GA 110 VSD, GA 132 VSD, GA 160 VSD€¦ · Table of contents 1 Safety precautions.....6

GA 110 VSD, GA 132 VSD, GA 160 VSD

Instruction book

Atlas Copco

GA 110 VSD, GA 132 VSD, GA 160 VSD

Instruction bookOriginal instructions

Copyright NoticeAny 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 is valid for CE as well as non-CE labelled machines. It meets therequirements for instructions specified by the applicable European directives as identifiedin the Declaration of Conformity.

2011 - 07

No. 2920 1728 05

www.atlascopco.com

Table of contents

1 Safety precautions..........................................................................................................6

1.1 SAFETY ICONS...................................................................................................................................6

1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................6

1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................6

1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................8

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................9

2 General description......................................................................................................11

2.1 INTRODUCTION.................................................................................................................................11

2.2 AIR AND OIL SYSTEM.........................................................................................................................13

2.3 COOLING AND CONDENSATE SYSTEM....................................................................................................17

2.4 ENERGY RECOVERY SYSTEM...............................................................................................................18

3 Elektronikon regulator.................................................................................................40

3.1 ELEKTRONIKON CONTROL SYSTEM.......................................................................................................40

3.2 CONTROL PANEL..............................................................................................................................42

3.3 FUNCTION KEYS...............................................................................................................................43

3.4 SCROLL KEYS..................................................................................................................................44

3.5 EMERGENCY STOP BUTTON................................................................................................................45

3.6 CONTROL PROGRAMS........................................................................................................................46

3.7 CALLING UP MENUS..........................................................................................................................48

3.8 MAIN SCREEN MENU.........................................................................................................................49

3.9 STATUS DATA MENU..........................................................................................................................50

3.10 MEASURED DATA MENU.....................................................................................................................53

3.11 COUNTERS MENU.............................................................................................................................54

3.12 TEST MENU.....................................................................................................................................55

3.13 MODIFY PARAMETERS.......................................................................................................................55

3.14 MODIFYING COMPRESSOR/MOTOR SETTINGS..........................................................................................56

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3.15 FAN MOTOR SETTINGS.......................................................................................................................57

3.16 MODIFYING DRYER MOTOR SETTINGS....................................................................................................58

3.17 MODIFYING PARAMETERS...................................................................................................................59

3.18 MODIFYING PROTECTION SETTINGS......................................................................................................60

3.19 MODIFYING SERVICE PLANS................................................................................................................61

3.20 PROGRAMMING CLOCK FUNCTION.........................................................................................................62

3.21 MODIFYING CONFIGURATION SETTINGS..................................................................................................67

3.22 SERVICE MENU................................................................................................................................68

3.23 SAVED DATA MENU...........................................................................................................................70

3.24 PROGRAMMABLE SETTINGS.................................................................................................................71

4 Installation.....................................................................................................................76

4.1 DIMENSION DRAWING........................................................................................................................76

4.2 INSTALLATION PROPOSAL...................................................................................................................80

4.3 ELECTRIC CABLE SIZE AND FUSES........................................................................................................86

4.4 ELECTRIC CONNECTIONS....................................................................................................................91

4.5 INSTALLATION INSTRUCTIONS FOR CUBICLE FAN....................................................................................100

4.6 INSTALLATION INSTRUCTIONS FOR HEAVY DUTY FILTER FOR VSD CUBICLE................................................103

4.7 INSTALLATION INSTRUCTIONS FOR DRYER BY-PASS ...............................................................................106

4.8 INSTALLATION INSTRUCTIONS GSM ALARM..........................................................................................108

4.9 PICTOGRAPHS...............................................................................................................................111

4.10 COOLING WATER REQUIREMENTS.......................................................................................................112

5 Operating instructions...............................................................................................116

5.1 INITIAL START-UP............................................................................................................................116

5.2 BEFORE STARTING..........................................................................................................................118

5.3 STARTING.....................................................................................................................................119

5.4 DURING OPERATION........................................................................................................................120

5.5 CHECKING THE DISPLAY...................................................................................................................121

5.6 STOPPING.....................................................................................................................................122

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5.7 TAKING OUT OF OPERATION..............................................................................................................123

5.8 USE OF AIR RECEIVER.....................................................................................................................123

6 Maintenance................................................................................................................125

6.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................125

6.2 MOTORS.......................................................................................................................................126

6.3 OIL SPECIFICATIONS........................................................................................................................127

6.4 OIL CHANGE..................................................................................................................................127

6.5 STORAGE AFTER INSTALLATION.........................................................................................................132

6.6 SERVICE KITS................................................................................................................................132

7 DD filter........................................................................................................................133

7.1 MAINTENANCE...............................................................................................................................133

7.2 FILTER ELEMENT CHANGE ................................................................................................................133

7.3 SERVICE INTERVALS........................................................................................................................134

7.4 FILTER DISPOSAL............................................................................................................................134

7.5 REFERENCE CONDITIONS.................................................................................................................134

7.6 PRINCIPAL DATA.............................................................................................................................134

8 Integrated dryer..........................................................................................................135

8.1 CONDENSATE DRAIN SYSTEM............................................................................................................135

8.2 MAINTENANCE INSTRUCTIONS...........................................................................................................136

8.3 PROBLEM SOLVING.........................................................................................................................137

9 Adjustments and servicing procedures...................................................................139

9.1 AIR FILTERS..................................................................................................................................139

9.2 COOLERS.....................................................................................................................................141

9.3 SAFETY VALVE...............................................................................................................................143

10 Problem solving..........................................................................................................145

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10.1 PROBLEM SOLVING.........................................................................................................................145

11 Technical data.............................................................................................................147

11.1 READINGS ON DISPLAY....................................................................................................................147

11.2 REFERENCE CONDITIONS.................................................................................................................148

11.3 LIMITS..........................................................................................................................................148

11.4 SETTINGS OF SAFETY VALVE.............................................................................................................149

11.5 SETTINGS OF CIRCUIT BREAKERS.......................................................................................................150

11.6 COMPRESSOR DATA........................................................................................................................150

12 Pressure equipment directives.................................................................................160

13 Documentation............................................................................................................161

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 Safety precautions, general

General precautions

1. The operator must employ safe working practices and observe all related work safety requirements andregulations.

2. If any of the following statements does not comply with the applicable legislation, the stricter of the twoshall apply.

3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,specialized personnel.

4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality,the compressed air must be adequately purified according to the applicable legislation and standards.

5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, thepower isolating switch must be opened and locked.On units powered by a frequency converter, wait six minutes before starting any electrical repair.

6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Neveruse the air to clean dirt from your clothes. When using the air to clean equipment, do so with extremecaution and wear eye protection.

7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shallbe replaced if unsuitable for safe operation.

8. It is not allowed to walk or stand on the roof of the unit.

1.3 Safety precautions during installationAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

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Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with the applicable safetyregulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden todwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept withinsafe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.

2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suctionduct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.

3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.4. 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 workingpressure.

5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can leadto internal fire or explosion.

6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under

heat and that it is not in contact with or close to flammable materials.8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is

remotely controlled and may start without warning.The operator has to make sure that the machine is stopped and that the isolating switch is open and lockedbefore any maintenance or repair. As a further safeguard, persons switching on remotely controlledmachines shall take adequate precautions to ensure that there is no one checking or working on themachine. To this end, a suitable 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 andthat 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 andprotected against short circuits by fuses in all phases. A lockable power isolating switch must be installednear the compressor.

