Atlas Copco GA50 (W) VSD, Instruction Book

Page 1: ...GA50 VSD and GA90 VSD compressors Industrial Air Division B 2610 Wilrijk Belgium Registration code Collection APC G VSD Tab 38 Sequence 980 Replaces No 2920 1190 04 No 2920 1190 05 1997 06 This instruction book meets the requirements for instructions specified by the machinery directive 89 392 EEC and is valid for CE as well as non CE labelled machines 2920119005 ...

Page 2: ... Atlas Copco Roto injectfluid 27 4 4 2 Mineral oil 27 4 5 Oil change 27 4 6 Oil filter change 28 4 7 Oil separator change 28 4 8 Storage after installation 29 4 9 Service kits 29 5 Adjustments and servicing procedures 29 5 1 Air filter 29 5 1 1 Recommendations 29 5 1 2 Servicing 29 5 2 Coolers 29 5 3 Safety valve 29 6 Problem solving 30 7 Principal data 31 7 1 Readings on display 31 7 2 Settings o...

Page 3: ...h is also provided An electric cabinet comprising the motor start and speed control system is located behind this panel 1 1 1 Air flow Figs 2 Air drawn through filter AF and check valve CV into compressor element E is compressed Compressed air and oil flow into air receiver oil separator AR The air is discharged through outlet valve AV via minimum pressure valve Vp air cooler Ca and moisture trap ...

Page 4: ...Industrial Air Division Instruction book Fig 2b Flow diagram of water cooled GA VSD compressor compressor running Fig 2a Flow diagram of air cooled GA VSD compressor compressor stopped and isolator switch switched off ...

Page 5: ...crease the motor speed If the net pressure keeps on rising when the motor runs at minimum speed the regulator will stop the motor If the motor is stopped automatically and the net pressure approaches the setpoint the regulator will restart the motor 1 3 Electrical system The system comprises Figs 6 1 Compressor motor M1 and fan motor M2 2 Elektronikon control module Fig 7a 3 Compressor start butto...

Page 6: ...ikon control module FC Oil filler plug FN Fan compressor coolers Gl Oil level gauge M1 Compressor motor M2 Fan motor OF Oil filter S0 Isolator switch SV Safety valve VP Venting plug oil cooler 1 Cooler plate 2 Flexible oil drain 3 Arrow rotation direction of fan motor Figs 3 Front views Fig 3b Front view of GA90 VSD Fig 3a Front view of GA50 VSD Ca E1 AV SO M1 F002 E CV OF FN 1 CO ...

Page 7: ...or compressor element outlet TT51 Temperature sensor cooling water outlet only on water cooled compressors Y1 Solenoid valve blow off MOTORS M1 Compressor motor M2 Fan motor compressor coolers ELECTRIC CABINET A1 R F I filter optional E1 Elektronikon control module E4 Communication module F1 F4 Fuses K15 Contactor fan motor K35 Thermistor relay motor temperature L1 Inductor Q15 Circuit breaker fan...

Page 8: ...2920 1190 05 8 Industrial Air Division Instruction book Fig 6a Electrical diagram of GA50 VSD ...

Page 9: ...9 2920 1190 05 Instruction book Industrial Air Division Fig 6b Electrical diagram of GA90 W VSD ...

Page 10: ...or Monitoring components subject to service The regulator continuously monitors the oil oil filter oil separator air filter and motor regreasing Each input is compared to programmed time intervals If these limits are exceeded a message will appear on display 4 Fig 7a to warn the operator to service the indicated component Automatic restart after voltage failure For compressors leaving the factory ...

Page 11: ...message Depressurize the compressor by switching off the isolator switch close the air outlet valve and open manual drain valve Check the sensor and its wiring The LED also blinks in case of a system failure due to hardware software or communication problems Consult the User manual for Elektronikon regulator section System failures The LED is alight in case of a shut down warning at the same time ...

Page 12: ...reaker fan motor Q16 Circuit breaker invertor S0 Isolator switch T1 Transformer T2 Transformer U1 Invertor 1 Vibration damper 2 Nut to be removed 3 Cover Figs 8 Electric cabinets Fig 8a Electric cabinet of GA50 VSD Fig 8b Electric cabinet of GA90 W VSD Q15 K15 F1 F2 T1 3 T2 SO U1 Q15 K15 Q16 F1 F2 2 1 1 2 U1 1 2 L1 1 2 ...

Page 13: ...n to a previously shown option or menu Slct Select To select a submenu or to read more details of a selection shown on display 1 5 Electric cabinet Figs 8 The cabinet comprises electric components such as the start and speed regulation unit of the motor U1 a transformer T1 and fuses F1 F4 as well as the start contactor K15 for the fan motor A fan motor circuit breaker Q15 is also provided If it sh...

Page 14: ...2920 1190 05 14 Industrial Air Division Instruction book 2 Installation 2 1 Dimension drawings Figs 10 Fig 10a Dimension drawing of GA50 VSD ...

Page 15: ...15 2920 1190 05 Instruction book Industrial Air Division Fig 10b Dimension drawing of GA50 W VSD ...

Page 16: ...2920 1190 05 16 Industrial Air Division Instruction book Fig 10c Dimension drawing of GA90 VSD ...

Page 17: ...17 2920 1190 05 Instruction book Industrial Air Division Fig 10d Dimension drawing of GA90 W VSD ...

Page 18: ...ize than those stated to comply with this requirement Use the original cable entrance In case additional holes must be provided in the cubicle take care that nothing can drop into the start and speed regulation unit U1 A ground fault circuit interrupter must not be used to connect GA VSD compressors Compressor type GA50 W VSD GA90 W VSD Voltage V 380 460 400 Frequency Hz 50 60 50 60 Maximum line c...

