Instruction book kit: Rebuild instruction for GA75VSD 400V

1/20 9820 3135 20Ed 00

Atlas Copco Stationary Air Compressors GA75VSD Instruction book Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium. Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. This instruction book meets the requirements for instructions specified by the machinery directive 98/37/EC and is valid for CE as well as non-CE labelled machines. For all AII compressors with an Mk3 & Mk4 Elektronikon controller With serial number AII 493 000 until AII 496 999 No. 9820 3135 20 2006-02-22

Instruction book kit: Rebuild instruction for GA75VSD 400V

2/20 9820 3135 20Ed 00

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life. Read this book before changing the machine to ensure correct handling, operation and proper maintenance from the beginning. The maintenance schedule comprises measures for keeping the machine in good condition. Keep this book available for the trained personnel from Atlas Copco and make sure that the machine is operated. Record all operating data, maintenance performed, etc. in an operator's logbook available from Atlas Copco. Follow all relevant safety precautions, including those mentioned in this book. Trained personnel from Atlas Copco who can be contacted for any further information must carry out repairs. In all correspondence always mention the type and the serial number, shown on the data plate and the number of this instruction. The company reserves the right to make changes without prior notice.

Instruction book kit: Rebuild instruction for GA75VSD 400V

3/20 9820 3135 20Ed 00

1 Table of content:

1 Table of content:................................................................................................................................. 3 2 Foreword and limitations:.................................................................................................................. 4

2.1 First some useful info:................................................................................................................................... 4 2.2 Unpacking the converter ACS 800: .............................................................................................................. 6

2.2.1 Unpacking the machine.......................................................................................................................... 6 3 Mounting of the VSD ACS800 in the converter cabinet: ................................................................ 7

3.1 Power connections of the converter: ............................................................................................................. 7 3.2 Control wiring:............................................................................................................................................ 12

4 Parameterise the new VSD .............................................................................................................. 14 4.1 Before start-up............................................................................................................................................. 14 4.2 Start up ...................................................................................................................................................... 14 4.3 Programming the new VSD ........................................................................................................................ 14

4.3.1 Control panel........................................................................................................................................ 14 4.3.2 Changing parameters............................................................................................................................ 15 4.3.3 Programming the new VSD ................................................................................................................. 15

5 Test .................................................................................................................................................... 20 5.1 Normal operation ........................................................................................................................................ 20 5.2 Communication........................................................................................................................................... 20 5.3 Temperature test.......................................................................................................................................... 20 5.4 Converter test .............................................................................................................................................. 20

Instruction book kit: Rebuild instruction for GA75VSD 400V

4/20 9820 3135 20Ed 00

2 Foreword and limitations: The replacement kit is designed for the replacement of the integrated converter of ABB ACS 600 series to the ABB converter ACS 800 series

2.1 First some useful info: Before starting rebuilding the compressor disconnect the power of the Compressor and wait for 5 minutes. For the Compressor with MkIII controller use the SD 9820 3135 18

Instruction book kit: Rebuild instruction for GA75VSD 400V

5/20 9820 3135 20Ed 00

For the Compressor with Mk IV controller use the SD 9820 3135 17

Instruction book kit: Rebuild instruction for GA75VSD 400V

6/20 9820 3135 20Ed 00

2.2 Unpacking the converter ACS 800:

2.2.1 Unpacking the machine

To rebuilt the converter use this instruction starting at the last point to the first instruction.

Instruction book kit: Rebuild instruction for GA75VSD 400V

7/20 9820 3135 20Ed 00

3 Mounting of the VSD ACS800 in the converter cabinet:

3.1 Power connections of the converter: 1st step Take out the previous (broken) converter ACS 600. Remove the ducting plate.

Disconnect the filter and remove it from the cubicle. Remove the short treated rods from the cubicle back plate. 2nd install the 4 threaded rods (L = 65 mm) in the backplate of the converter cubicle. 2 threaded rods at the top 2 threaded rods at the bottom + 2 nuts M8 ( as on the picture)

Instruction book kit: Rebuild instruction for GA75VSD 400V

8/20 9820 3135 20Ed 00

Install the L support on the 2 top rods and screw them with a washer and nut.

Instruction book kit: Rebuild instruction for GA75VSD 400V

9/20 9820 3135 20Ed 00

3rd step

Unpack the new converter and change install/screw the new converter (ACS800) on then new backplate: Remark the converter needs to be installed on the left side of the mounting plate.

Instruction book kit: Rebuild instruction for GA75VSD 400V

10/20 9820 3135 20Ed 00

4th step The 4th step is mounting the converter + back plate in the converter cubicle. Mount the Duct on top of the converter.

Remark: The chimney duct needs to fit in the converter. Pay attention to the sticker UP

Place the horizontal duct on the chimney duct and fix it with 5 bolds.

Connect the horizontal duct to the L profile support.

Instruction book kit: Rebuild instruction for GA75VSD 400V

11/20 9820 3135 20Ed 00

5th step Connect the supply & motor cables.

Connect power cable in the correct way

Connect the Earth wire

Instruction book kit: Rebuild instruction for GA75VSD 400V

12/20 9820 3135 20Ed 00

Please note that it is important to mount all protective covers.