12. On machines with automatic start/stop system or if the automatic restart function after voltage failure isactivated, a sign stating "This machine may start without warning" must be affixed near the instrumentpanel.

13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-returnvalves (check valves) must not be relied upon for isolating pressure systems.

14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressurevessel or auxiliary installed outside the machine to contain air above atmospheric pressure must beprotected by a pressure relieving device or devices as required.

15. Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally touchedby personnel in normal operation must be guarded or insulated. Other high temperature piping must beclearly marked.

16. For water-cooled machines, the cooling water system installed outside the machine has to be protected bya safety device with set pressure according to the maximum cooling water inlet pressure.

17. If the ground is not level or can be subject to variable inclination, consult the manufacturer.

Also consult following safety precautions: Safety precautions during operation and Safetyprecautions 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 applicationwhich are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

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1.4 Safety precautions during operationAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during operation

1. Never touch any piping or components of the compressor during operation.2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or

air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make surethat a hose is fully depressurized before disconnecting it.

3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that thereis no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remotestart equipment.

4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors orparticles.

5. Never operate the machine below or in excess of its limit ratings.6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to

carry out routine checks. Wear ear protectors when opening a door.On compressors without bodywork, wear ear protection in the vicinity of the machine.

7. People staying in environments 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 are not obstructed by dirt or paint• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free

of wear or abuse9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take

precautions against air pollution and possible contamination of the breathing air.10. Do not remove any of, or tamper with, the sound-damping material.11. 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 beprotected by a pressure relieving device or devices as required.

Also consult following safety precautions: Safety precautions during installation and Safetyprecautions 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 applicationwhich are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

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1.5 Safety precautions during maintenance or repairAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).2. Use only the correct tools for maintenance and repair work.3. Use only genuine spare parts.4. All maintenance work shall only be undertaken when the machine has cooled down.5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the starting

equipment.6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there

is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remotestart equipment.

7. Close the compressor air outlet valve before connecting or disconnecting a pipe.8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure

and relieve the entire system of pressure.9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against

toxic vapours of cleaning liquids.10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts

and exposed openings with a clean cloth, paper or tape.11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely

purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify,pressure vessels.

12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, themachine shall be stopped but no inspection covers shall be opened before sufficient cooling time haselapsed; 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, 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,

temperatures and time settings are correct. Check that all control and shut-down devices are fitted and thatthey function correctly. If removed, check that the coupling guard of the compressor drive shaft has beenreinstalled.

17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separatorvessel for carbon deposits; if excessive, the deposits should be removed.

18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from enteringthem, e.g. when steam cleaning.

19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodyworkand in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it bygenuine material from the manufacturer to prevent the sound pressure level from increasing.

20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.21. The following safety precautions are stressed when handling refrigerant:

• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, usebreathing protection.

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• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. Ifliquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flushabundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medicalfirst aid.

Also consult following safety precautions: Safety precautions during installation and Safetyprecautions 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 applicationwhich are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

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2 General description

2.1 Introduction

General view

General view of GA VSD

Description of GA VSD compressors

GA VSD (Variable Speed Drive) compressors are single-stage, oil-injected screw compressors directly drivenby an electric motor. The compressors deliver pulsation-free air. By continuously matching the speed of thedrive motor to the air net pressure, the compressor optimizes energy consumption and reduces the operatingpressure band.

GA VSD compressors are air-cooled.

GA W VSD compressors are water-cooled.

The following features are available as an option:

Full-Feature

A refrigerant dryer is fully integrated into the bodywork of the compressor. This All-in-one feature reducesthe required space for installation and provides savings on piping installation costs.

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DD filter

The compressor is provided with an integrated filter of the DD type to limit carry-over of solid particles andoil. By integrating a DD filter, the compressor delivers Quality Air according to ISO 8573-1, Class 2.4.2.

Energy recovery

The compressor is provided with an Atlas Copco energy recovery system to recover the major part of thecompression heat in the form of hot water without any influence on the compressor performance.

High ambient temperature (HAT)

The compressor is specially designed for continuous operation under humid and high ambient temperatureconditions. The maximum ambient temperature is:

• 50 ˚C (122 ˚F) for GA Full Feature and GA Full Feature with DD filter• 55 °C (131 °F) for GA Pack

Roto-Xtend Duty Fluid

Roto-Xtend Duty Fluid is a special, long-life lubricant for GA oil-injected screw compressors. It providesbetter cooling and extends the oil change interval.

SPM monitoring

A number of vibration sensors are provided on the drive motor and compressor elements. The readings canbe called up on the display of the Elektronikon regulator.

Anchor pads

Steel plates, fitting in the forklift slots, and bolts are shipped loose with the compressor. With these platesand bolts, the compressor frame can be fixed to the floor.

Automatic water shut-off

A water shut-off valve is provided in the cooling water system to shut off the system when the compressor isnot in operation.

GSM alarm

The compressor is equipped with a device that is able to send SMS messages or emails to one or more pre-defined cell phones via a built-in modem at pre-defined events to give information about the status of themonitored equipment involved.

Heavy duty filter for VSD cubicle

A heavy-duty filter is provided to allow the compressor to operate in heavily contaminated surroundings (e.g.cement or mining industry).

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2.2 Air and oil system

Flow diagrams

Flow diagram for air-cooled GA VSD compressors

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Flow diagram for water-cooled GA VSD compressors

Position of components

Main components

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Rear view of air-cooled GA

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Rear view of water-cooled GA

Air flow

Air drawn through filter (AF) is compressed in compressor element (E). Compressed air and oil are dischargedthrough check valve (CV) to air receiver/oil separator (AR) where oil is separated from the compressed air.The air is blown through minimum pressure valve (Vp) to air cooler (Ca).

On GA Pack compressors, the cooled air is discharged through condensate trap (MTa) and outlet (AOw)towards the air net.

On GA Full-Feature compressors, the cooled air is discharged through condensate trap (MTa) and outlet(AOd) towards the air net via the integrated air dryer.

Check valve (CV) prevents blow-back of compressed air.

Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure. Thevalve has a built-in check valve.

Oil system

Air pressure forces the oil from receiver (AR) through oil cooler (Co), filters (OF), oil stop valve (Vs) and anoil injection valve to the compressor element (E) and the lubrication points. The oil injection valve will openat higher ambient temperatures to keep the element outlet temperature low.

A by-pass valve by-passes the oil cooler (Co) when the injection pressure is low, to ensure a sufficient initialoil flow to the element when starting the compressor or when switching from unload to load.

For air-cooled units, the oil temperature is controlled by regulating the speed of the fans (FN), to avoidovercooling and consequently condensation in the air receiver (AR).

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On air-cooled compressors with energy recovery or water-cooled compressors, the oil temperature iscontrolled by a thermostatic or electronic valve to avoid overcooling and consequently condensation in theair receiver (AR).

In the air receiver (AR) most of the oil is removed from the air centrifugally. Almost all of the remaining oilis removed by the separator element.

2.3 Cooling and condensate system

Condensate drain system

Condensate drains of air-cooled GA

Condensate drains of water-cooled GA

Dac Automatic condensate drain, compressorDad Automatic condensate drain, dryer (Full-Feature compressors only)Daf Automatic condensate drain, DD filter (option)Dmc Manual condensate drain

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A condensate trap is installed downstream of the air cooler to prevent condensate from entering the air outletpipe. The trap is provided with a float valve for automatically draining condensate and with a manual drainvalve.

On Full-Feature compressors a condensate trap is also installed downstream of the dryer. This trap is alsoprovided with a float valve for automatically draining condensate.

