or flashes ...

Page 69: ...ronikon I after remedying the problem cause unlock the button by pulling it out and press the reset key 14 before restarting Do not use emergency stop button 10 for normal stopping Close air outlet valve AV see section Introduction Open the manual drain Dm Switch off the voltage 5 7 Taking out of operation Warning The operator must apply all relevant Safety precautions Procedure Step Action Stop t...

Page 70: ... permit any pressure in the system to escape Shut off and depressurise the part of the air net which is connected to the outlet valve Disconnect the compressor air outlet pipe from the air net Drain the oil Drain the condensate circuit and disconnect the condensate piping from the condensate net Instruction book 68 API451763 ...

Page 71: ...perator must apply all relevant Safety precautions Failure to adhere to these maintenance recommendations can result in damage fire explosion or injury Warranty Product Liability Use only authorised parts Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability Service kits For overhauling or carrying out preventive maintenance service kits ...

Page 72: ...in the schedule below Reset the service timer after servicing see section Calling up resetting service timer Preventive maintenance schedule Daily and 3 monthly check list Period Action Daily Check oil level Check readings on display Check that condensate is discharged during loading Drain condensate Check air filter service indicator Check the service indicator on the DDx and PDx filters if provi...

Page 73: ...ion Compressor data Exposure of the compressor to external pollutants operation at high humidity combined with low duty cycles or operation at higher temperatures may require a shorter oil exchange interval Contact Atlas Copco if in doubt Important Always consult Atlas Copco if a timer setting has to be changed For the change interval of oil and oil filter in extreme conditions of temperature humi...

Page 74: ...e a week until warm Load and unload the compressor a few times If the compressor is going to be stored without running from time to time protective measures must be taken Consult your supplier 6 4 Service kits Service kits For overhauling and for preventive maintenance a wide range of service kits is available Service kits comprise all parts required for servicing the component and offer the benef...

Page 75: ...waste collection point Refer to local regulations for directions on how to dispose of this product in an environmental friendly manner Instruction book API451763 73 ...

Page 76: ...ssary remove dust with a brush and or compressed air jet Bearing maintenance The motor bearings do not need to be regreased during their normal service life 7 2 Air filter Location of air filter Air filter GA 15 up to GA 22 Recommendations 1 Never remove the filtration element while the compressor is running Instruction book 74 API451763 ...

Page 77: ...tors 1 Stop the compressor Switch off the voltage 2 Remove the side panel 3 Remove the cover of air filter AF by turning it anti clockwise Remove the filter element If necessary clean the cover 4 Fit the new element and the cover 5 Reset the air filter service warning 7 3 Oil and oil filter change Warning The operator must apply all relevant Safety precautions Always drain the compressor oil at al...

Page 78: ...nd 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 Insert an elbow coupling in the filler plug FC for easy filling Fill the air receiver oil tank OT with oil until the level reaches the middle of sight glass Gl Take care that no dirt drop...

Page 79: ... 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 by hand 3 Reset the service timer For compressors equipped with an Elektronikon I regulator see section Calling up resetting service timer 7 5 Coolers General Keep the coolers clean t...

Page 80: ...sult Atlas Copco 7 6 Safety valves Location of safety valve GA 15 up to GA 22 Operating Operate the safety valve from time to time by unscrewing the cap one or two turns Retighten it afterwards Testing Before removing the valve depressurize the compressor See also section Problem solving The safety valve SV can be tested on a separate air line If the valve does not open at the set pressure stamped...

Page 81: ...discharge pipe can become quite hot up to 110 C 230 F Therefore wait until the dryer has cooled down before removing the panels Before starting any maintenance or repair work switch off the voltage and close the air inlet and outlet valves Local legislation Local legislation may stipulate that Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function mu...

Page 82: ...n Shut down warning Condition Fault Remedy Compressor starts running but does not load after a delay time Solenoid valve out of order Replace valve Inlet valve stuck in closed position Have valve checked Leak in control air tubes Replace leaking tubes Minimum pressure valve leaking when net is depressurized Have valve checked Compressor does not unload safety valve blows Solenoid valve out of orde...

Page 83: ...ement 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 restriction or improve ventilation of the compressor room Avoid recirculation of cooling air If installed check capacity of compressor room fan Oil cooler clogged Clean cooler Bypass valve ...

Page 84: ...t compressor motor has tripped Motor will restart when motor windings have cooled down Electronic condensate drain remains inoperative Electronic drain system clogged Have system inspected Clean the filter of the automatic drain by opening the manual drain valve Check functioning of the drain by pushing the test button Condensate trap continuously discharges air and water Automatic drain out of or...

Page 85: ...nals must not deviate more than 10 of the nominal voltage It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5 of the nominal voltage IEC 60204 1 If cables are grouped together with other power cables it may be necessary to use cables of a larger size than those calculated for the standard operating conditions Use the original cable entry See ...

Page 86: ... circuit For CSA 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 Recommended cable size Type V Hz Approval ItotP 1 ItotFF 1 Recommended wire section 2 Recommended wire section 3 Main fuses A 4 GA 18 200 60 CSA UL 84 89 4 x AWG2 4 x AWG1 125 GA 18 230 60 CSA UL 72 77 4...

Page 87: ...imum working pressure bar 4 Maximum air inlet temperature C 46 Minimum ambient temperature C 0 9 6 Compressor data for GA 15 up to GA 22 Reference conditions All data specified below apply under reference conditions see section Reference conditions and limitations GA 18 125 psi Frequency Hz 60 Maximum unloading pressure bar e 9 1 Maximum unloading pressure Full Feature units bar e 8 85 Nominal wor...

Page 88: ...l motor power kW 18 Dryer power at full load Full Feature units kW 0 8 Dryer power at unloaded operation kW 0 6 Refrigerant type Full Feature units R404A Refrigerant quantity Full Feature units kg 0 6 Oil capacity l 7 25 Sound pressure level Pack and Full Feature according to ISO 2151 2004 dB A 73 Instruction book 86 API451763 ...

Page 89: ...ust be made to this vessel by welding drilling or other mechanical methods without the written permission of the manufacturer The pressure and temperature of this vessel must be clearly indicated The safety valve must correspond with pressure surges of 1 1 times the maximum allowable operating pressure It should guarantee that the pressure will not permanently exceed the maximum allowable operatin...

Page 90: ...for the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this compressor Local legal requirements and or use outside the limits and or conditions as specified by the manufacturer may require other inspection periods as mentioned below Instruction book 88 API451763 ...

Page 91: ...iver CE 500 l 14 bar 10 120 C SPV 1622 4784 00 air receiver ASME 500 l 14 bar 10 120 C 1622 4787 00 air receiver DIR 500 l 14 bar 10 120 C 1622 4786 00 air receiver MOM 500 l 14 bar 10 120 C Component Description number of cycles 1 Minimum wall thickness Inspection frequency 2 1622 4702 50 oil separator vessel 2 x 106 2 mm shell 2 13 mm heads 10 years 1 The number of cycles refers to the number of...

Page 92: ...gium 2 Applicable directives 3 Standards used On the Declaration of Conformity Declaration by the Manufacturer the harmonized and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this device Instruction book 90 API451763 ...

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Page 94: ...stomers towards the environment and the people around us We make performance stand the test of time This is what we call Sustainable Productivity www atlascopco com Atlas Copco Airpower NV All rights reserved Designs and specifications are subject to change without notice or obligation ...