3.2 Control wiring: 1st step

Communication module (RMBA module) Digital IO connections (X21 & X22)

Instruction book kit: Rebuild instruction for GA75VSD 400V

13/20 9820 3135 20Ed 00

Connect the control wires as on the service diagram

Instruction book kit: Rebuild instruction for GA75VSD 400V

14/20 9820 3135 20Ed 00

4 Parameterise the new VSD 4.1 Before start-up Check all connections according the service diagram Check that there are no tools left in the electrical cubicle. Check all earth connections

4.2 Start up Put power on the converter And wait for 1 minute

4.3 Programming the new VSD 4.3.1 Control panel

Instruction book kit: Rebuild instruction for GA75VSD 400V

15/20 9820 3135 20Ed 00

4.3.2 Changing parameters

4.3.3 Programming the new VSD

Enable the option modbus

Push the Emergency stop button and wait for 5 minutes. Pull the emergency stop button

Program the parameters in parameter group 99:

Push the Emergency stop button and wait for 5 minutes. Pull the emergency stop button

Do the ID magnetisation and wait for 1 minute. Do not start the quick commissioning and press the PAR button. Program the other parameters

Instruction book kit: Rebuild instruction for GA75VSD 400V

16/20 9820 3135 20Ed 00

Check the cubicle number

GA 75VSD 1900 2021 51 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 53 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 52 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 54 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 56 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 57 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 58 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 59 GA 75 VSD 9824 0733 11

GA 75VSD 1900 2021 86 GA 75VSD 9824 0733 11

GA 75VSD 1900 2021 92 GA 75VSD 9824 0733 12

GA 75VSD 1900 2021 93 GA 75VSD 9824 0733 12 Program the other parameters Compressor GA75VSD GA75VSD Voltage range 380-500V 380-500V Parameter set 9824 0733 11 9824 0733 12 Edition 0 0

Par. NAME VALUE VALUE 01 ACTUAL SIGNALS 02 ACTUAL SIGNALS 03 ACTUAL SIGNALS 09 ACTUAL SIGNALS 10 START/STOP/DIR

10,01 EXT1 STRT/STP/DIR COMM.CW COMM.CW 10,02 EXT2 STRT/STP/DIR KEYPAD KEYPAD 10,03 DIRECTION FORWARD FORWARD 10,04 EXT 1 STRT PTR 0X0 0X0 10,05 EXT 2 STRT PTR 0X0 0X0 10,06 JOG SPEED SELECT NOT SEL NOT SEL

11 REFERENCE SELECT 11,01 KEYPAD REF SEL REF1 (rpm) REF1 (rpm) 11,02 EXT1/EXT2 SELECT DI2 DI2 11,03 EXT REF1 SELECT COMM. REF COMM. REF 11,04 EXT REF1 MINIMUM [rpm] 0 011,05 EXT REF1 MAXIMUM [rpm] 2700 285011,06 EXT REF2 SELECT KEYPAD KEYPAD 11,07 EXT REF2 MINIMUM [%] 0 011,08 EXT REF2 MAXIMUM [%] 100 10011,09 EXT 1/2 SEL PTR 0X0 0X0 11.10 EXT 1 REF PTR 0X0 0X0 11,11 EXT 2 REF PTR 0X0 0X0

Instruction book kit: Rebuild instruction for GA75VSD 400V

17/20 9820 3135 20Ed 00

12 CONSTANT SPEEDS

12,01 CONST SPEED SEL DI2(SPEED2) DI2(SPEED2) 12,02 CONST SPEED 1 [rpm] 0 0 12,03 CONST SPEED 2 [rpm] 600 600 12,04 CONST SPEED 3 [rpm] 0 0 12,05 CONST SPEED 4 [rpm] 0 0 12,06 CONST SPEED 5 [rpm] 0 0 12,07 CONST SPEED 6 [rpm] 0 0 12,08 CONST SPEED 7 [rpm] 0 0 12,09 CONST SPEED 8 [rpm] 0 0 12.10 CONST SPEED 9 [rpm] 0 0 12,11 CONST SPEED 10 [rpm] 0 0 12,12 CONST SPEED 11 [rpm] 0 0 12,13 CONST SPEED 12 [rpm] 0 0 12,14 CONST SPEED 13 [rpm] 0 0 12,15 CONST SPEED 14 [rpm] 0 0 12,16 CONST SPEED 15 [rpm] 0 0

13 ANALOGUE INPUTS 14 RELAY OUTPUTS

14,01 RELAY RO1 OUTPUT READY READY 14,02 RELAY RO2 OUTPUT RUNNING RUNNING 14,03 RELAY RO3 OUTPUT FAULT(-1) FAULT(-1)

15 ANALOGUE OUTPUTS 15,01 ANALOGUE OUTPUT1 M1 TEMP MEAS M1 TEMP MEAS

16 SYST CTRL INPUTS 16,01 RUN ENABLE DI1 DI1 16,02 PARAMETER LOCK LOCKED LOCKED 16,03 PASS CODE 0 016,04 FAULT RESET SEL COMM.CW(7) COMM.CW(7) 16,05 USER MACRO IO CHG NOT SEL NOT SEL 16,06 LOCAL LOCK ON ON 16,07 PARAMETER SAVE DONE DONE 16,08 RUN ENA PTR 0X0 0X0