Cooling system

On air-cooled compressors, the air and oil coolers are cooled by fans.

Water-cooled compressors are provided with a cooling water system, including combined oil and air coolers.

2.4 Energy recovery system

General description

The maximum allowed pressure at the water side of the heat exchanger is 10 bar (145 psi).

The energy required in any compression process is mainly transformed into heat. The major part of thecompression heat is dissipated through the oil system. The Atlas Copco energy recovery systems are designedto recover most of the above-mentioned heat as warm or hot water without any adverse influence on thecompressor performance.

After the compression stage, the oil is separated from the compressed air. The compressed air flows to theaftercooler and the oil flows to the oil cooler. The energy in the oil can be recovered by installing a heatexchanger in front of the oil cooler.

The energy recovery systems can be applied as low temperature rise / high water flow systems (e.g. centralheating in closed water circuits) or as high temperature rise / low water flow systems (e.g. pre-heating ofboiler feed water in open water circuits).

Main components

The system mainly comprises:

• Oil/water heat exchanger (HE)• Energy recovery valve (Y152)• Oil by-pass valve (Y151)• Temperature sensors for water inlet and outlet• The necessary pipes, brackets, bolts, etc.

Installation

The package includes:• a general by-pass system, to shut down the energy recovery system• a by-pass system to prevent the oil outlet temperature from dropping below the minimum value.

When the Energy Recovery system is working, this by-pass system makes the oil flow through the EnergyRecovery heat exchanger instead of the normal oil cooler

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Energy recovery system

Pressure drop, water side

Text on figure

(1) Pressure drop (kPa)(2) Pressure drop (bar)(3) Water flow (l/s)

For GA 90-132:• pd = 6.96 F2 + 2.71 F

For GA 160:• pd = 4.23 F2 + 1.62 F

With:• pd = pressure drop in kPa• F = water flow in L/s

The pressure drops calculated with the formulas above are indicative.

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Flow diagram

The recovery water enters the unit at the heat exchanger inlet connection (Wi). In the heat exchanger thecompression heat is transferred from the compressor to the water. The water leaves the heat exchanger viathe outlet connection (Wo).

Installation

The compressor frame is prepared for the Energy Recovery system. Before mounting the installation, the twolaser prepared holes in the frame must be cut out.

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Air-cooled compressors

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Water-cooled compressors

Operation

The compressor oil flow is controlled by two by-pass valves (Y152 and Y151 ), ensuring reliable compressoroperation and optimum energy recovery.

Recoverable Energy

The graphs of section Principal data below represent the performance for each power variant of GA90-160+at reference working pressure. The curves represent the limits of the energy recovery area and were obtainedwith the temperature of the element outlet as indicated in the graph. All points below the curve with Tc=85°C are possible working points where the recovered energy is maximized for lower element outlettemperatures.

The formula to calculate the amount of recovered energy is:

Q (kW) = 4.2 x q (l/s) x dT (°C)

with

• q = water flow in l/s• dT = temperature difference between water at inlet and outlet

For a VSD compressor, when running at a lower motor speed, the recoverable energy will be lower, becausethe dT that can be reached is smaller. This can be calculated by using the graph for maximum speed (see“performance curves”) and then recalculating the dT:

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dTv=dT x (RPMv/RPMmax)

dTv = the lower temperature rise that can be reached at lower motor speed

RPMv = the lower motor speed

RPMmax = the maximum motor speed that can be reached by the GA VSD

Settings

The compressor should never be running in “lowest dewpoint mode”. (See section Modifying fan motorsettings). The vessel temperature setting has to be set by an Atlas Copco service technician.

Regulation

The element outlet temperature must always be higher than the condensation temperature. (see sectionStarting). The software in the Elektronikon regulator of GA90-160+ compressors prevents the outlettemperature of the compressor element from dropping below the condensation temperature. Electronic valve(Y152) will be used to switch the Energy Recovery system on or off and to regulate the energy recovery.Electronic valve (Y151) is used to regulate the oil flow through the heat exchangers and consequently thecompressor element outlet temperature. The regulation will aim for an element outlet temperature of 90 °C /194 °F.

Start status

Compressor stopped, Energy Recovery 0%, all oil goes through normal oil cooler.

Unloaded operation

No Energy Recovery, oil flows through the regular oil cooler and is PI-regulated.

Loaded operation

• Compressor loads, cooling doesn’t change• Cooling stabilizes through regular oil cooler with PI-regulation, no Energy Recovery yet• Electronic valve (Y152) starts opening, the Energy Recovery is started. The flow through the oil cooler

is PI-regulated• Depending on the needed cooling:

• Less cooling is needed: flow through Energy Recovery cooler is PI-regulated, flow through oil cooleris minimum

• More cooling is needed: flow through Energy Recovery cooler is maximum, flow through oil cooleris PI-regulated

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Calculation examples

Example point X

High temperature rise, low water flow application, e.g. pre-heating of boiler feed water in open circuit:

• Compressor unit: GA160-50Hz• Working pressure: 14 bar / 200 psi• Water flow: 0.6 l/s / 1.27 cfm• Water inlet temperature: 36°C / 97 °F• Water outlet temperature: 90 °C / 194 °F

The formula to calculate the amount of recovered energy results in (2):

• 4.2 x 0.6 x (90 - 36) = 136 kW ( ± as indicated on the curve)

The outlet temperature for a water flow of 0.6 l/s can be calculated backwards from formula (2):

• Toutlet = 36 + (136 / (4.2 x 0.6)) = 90 °C

Total pressure drop on waterside is (1):

• pd = (4.23 x 0.6²) + (1.62 x 0.6) = 2.5 kPa = 25 mbar

Example point Y

Low temperature rise, high water flow application, e.g. central heating in closed circuit:

• Compressor unit: GA160-50Hz• Working pressure: 14 bar / 200 psi• Water flow: 4 l/s / 0.87 cfm• Water inlet temperature: 55.8°C / 132.4 °F• Water outlet temperature: 64.2 °C / 147.6 °F


• 4.2 x 4 x (64.2-55.8) = 141 kW ( ± as indicated on the curve of 85°C)

The outlet temperatures for a water flow of 6 l/s can be calculated backwards from formula (2):

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• Toutlet = 55.8 + (141 / (4.2 x 4)) = 64.2°C


• pd = (4.23 x 4²) + (1.62 x 4) = 74 kPa = 0.74 bar

Example point Y for a GA VSD working at 1500 RPM, when max RPM is 3000:

dT = 90-36 = 54°C

RPMv = 1500

RPMmax = 3000

dTv = 54 x (1500/3000) = 27 °C

Q = 4.2 x 0.6 x 27 = 68 kW

Example point Z

• Compressor unit: GA160-50Hz• Working pressure: 14 bar / 200 psi• Water flow: 1 l/s / 2.12 cfm• Water inlet temperature: 60°C / 140 °F• Water outlet temperature: 87.8°C / 190 °F


• 4.2 x 1 x (87.8-60) = 117 kW

The outlet temperatures for a water flow of 1 l/s can be calculated backwards from formula (2):

• Toutlet = 60 + (117 / (4.2 x 1)) = 87.8°C


• pd = (4.23 x 1²) + (1.62 x 1) = 5.85 kPa = 58.5 mbar

This proves that it is possible to work at higher temperatures, but with less heating power.

The temperature of the vessel can be set to 100°C as well. The installation can work in a higher curve,to obtain a higher water outlet temperature. This setting must be done by a service technician of AtlasCopco.