Page 19: ... on a level floor suitable for taking the weight of the compressor 2 Compressed air outlet valve Ref Description recommendation 3 The maximum total pipe length including interconnecting piping between compressor and receiver can be calculated as follows P x d5 x P L _________________________ 450 x Qc1 85 Fig 11b Installation proposal of GA90 VSD ...

Page 20: ...opco 6 Control module with monitoring panel 7 Mains cables entry 8 High efficiency filter type PD optional Filter traps solid particles down to 0 01 micron with max oil carry over of 0 01 mg m3 A PD filter must be installed downstream of a DD filter optional If oil vapour and odours are undesirable a filter of the QD type optional should be installed downstream of the PD filter 2 4 Electrical conn...

Page 21: ...n 2 3 6 Check the oil level The pointer of the level gauge Gl Figs 12 should register in the green or orange range The bottle delivered loose with the compressor is filled with Atlas Copco Roto injectfluid and can be used for topping up 7 For GA90 VSD a noise damping kit is available as an option including a cooling air outlet duct and baffle plates 8 On water cooled compressors Close the cooling ...

Page 22: ... HIGH range If the pointer registers in the LOW range depressurize the oil system by switching off the isolator switch close the air outlet valve and open manual drain valve Dm Fig 5 Wait until the compressor has depressurized Unscrew oil filler plug FC Figs 12 only one turn to permit any pressure in the system to escape Remove the filler cap and add oil until the level reaches the filler neck ada...

Page 23: ... permit any pressure in the system to escape Remove the filler plug and add oil until the level reaches the filler neck adapter part included Tighten the plug 2 If automatic operation LED 1 is alight the regulator is automatically controlling the compressor i e matching the compressor speed to the net pressure starting and stopping the compressor whenever necessary Warning When the motors are stop...

Page 24: ...ch is connected to the outlet valve Disconnect the compressor air outlet pipe from the air net 5 Isolate the compressor water system only on water cooled compressors from the cooling water net 6 Drain the oil water and condensate circuits 7 Disconnect the compressor condensate piping from the condensate drain net 4 Maintenance Attention Before starting any maintenance press stop button O 9 Fig 7a ...

Page 25: ...8 3 4 7 1 Check readings on display 8 10 Check that condensate is discharged during operation Da 3 5 10 Drain condensate Dm Monthly Clean compressor 3 monthly 5 3 Operate safety valve SV 8 Carry out a LED display test Check for oil leaks 500 1 Clean cooling air openings of electric cabinet 500 5 2 1 Inspect coolers Ca Co clean if necessary 500 1 7 Remove air filter element AF inspect 500 4 Check p...

Page 26: ... program the compressor will run at a speed of 1200 rpm and the compressed air is blown off via solenoid valve Y1 Figs 2 When the regreasing program has finished the compressor can be put into operation again by pressing the start button Reset the regulator as described in the User manual for Elektronikon regulator section Service reset 4 2 Compressor motor M1 Figs 3 Tubes with the correct type of...

Page 27: ...lve AV Fig 1 open manual drain valve Dm Fig 5 and wait until the compressor has depressurized Unscrew oil filler plug FC only one turn to permit any pressure in the system to escape 2 Remove vent plug VP Figs 3a and 4 Drain the oil by removing drain plugs DP1 DP2 and DP3 Figs 2 Fit and tighten all plugs after draining Collect the oil in a collector and deliver it to the oil collection service 3 Fi...

Page 28: ...ighten plug FC Tighten the plug in the oil filter housing and vent plug VP Figs 3a and 4 7 Reset the oil filter service warning 1 4 7 Oil separator change 1 Stop the compressor switch off the isolator switch close the air outlet valve AV Fig 1 and open manual drain valve Dm Fig 5 Wait until the compressor has depressurized Unscrew oil filler plug FC Figs 12 only one turn to permit any pressure in ...

Page 29: ...dirty element by a new one 3 Discard the element when damaged 5 1 2 Servicing 5 1 2 1 GA50 W VSD 1 Release the snap clips and remove the dust trap Remove the filter element and clean the filter chamber 2 Install the new element and the dust trap 3 Reset the air filter service indicator Reset the air filter service warning 1 5 1 2 2 GA90 W VSD AF Fig 4 1 Unscrew the wing nut of the filter cover Rem...

Page 30: ...lace filter element c Solenoid valve Y1 malfunctioning c Remove and check valve replace if necessary d Oil separator element OS clogged d Replace element e Air leakage e Check and correct as necessary f Safety valve SV leaking f Remove and check Replace if not airtight after reinstalling g Compressor element E out of order g Consult Atlas Copco Only on GA50 VSD h Nozzle Rf1 in wrong position h Cor...

Page 31: ...0 C Shown When using the function key 5 belowMore on the main display Fig 7b Sensor TT51 Figs 6 7 2 Settings of safety valve GA50 W VSD 14 5 bar e GA90 W VSD 14 5 bar e 7 3 Settings of circuit breakers 7 3 1 GA50 W VSD Circuit breaker Supply Fre Maximum voltage quency setting Fan motor Q15 Fig 8a 400 V 50 Hz 4 2 A 7 3 2 GA90 W VSD Circuit breaker Supply Fre Maximum voltage quency setting Fan motor...

Page 32: ...r inlet temperature C 40 40 40 Minimum air inlet temperature C 0 0 0 Maximum cooling water outlet temperature 6 C 50 50 50 Maximum cooling water inlet pressure 6 bar e 5 5 5 Recommended cooling water flow 6 cooling water inlet temperature below 25 C 7 l s 1 5 1 5 1 5 cooling water inlet temperature between 25 C and 40 C l s 2 2 2 2 2 2 Temperature of air leaving air outlet valve approx C 30 30 30 ...