20 LIMITS 20,01 MINIMUM SPEED [rpm] 600 600 20,02 MAXIMUM SPEED [rpm] 2700 2850 20,03 MAXIMUM CURRENT [%Ihd] Maximum rating Maximum rating 20,04 TORQ MAX LIM1 [%] 300 300 20,05 OVERVOLTAGE CTRL ON ON 20,06 UNDERVOLTAGE CTRL ON ON 20,07 MINIMUM FREQ [Hz] 20,08 MAXIMUM FREQ [Hz] 20,11 P MOTORING LIM [%] 300 300 20,12 P GENERATING LIM [%] -300 -300 20,13 MIN TORQ SEL NEG MAX TORQ NEG MAX TORQ 20,14 MAX TORQ SEL MAX LIM1 MAX LIM1 20,15 TORQ MIN LIM1 [%] 0 0 20,16 TORQ MIN LIM2 [%] 0 0 20,17 TORQ MAX LIM2 [%] 300 300 20,18 TORQ MIN PTR 0X0 0X0 20,19 TORQ MAX PTR 0X0 0X0 20.20 MIN AI SCALE [%] 0 0 20,21 MAX AI SCALE [%] 300 300

Instruction book kit: Rebuild instruction for GA75VSD 400V

18/20 9820 3135 20Ed 00

21 START/STOP

21,01 START FUNCTION CNST DC MAGN CNST DC MAGN 21,02 CONST MAGN TIME [ms] 500 500 21,03 STOP FUNCTION COAST COAST 21,04 DC HOLD NO NO 21,05 DC HOLD SPEED [rpm] 5 5 21,06 DC HOLD CURR [%] 30 30 21,07 RUN ENABLE FUNC COAST STOP COAST STOP 21,08 SCALAR FLYSTART OFF OFF 21,09 START INTRL FUNC OFF2 STOP OFF2 STOP 21.10 ZERO SPEED DELAY [s] 0,5 0,5

22 ACCEL/DECEL 22,01 ACC/DEC SEL ACC/DEC 1 ACC/DEC 1 22,02 ACCEL TIME 1 [s] 15 15 22,03 DECEL TIME 1 [s] 15 15 22,04 ACCEL TIME 2 [s] 60 60 22,05 DECEL TIME 2 [s] 60 60 22,06 ACC/DEC RAMP SHPE [s] 0 0 22,07 EM STOP RAMP TIME [s] 0 0 22,08 ACC PTR 0X0 0X0 22,09 DEC PTR 0X0 0X0

23 SPEED CTRL 23,01 GAIN 20 20 23,02 INTEGRATION TIME [s] 1,5 1,5 23,03 DERIVATION TIME [ms] 0 0 23,04 ACC COMPENSATION [s] 0 0 23,05 SLIP GAIN [%] 100 100 23,06 AUTOTUNE RUN NO NO

25 CRITICAL SPEEDS 25,01 CRIT SPEED SELECT OFF OFF

26 MOTOR CONTROL 26,01 FLUX OPTIMIZATION NO NO 26,02 FLUX BRAKING YES YES 26,03 IR-COMPENSATION [%] 26,04 IR STEP-UP FREQ [Hz] 26,05 HEX FIELD WEAKEN OFF OFF 26,06 FLUX REF PTR 0X402710 0X402710

27 BRAKE CHOPPER 27,01 BRAKE CHOPPER CTL OFF OFF

Instruction book kit: Rebuild instruction for GA75VSD 400V

19/20 9820 3135 20Ed 00

30 FAULT FUNCTIONS

30,01 AI

Instruction book kit: Rebuild instruction for GA75VSD 400V

20/20 9820 3135 20Ed 00

5 Test

5.1 Normal operation Start the compressor (All functions start/stop) Put the set point pressure on 7 bar(e) Check the motor speed and converter speed Stop the compressor (NOT with the Emergency Stop button)

5.2 Communication Pull the communication connector (2x2) on the compressor controller and start on the

compressor controller. (You should get the converter time out and compressor shall not start)

Put the communication connector back in reset the compressor and start the compressor. Check that the compressor is running and pull the communication connector (2x2) MkIV during operation

(You should get the converter time out and compressor shall stop) Put the communication connector back in reset the compressor and start the compressor.

Check that the compressor is running. Stop the compressor and unscrew the wire 44 on terminal 1x5:44 and start the compressor (You should get converter format failure and compressor stops)

Screw the bridge back in and start the compressor see that the compressor is running fine and unscrew the wire during operation.(you should get converter format failure).

Restore all wiring and start the compressor.

5.3 Temperature test Pull the temperature sensor element outlet and start the machine (you should get sensor error and compressor stops) Reset the compressor and put the temperature sensor back in and pull the temperature

sensor during operation. (you should get sensor error and compressor stops)

5.4 Converter test When the compressor is standing still push the start button on the converter. The converter is not allowed to start.