Example point below the lowest curve

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• Compressor unit: GA 160 VSD• Working pressure: 8 bar / 116 psi• Water inlet temperature: 30 °C / 86 °F• Water outlet temperature: 60 °C / 140 °F

The lowest curve is the maximum energy that can be recovered. If it is necessary to work in the area belowthe lowest curve, you have to calculate with the 140.5kW anyway.

dT=30 °C/ 54 °F (60 °C - 30 °C / 140 °F - 86 °F)

c = 4.2 J/kgK (for water)

Q= 140.5 kW (lowest curve)

Formula for recovered energy is : ==> Q = m x c x dT

==> m = Q / (c x dT)

==> m = 140.5 / (4.2 x 30)

==> m = 1.115 l/s

Additional safety precautions

• The parts must only be lifted using suitable equipment in accordance with the applicable safety regulations.Loose or pivoting parts must be securely fastened before lifting.

• Wear a safety helmet when working in the area of overhead or lifting equipment.• Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.• Protection caps, bags, etc. must be removed before connecting the pipes.• Water hoses must be of correct size and suitable for the working pressure.• The water connections must be free of strain.• Pipe work or other parts with a temperature in excess of 80˚C (176˚F) must be guarded or insulated. Other

high-temperature pipe work must be clearly marked.

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• The water system installed outside the machine has to be protected by a safety device with set pressureaccording to the maximum cooling water inlet pressure.

• All maintenance work shall only be undertaken when the machine has cooled down.• Never weld or perform any operation involving heat near the oil system.

Principal data

Performance curves

The given curves show only indicative values. Some deviations may be possible,depending on the circumstances. The fine tuning of the installation must be done on site,by a service technician of Atlas Copco.

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Spare parts list

Air-cooled compressors

Ref Qty Partnumber Name Extra info1 1 1623 2823 00 Pipe 1 0147 1322 03 Bolt, M8 x 16 Pipe to frame 2 0147 1362 03 Bolt, M10 x 25 Pipe to block 2 0301 2344 00 Washer Pipe to block 1 0663 2107 77 O-ring Pipe to block2 1 1623 2824 00 Pipe 1 0147 1322 03 Bolt, M8 x 16 Pipe to frame 2 0147 1362 03 Bolt, M10 x 25 Pipe to block 2 0301 2344 00 Washer Pipe to block 1 0663 2107 77 O-ring Pipe to block

3 11623 1346 00 or 16232779 00 Block

2 0211 1375 03 Screw, M10 x 90 Block to cooler 1 0663 2107 77 O-ring

4 11623 1404 00 or 16232755 00 Heat exchanger

2 0211 1375 03 Screw, M10 x 90 Block to cooler

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Ref Qty Partnumber Name Extra info

5 11623 1347 00 or 16232780 00 Block

1 0663 2107 77 O-ring 6 1 1623 1245 00 Support 5 1619 2766 00 Bolt, M8 x 20 Support to frame7 2 1623 1774 00 Bracket 4 0147 1326 03 Bolt, M8 x 30 Brackets to support, over cooler 4 0301 2335 00 Washer Brackets to support, over cooler 2 0147 1362 03 Bolt, M10 x 25 Block to hose assembly 1 0663 2107 77 O-ring Block to hose assembly8 1 1623 1248 00 Hose assembly 2 0147 1362 03 Bolt, M10 x 25 Hose assembly to valve 2 0301 2344 00 Washer Hose assembly to valve 1 0663 2109 68 O-ring Hose assembly to valve 1 0661 1000 25 Seal washer 1 0686 3716 01 Plug 9 1 1623 1213 00 Valve 3 0147 1322 03 Bolt, M8 x 16 Valve to frame 2 0147 1364 03 Bolt, M10 x 35 Valve to hose assembly 2 0301 2344 00 Washer Valve to hose assembly 2 0266 2111 00 Nut, M10 Valve to hose assembly 1 0663 2109 68 O-ring Valve to hose assembly10 1 1623 1285 00 Hose assembly 1 0634 1000 28 Victaulic, DN 40 Hose assembly to pipe11 1 0162 31288 00 Pipe 1 0634 1000 28 Victaulic, DN 40 Pipe to cooler 2 0634 1001 51 Coupling, DN32 Valve to pipe + pipe to cooler12 1 1623 1317 00 Pipe 2 0147 1362 03 Bolt, M10 x 25 Hose assembly to block 2 0301 2344 00 Washer Hose assembly to block 1 0663 2107 77 O-ring Hose assembly to block13 1 1623 1247 00 Hose assembly 2 0147 1364 03 Bolt, M10 x 35 Hose assembly to valve 2 0301 2344 00 Washer Hose assembly to valve 2 0266 2111 00 Nut, M10 Hose assembly to valve 1 0663 2109 68 O-ring Hose assembly to valve14 1 0162 31213 00 Valve 3 0147 1322 03 Bolt, M8 x 16 Valve to frame15 1 0162 32825 00 Pipe 2 0634 1001 51 Coupling, DN32 Valve to pipe & pipe to hose assembly 2 0147 1362 03 Bolt, M10 x 25 Valve to hose assembly 2 0301 2344 00 Washer Valve to hose assembly

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Ref Qty Partnumber Name Extra info 1 0663 2109 68 O-ring Valve to hose assembly16 1 1623 1255 00 Hose assembly 1 0663 2109 68 O-ring Hose assembly to vessel 2 0147 1365 03 Bolt, M10 x 40 Hose assembly to vessel 2 0301 2344 00 Washer Hose assembly to vessel 1 2250 2528 00 Plug screw, 1 1/4" In hose assembly 1 0661 1000 31 Seal washer In hose assembly 1 0574 8235 11 Hose assembly Drain cooler 1 1614 9252 00 Plug End of hose assembly 1 1079 5840 15 Nipple Between cooler & hose assembly 1 0661 1000 27 Seal washer Between cooler & hose assembly17 2 1089 0574 70 Temperarure sensor

Water-cooled compressors

Ref Qty Partnumber Name Extra info1 1 1623 2823 00 Pipe 1 0147 1322 03 Bolt, M8 x 16 Pipe to frame

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Ref Qty Partnumber Name Extra info 2 0147 1362 03 Bolt, M10 x 25 Pipe to block 2 0301 2344 00 Washer Pipe to block 1 0663 2107 77 O-ring Pipe to block2 1 1623 2824 00 Pipe 1 0147 1322 03 Bolt, M8 x 16 Pipe to frame 2 0147 1362 03 Bolt, M10 x 25 Pipe to block 2 030 12344 00 Washer Pipe to block 1 0663 2107 77 O-ring Pipe to block

3 11623 1346 00 or 16232779 00 Block

2 0211 1375 03 Screw, M10 x 90 1 0663 2107 77 O-ring Block to cooler4 1 1623 1245 00 Support 4 0147 1326 03 Bolt, M8 x 30 Brackets to support, over cooler5 2 1623 1774 00 Bracket 4 0301 2335 00 Washer Brackets to support, over cooler

6 11623 1404 00 or 16232755 00 Heat exchanger

5 1619 2766 00 Bolt, M8 x 20 Support to frame

7 11623 1347 00 or 16232780 00 Block

2 0211 1375 03 Screw, M10 x 90 Block to cooler 1 0663 2107 77 O-ring 2 0147 1362 03 Bolt, M10 x 25 Block to hose assembly 2 0301 2344 00 Washer Block to hose assembly 1 0663 2107 77 O-ring Block to hose assembly8 1 1623 1287 00 Hose assembly 2 0147 1362 03 Bolt, M10 x 25 Hose assembly to valve 2 0301 2344 00 Washer Hose assembly to valve 1 0661 1000 25 Seal washer 1 0686 3716 01 Plug 9 1 1623 1213 00 Valve 1 0663 2109 68 O-ring Hose assembly to valve10 1 1623 1586 00 Pipe 2 0634 1001 51 Coupling, DN32 Valve to pipe & pipe to hose assembly 2 0147 1362 03 Bolt, M10 x 25 Block to hose assembly 2 0301 2344 00 Washer Block to hose assembly 1 0663 2107 77 O-ring Block to hose assembly11 1 1623 1286 00 Hose assembly 2 0147 1364 03 Bolt, M10 x 35 Hose assembly to valve 2 0266 2111 00 Nut, M10 Hose assembly to valve 2 0301 2344 00 Washer Hose assembly to valve

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Ref Qty Partnumber Name Extra info12 1 1623 1213 00 Valve 1 0663 2109 68 O-ring Hose assembly to valve 2 0147 1363 03 Bolt, M10 x 30 Valve to pipe 2 0301 2344 00 Washer Valve to pipe 2 0266 211 100 Nut, M10 Valve to pipe13 1 1623 2065 00 Pipe 1 0663 2109 68 O-ring Valve to pipe 1 2250 2528 00 Plug screw, 1 1/4" In pipe 1 0661 1000 31 Seal washer In pipe 1 0574 8235 11 Hose assembly Drain cooler 1 1614 9252 00 Plug End of hose assembly 1 1079 5840 15 Nipple Between cooler & hose assembly 1 661100027 Seal washer Between cooler & hose assembly14 2 1089 0574 70 Temperarure sensor

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3 Elektronikon regulator

3.1 Elektronikon control system

Main functions

In general, the Elektronikon regulator has the following functions:

• Controlling the motor speed (Variable Speed Drive), reducing the power consumption and pressure band.• Controlling the speed of the fans of the coolers, reducing the power consumption and noise level.• On Full-Feature compressors, controlling the speed of the compressor motor of the air dryer, reducing the

power consumption and regulating the dryer performance.• Protecting the compressor.• Monitoring components - service warning.• Automatic restart after voltage failure.

Controlling the compressor speed - reducing power consumption and pressure band

VSD compressors optimise the power consumption and reduce the operating pressure band by matching themotor speed to the air net pressure.

The regulator will continuously vary the motor speed maintaining the net pressure as close as possible to theprogrammed pressure set-point. The pressure fluctuations will be very low.

Indirect stopping

Example of a pressure/time diagram

Ref. Designation(1) Pressure(2) Direct stop offset(3) Set-point(4) Motor speed

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Ref. Designation(5) Minimum(6) Time(7) Load(8) Indirect stop(9) Start(10) Indirect stop offset

If the motor is running at minimum speed and the net pressure rises to a value equal to the sum of theprogrammed pressure set-point and the programmed indirect stop offset, the compressor will stop.

When the net pressure drops, the regulator will calculate the optimum moment to restart the compressor toavoid the net pressure decreasing below the pressure set-point (anticipated starting).

Direct stopping

If the net pressure should rise to a value equal to the sum of the programmed pressure set-point and theprogrammed direct stop offset, the compressor will be stopped immediately.

The regulator will calculate the optimum moment to restart the compressor.

Protecting the compressor

Control panel

Shut-down and motor overload

If the element outlet temperature or compressor outlet temperature exceeds the programmed shut-down level,the compressor will be stopped. LED (2) will flash and a message will appear on display (1).

The compressor will also be stopped if there is overload of the drive motor.

On air-cooled compressors, the compressor will also stop if there is overload of the fan motors.

If there is overload of the dryer motor, the dryer will be stopped and a message will appear on display (1) towarn the operator.

Consult the section Maintenance warnings and remedy the problem. After remedying the problem and whenthe shut-down condition has disappeared, switch on the voltage and press the Reset key.

Shut-down warning

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If the element outlet temperature or compressor outlet temperature exceeds a programmed value below theshut-down level, LED (2) will be lit and a message will appear on display (1) to warn the operator before theshut-down level is reached.

Consult the section Maintenance warnings, stop the compressor and remedy the problem.

The message disappears as soon as the warning condition disappears.

Service warning

A number of service operations are grouped (called Level A, B, C, ...). Each level has a programmed timeinterval. If a time interval is exceeded, a message will appear on display (1) to warn the operator to carry outthe service actions belonging to that level.

Automatic restart after voltage failure

The regulator has a built-in function to automatically restart the compressor if the voltage is restored aftervoltage failure. This function is deactivated in compressors leaving the factory. If desired, the function canbe activated. Consult Atlas Copco.

If activated and provided the module was in the automatic operation mode, the compressorwill automatically restart if the supply voltage to the module is restored within aprogrammed time period.The power recovery time (the period within which the voltage must be restored to have anautomatic restart) can be set between 15 and 3600 seconds or to Infinite. If the powerrecovery time is set to Infinite, the compressor will always restart after a voltage failure,no matter how long it takes to restore the voltage. A restart delay can also be programmed,allowing e.g. two compressors to be restarted one after the other.

3.2 Control panel

Elektronikon regulator

Control panel

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Parts and functions

Reference Designation Function1 Start button Button to start the compressor. LED (8) lights up

indicating that the Elektronikon regulator is operative.2 Display Shows messages about the compressor operating

condition, a service need or a fault.3 Scroll keys Keys to scroll upwards or downwards through the

display.4 Tabulator key Key to select the parameter indicated by the horizontal

arrow. Only the parameters followed by an arrowpointing to 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 that the regulator is automatically controlling

the compressor.9 Stop button Button to stop the compressor. LED (8) goes out.S2 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.

3.3 Function keys

Control panel

Function keys

The keys (1) are used:

• To manually load/unload the compressor (not for VSD compressors)• To call up or to program settings• To reset a motor overload, shut-down or service message, or an emergency stop

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• To access all data collected by the regulator

The functions of the keys vary depending on the displayed menu. The actual function is indicated just abovethe relevant key. The most common functions are listed below:

Designation Function“Add” To add compressor start/stop commands (day/hour)“Back” To return to a previously 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” Not used on VSD (Variable Speed Drive) compressors

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” Starting from a submenu, to return to a previous menu“Modify” To modify programmable settings“Program” To program modified settings“Reset” To reset a timer or message“Return” To return to a previously shown option or menu“Unload” Not used on VSD (Variable Speed Drive) compressors

To unload the compressor manually“Extra” To find the module configuration of the regulator

3.4 Scroll keys

Control panel

The keys (1) allow the operator to scroll through the display.

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As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll keywith the same symbol can be used to see the next item.

As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key withthe 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

Description

In case of emergency, press button (S2) to stop the compressor immediately.

Using the emergency stop breaks the circuit to:

• the variable speed drive unit of the drive motor.• on air-cooled compressors, the variable speed drive unit of the fan motors.• on Full-Feature compressors, the dryer fan motor.• on GA (W) VSD Full-Feature compressors, the variable speed drive unit of the compressor motor of the

dryer.

By using the emergency stop, solenoid valve (Y2) will open the blow-off port, resulting in depressurisationof the air receiver.

At the occurrence of an emergency stop, the compressor element is stopped immediately and the solenoidvalve will be deactivated by Elektronikon ® regulator. No unload status is reached. The check valve preventsoil flow back from reversed rotation of the compressor element.

Before starting any maintenance or repairs, wait until the compressor hasstopped and open the isolating switch (customer's installation) to switch off thevoltage to the compressor.Close the air outlet valve and open the manual condensate drain valves todepressurize the air system.Apply all relevant Safety precautions.

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3.6 Control programs

Function

In order to facilitate programming and controlling, menu-driven control programs have been implemented inthe regulator.

Menu flow for air-cooled GA 132/160 VSD compressors (simplified example)

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Menu flow for water-cooled GA 132 W/160 W VSD compressors (simplified example)

Program FunctionMain screen Shows in brief the operational status of the compressor. 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 servicecondition.

“Measured Data” Calls up the data currently measured and the status of a number of inputs.

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Program Function“Counters” Calls up:

• running hours• regulator (module) hours• number of motor starts

“Test” Display test.“Modify Parameters” Modifying the settings for:

• Parameters (e.g. loading and unloading pressures)• Protections (e.g. temperature shut-down level)• Service plans (timers for service plans)• Clock functions (automatic compressor start/stop/pressure band commands)• Configuration (time, date, display language,...)

“Service” Calls up service plans and resets the timers after carrying out the service actions ina 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 automatically.

Example of Main screen of GA 132/160 VSD compressors

“Compressor Outlet” 7.5 bar.“Compressor Speed” 2100 rpm“Menu”F1 F2 F3

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After pressing the “Menu” (F1) key, the option “Status Data” will be followed by a horizontal arrow:

• Either press the tabulator key (2) to select this menu,• or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow and then press

the tabulator key (2) to select this menu.

The arrow down key (1) can be used for a quick look at the actual compressor status.

3.8 Main screen menu

Function

Control panel

The Main screen menu shows the status of the compressor operation and is the gateway to all functionsimplemented 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 returnto the Main screen.

Whenever displayed on a submenu screen, press the “Mainscreen” (F1) key to return to the Main screen.

Example of Main screen of GA 132/160 VSD compressors


The display indicates:

• The name of the sensor and its actual reading

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• Messages regarding the compressor operating condition• Just above the function keys (3), the actual functions of these keys

3.9 Status data menu

Warning

Before starting any maintenance or repairs, press the stop button (4), wait until thecompressor has stopped, press the red emergency stop button and open the isolatingswitch (customer's installation) to switch off the voltage to the compressor.

Close the air outlet 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 andservice condition.

Procedure

Starting from the Main screen (see Main screen menu):

• Press the key “Menu” (F1): the option “Status Data” will be followed by a horizontal arrow.• Press the tabulator key (2).

No message exists

• General alarm LED (1) is out and the message on the display will indicate that all conditions are normal:

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“All Conditions Are OK”..“Menu” “Help”F1 F2 F3

A shut-down message exists

• In case the compressor is shut down, LED (1) will blink.• In case of a shut-down due to too high a temperature at the outlet of the compressor element:

“Element Outlet” 114˚C. “Shutdown” “Maximum” 110˚C“Menu”*** “Help” ***”Reset”F1 F2 F3

• The indicators (***) are blinking. The screen shows the actual reading and the shut-down setting.• It remains possible to scroll through other menus, e.g. to check the values of other parameters.

When returning to the “Status Data” menu, the option “Shutdowns” will blink. This option can be selectedby pressing the tabulator key (2) to return to the above shut-down screen.

Shut-down reset

• Switch off the voltage and remedy the trouble. After remedying and when the shut-down condition hasdisappeared, 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 meansof 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-down warning exists, LED (1) is alight. The Main screen will change into a screen similar to theone below:

“Compressor Outlet” 7.0 bar.*** “Shutdown Warning” ***“Menu”*** ***F1 F2 F3

• The message “Shutdown Warning” appears.• Press the key “Menu” (F1) and the tabulator key (2) to select the “Status data” menu; the option

“Protection” is blinking.• Scroll to this option and select it by pressing the tabulator key (2). A screen similar to the one below

appears:

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“Element 1 Outlet” 103˚C.“Shutd. Warn.” “Maximum” 100˚C“Menu”*** ***F1 F2 F3

• The screen indicates that the temperature at the outlet of compressor element 1 exceeds the programmedshut-down warning level.

• If necessary, stop the compressor by means of stop button (4) and wait until it has stopped.• Switch off the voltage, inspect and remedy.• The warning message will disappear automatically as soon as the warning condition disappears.

A service warning exists

• LED (1) is alight. The Main screen will change into a screen similar to the one below:

“Compressor Outlet” 7.0 bar.“*Service Required*” “Menu”*** ***F1 F2 F3

• The indicators (***) are blinking and the service warning message 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 pressuredrop of the air filter).

• “Plan”: if a service plan interval is exceeded.• Stop the compressor and switch off the voltage.• In case the service message was referring to “Inputs” (air filter): replace the filter, switch on the voltage,

scroll in the “Status Data” menu to “Inputs” and press the “Reset” key to reset the service message.• In case the service message was referring to “Plan”: carry out the service actions related to the indicated

plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See Service menu.

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3.10 Measured data menu

Control panel

Function

To call up information regarding the actually measured data and the status of some inputs such as the motoroverload protection. Consult the menu flow in section Control programs.

Procedure


• 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 service level can be called up by pressing key(2).

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3.11 Counters menu

Control panel

Function

To call up:

• The running hours• The loaded hours• The number of motor starts• The number of hours the regulator (module) has been under tension• The number of load cycles

Procedure


• 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

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3.12 Test menu

Control panel

Function

To carry out a display test, i.e. to check whether the display and LEDs are still intact.

Procedure

• Starting from the Main screen (see Main screen menu), press the “Menu” (F1) key.• Press arrow down key (1) until “Test” is followed by a horizontal arrow.• Activate the menu by pressing the key (2).

To perform a display test:

• If necessary, scroll through the menu until “Display Test” is followed by a horizontal arrow.• Press the key (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

Function

To modify a number of programmable settings:

• Compressor/motor settings (see section Modifying compressor/motor settings).• Fan motor settings (see section Modifying fan motor settings).• Dryer motor settings (see section Modifying dryer motor settings).• Parameters (see section Modifying parameters).• Protections (see section Modifying protections).• Service plan settings (see section Modifying service plan settings).• Clock function settings (see section Modifying clock function settings).• Configuration settings (see section Modifying configuration settings).

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3.14 Modifying compressor/motor settings

Control panel

Function

To modify a number of settings. Consult the menu flow in section Control programs.

Procedure


• Press the key “Menu” (F1).• Press the arrow down key (1) until “Modify parameters” is followed by an arrow pointing to the right.• Activate the menu by pressing tabulator key (2).• The first option (“Compressor Motor”) will be followed by a right pointing arrow. Press key (2): the first

item “Setpoint 1” and its setting will appear.• Use keys (1) to scroll until the parameter to be modified is followed by a horizontal arrow.• For each parameter, the modifying procedure is similar to the example below.

Modifying the net pressure setpoints

If desired, the operator can program two setpoints “Setpoint 1” and “Setpoint 2”.

• Consult the section above for selecting the option “Setpoint 1”.• The screen shows that the current setting is 7.0 bar(e).• To modify this setting, press the key “Modify” (F2); The setting will blink.• The key “Limits” can be used to find out the limitations for the parameter. Use the scroll keys (1) to change

the value.• 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).• If required, the procedure to modify “Setpoint 2” is similar to the description above.

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“Setpoint 1” 7.0 bar “Setpoint 2” 6.0 bar“Indirect Stop Level” 0.3 bar“Menu” “Modify”F1 F2 F3

The regulator will not accept new values beyond the limitations.

It is possible to check the limitations which are valid for the parameter to be modified byselecting “Limits”.

3.15 Fan motor settings

Control panel

Function

To modify the fan motor operation mode. Consult the menu flow in section Control programs.

Procedure

Starting from the Main screen (see section 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 the tabulator key (2).• The first item “Fan Motor” will be followed by a horizontal arrow.• Press the tabulator key (2) to activate the menu.• Press the arrow down key (1) until the option “Fan Operation Mode” is followed by the end marker; the

following screen appears:

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“Minimum Speed” 600 “rpm”“Maximum RPM Reduction” 100 “pct”“Fan Operation Mode” “Normal”“Menu” “Modify” F1 F2 F3

• The screen shows that the current fan operation mode is “Normal”. To modify this setting, press the“Modify” key (F2); the operation mode will flash.

• Use the scroll keys to change the operation mode.• Press the “Program” key (F1) to program the new mode or the “Cancel” key (F3) to cancel the modification

operation.

It is possible to program two operation modes:

• “Normal”: In this mode, the fan algorithm will optimize the fan speed to get a lower power consumptionfor the compressor. This operation mode is recommended to be used with Pack compressors.

• “Lowest Dewp.”: In this mode, the fan algorithm will try to cool down the air to the lowest temperaturepossible in order to get the Lowest LAT possible in any ambient condition. This operation mode isrecommended to be used with a Full-Feature compressor or with a compressor with a stand-alone dryercombination.

3.16 Modifying dryer motor settings

Control panel

Function

To modify a number of dryer settings. Consult the menu flow in the section Control programs.

Procedure


• Press the “Menu” (F1) key.• Press the scroll key (1) until “Modify parameters” is followed by an arrow pointing to the right.• Activate the menu by pressing tabulator key (2).

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• The first option “Compressor Motor” will be followed by an arrow pointing to the right.• Press the arrow down key (1) to scroll until “Dryer Motor” is followed by a horizontal arrow.• Activate the menu by pressing tabulator key (2).

Modifying the dryer operation mode

It is possible to program three operation modes:

• Economy: the set-point of the pressure dew-point is ambient temperature minus 20 ˚C (77 ˚F) (minimumset-point is 3 ˚C (37.4 ˚F))

• Lowest dew-point: the set-point of the pressure dew-point is ambient temperature minus 25 ˚C (68 ˚F)(minimum set-point is 2.5 ˚C (36.5 ˚F))

• Maximum saving: the set-point of the pressure dew-point is ambient temperature minus 15 ˚C (59 ˚F)(minimum set-point is 3 ˚C (37.4 ˚F))

Procedure

• Activate the “Dryer Motor” menu as described above.• Press the arrow down key (1) to scroll until “Dryer Operation Mode” is followed by a horizontal arrow.• Activate the menu by pressing tabulator key (2).• The screen shows the actual operation mode. To modify this mode, press the Modify (F2) key; the operation

mode will flash.• Use the scroll keys (1) to change the operation mode.• Press the ”Program” (F1) key to program the new value or the “Cancel” (F3) key to cancel the modification

operation (the original value will be retained).

3.17 Modifying parameters

Function

Control panel

To modify a number of parameters. Consult the menu flow in section Control programs.

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Procedure


• 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 the tabulator key (2).• Use the arrow down key until the option “Parameters” is followed by a horizontal arrow.• Press the tabulator key (2): the first item and its setting will appear.• Press the arrow down key (1) until the parameter to be modified is followed by a horizontal arrow.• To modify this setting, press the key “Modify”; the setting starts blinking.• The key “Limits” can be used to find out the limitations for the parameter. Use the arrow up or arrow

down key to change the value.• Press the key “Program” to program the new setting or the key “Cancel” to cancel the modification

operation.

The procedure to modify other parameters is similar.

The regulator will not accept new values beyond the limitations. Press the key “Limits” to checkthe limitations for the parameter. Consult Programmable settings for the most importantsettings.

3.18 Modifying protection settings

Control panel

Function

To modify protection settings:

• “Shutdown”, e.g. for the compressor element outlet temperature• “Shutdown warning”, e.g. for the compressor element outlet temperature• “Warning”, e.g. for the dew-point temperature• “Service warning”, e.g. for the maximum pressure drop over the air filter

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To check various compressor conditions, e.g. the status of the emergency stop button. Some parameters cannotbe modified.

Procedure


• Press the “Menu” (F1) key.• Press the arrow down key (1) until “Modify parameters” is followed by a horizontal arrow.• Activate the menu by pressing the tabulator key (2).• Press the arrow down key (1) until “Protections” is followed by 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

• The screen (see example below) shows the current temperature on the first line and the shut-down settingon the third line. To modify the setting, press the “Modify” (F2) key; the setting will flash.

• The “Limits” (F2) key can be used to find out the limits for the parameter.• Use the scroll keys (1) to change the setting.• Press ”Program” (F1) to program the new value or “Cancel” (F3) to cancel the modification operation.• The screen (see example below) shows a horizontal arrow indicating that the shut-down warning value

can be modified (the procedure is similar to the description above).• The procedure to modify other items is similar. For some settings, a delay can be programmed.

Example of the screen for GA compressors

“Element Outlet” 94˚C

“Shutdown” “Maximum” 110˚C“Menu” “Modify”F1 F2 F3

The regulator will not accept new values beyond the limits. Press the key “Limits” to checkthe limits for the parameter. Consult Programmable settings for the most important settings.

3.19 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 reachingan interval, a message will appear on the screen indicating which Service plans are to be carried out.

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Always consult your Atlas Copco Customer Centre in case any timer should be changed. Theintervals must not exceed the programmed nominal values.

3.20 Programming clock function

Control panel

Function

To program:

• Time-based start/stop commands for the compressor• Time-based change-over commands for the net pressure band

Programming start, stop and pressure band commands

In this example, the compressor will be programmed as follows:

• On Monday at 06:15 starting in pressure band 1• On Friday at 18:00 changing over to pressure band 2• On Saturday at 18:00 stopping


• 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); following screen appears:

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“Clock Function”“Not Activated”

.“Menu” “Modify” “Delete”F1 F2 F3

• Press the tabulator key (2), following screen appears:

“Monday”“Tuesday”“Wednesday”“Menu” “Delete”F1 F2 F3

• Use the scroll keys (1) until the day on which a command must be programmed is followed by a horizontalarrow. Press the tabulator key (2); following screen appears:

--:-- ------------------------:-- ------------------------:-- ----------------------“Menu” “Modify” “Delete”F1 F2 F3

• Press the key “Modify” (F2). The first two dashes will flash. Use the scroll keys (1) to enter “06”. Pressthe tabulator key (2) to jump to the following two dashes. Use the scroll keys to enter “15”. Press thetabulator key to jump to the row of dashes. Use the scroll keys to enter the command “Start Compressor”.

• Press the key “Program” to program the command : “06:15 Start Compressor”.• Press the arrow down key (1): the horizontal arrow indicates that the second line is accessible. Press the

key “Modify” and 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 similarway as described above.

• Press the key “Menu” (F1) and scroll to “Saturday”. Programming the command “18:00 Compressor Stop”is carried out in a similar way as described above.

Activating/deactivating the timer

• The timer can only be activated if at least one start/stop command is programmed.• Starting from the Main screen, press the key “Menu” (F1).• Use arrow down key (1) until the option “Modify Parameters” is followed by a horizontal arrow.

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• Press the tabulator key (2) to activate the menu.• Use the arrow down key until the option “Clock Function” is followed by a horizontal arrow, press the

tabulator key (2), following screen appears:



• Press the key “Modify”, “Not Activated” starts blinking.• Press the arrow down key (1) “Not Activated” changes to “Activated”.• Press the key “Program”.

It is necessary to program the start/stop commands in successive order timewise. Programthe commands from Monday till Sunday, e.g.:• 07.30 Start Compressor• 07.30 Pressure Band 1• 08.30 Pressure Band 2• 18.00 Stop Compressor

Make sure that the timer function is activated (“Activated”). If not, the programmed start/stopcommands will not be executed.

The timer can be deactivated again. In this case, the programmed start/stop commands willnot be executed (but remain in the memory of the regulator).

Modifying a command

Suppose the command to stop the compressor on Saturday 18:00 is to be modified, i.e. stopping at 17 o'clockinstead 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 Function” is followed by a horizontal arrow.

Press the tabulator key, following screen appears:




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• Scroll through the display until “Saturday” is followed by a horizontal arrow. Press the tabulator key (2).If necessary, scroll through the commands until the command to be modified is followed by a horizontalarrow. Press the key “Modify”, the first two digits of the command start blinking. Modify as requiredusing the scroll keys, i.e. in the example above change “18” into “17” using the arrow up key (1).

• If necessary, press the tabulator key (2) to go to the next field to be modified, the minutes indication andthe start/stop/pressure band indication.

• Press the key “Program” to program the new command or the key “Cancel” to quit without reprogramming.

Adding a command at the end of an existing list

• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key 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 Function” is followed by a horizontal arrow.

Press the tabulator key, following screen appears:



Suppose the command to stop the compressor at 18:00 must be added to the list of Monday



• 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 isindicated by the horizontal arrow.

• Press the key “Modify”; the first two digits start blinking. Enter “18:00 Compressor Stop” using the scrollkeys (1) to modify a field and the tabulator key (2) to jump from one field to another.

• Press the key “Program” to program the new command or the key “Cancel” to quit without reprogramming.

Adding a command between two existing commands

Suppose the command “17:00 Pressure Band 2” must be added to the following list:

• 06:00 Start Compressor

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• 06:00 Pressure Band 1• 18:00 Stop Compressor

The regulator does not allow to enter a new command which is situated before the last command in the listtimewise.

Scroll through the display until the command before which the new command must be entered is followedby a horizontal arrow (in the example above: “18:00 Stop Compressor”) and press the key “Modify”.

Change this command to the new command (in the example above “17:00 Pressure Band 2”)

Press the arrow down key and add the last command of the list (in the example above “18:00 Stop Compressor”and press the key “Program”.

Deleting a command

• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the option“Modify Parameters” is followed by a horizontal arrow.

• Activate the menu by pressing the tabulator key (2).• Use the scroll keys (1) to scroll until the option “Clock Function” is followed by a horizontal arrow. Press

the tabulator key, following screen appears:



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.

Deleting a specific command

• Scroll through the display until the command to be deleted is followed by a horizontal arrow. Press thekey “Delete”, a question to confirm the deleting operation will appear.

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3.21 Modifying configuration settings

Control panel

Function

To modify a number of parameters. Consult the menu flow in section Control programs.

Procedure


• Press the key “Menu” (F1).• Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to the right.• Activate the menu by pressing tabulator key (2).• Press the arrow down key (1) to scroll until “Configuration” is followed by a horizontal arrow.• Activate the menu by pressing tabulator key (2): the first item will appear. Scroll through the display until

the option to be modified is followed by a horizontal arrow. Select the option by pressing the tabulatorkey (2).

• In case of the option “Time”, the second line on the screen indicates the actual setting, e.g. “14:30”. Tomodify this setting, press the key “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 modificationoperation (the original value will be retained).

• The procedure to modify other parameters is similar.

Programming compressor control modes

The compressor can be controlled locally, remotely or via a local area network (LAN).

Procedure

• Activate the menu “Configuration” as described above.• Scroll through the display until the option “C.C.M.” is indicated and press the “Modify” key. Following

screen appears:

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.“C.C.M.” “Local Control”.“Program” “Cancel”F1 F2 F3

• “Local Control” is blinking, use the scroll keys (1) to select the desired control mode.• Press the key “Program” to program the new control mode or “Cancel” to quit without reprogramming.

3.22 Service menu

Control panel

Function

• To reset the service plans which are carried out.• To check when the next service plans are to be carried out.• To find out which service plans were carried out previously.

Service plans

A number of service operations are grouped (called Level A, Level B, etc...). Each level stands for a numberof service actions to be carried out at the time intervals programmed in the Elektronikon regulator.

When a service plan interval is reached, a message will appear on the screen, see section Status data. Aftercarrying out the service actions related to the indicated levels, the timers are to be reset.

Example

Service plans IntervalsService plan A Every 4000 running hoursService plan B Every 8000 running hoursService plan C Every 16000 running hours

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Service actions according to IntervalsService plan A 4000 running hoursService plan A and B 8000 running hoursService plan A 12000 running hoursService plan A, B and C 16000 running hours... ...

Procedure


• Press the key “Menu” (F1).• Press the arrow down key (1) until “Service” is followed by a horizontal arrow.• Activate the menu by pressing tabulator key (2).• A screen similar to the one below appears:

“Service Timer”“Running Hours”

7971 “hrs”“Menu” “Reset”F1 F2 F3

• The screen shows that the total compressor running time is 7971 hours.• Press the tabulator key (2), following screen appears:

“Next Timer”“Level” A B

8000 “hrs”“Back” “Reset”F1 F2 F3

• The screen shows that the next service plans to be carried out are plans A and B and that these plans areto be carried out every 8000 running hours.

• Press the arrow down key (1) to find out which service plans were carried out previously, following screenappears:

“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 the voltage and scroll to the “Next Timer” service screen.• Press the “Reset” button (F3). Confirm the question for resetting.

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The “Reset” button only appears when the “Next Timer” level is almost reached.

After pressing the arrow down key in the “Service Timer” screen, the “Life Time” hours areshown, i.e. the number of hours elapsed since initial programming ex-factory. This timer isnot taken into account.

3.23 Saved data menu

Control panel

Function

To call up some data saved by the regulator. These data are:

• Last shut-down data• Last emergency stop data

Procedure


• Press the key “Menu” (F1).• Press the arrow down key (1) until “Saved Data” is followed by a horizontal arrow.• Activate the menu by pressing the tabulator key (2).• The first option is shown “Last 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.

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3.24 Programmable settings

Compressor/motor

Minimumsetting

Factorysetting

Maximumsetting

Set-point 1/2 GA VSD 8.5 bar Pack compressor bar(e) 3.5 8.0 8.5GA VSD 8.5 bar (123 psi) Pack compressor psig 51 116 123GA VSD 8.5 bar Full-Feature compressor bar(e) 3.5 8.0 8.3GA VSD 8.5 bar (123 psi) Full-Featurecompressor

psig 51 116 120

GA VSD 8.5 bar Full-Feature compressorwith DD filter

bar(e) 3.5 8.0 8.1

GA VSD 8.5 bar (123 psi) Full-Featurecompressor with DD filter

psig 51 116 117

GA VSD 125 psi (8.6 bar) Pack compressor bar(e) 3.5 8.6 9.1GA VSD 125 psi Pack compressor psig 51 125 132GA VSD 125 psi (8.6 bar) Full-Featurecompressor

bar(e) 3.5 8.6 8.9

GA VSD 125 psi Full-Feature compressor psig 51 125 129GA VSD 125 psi (8.6 bar) Full-Featurecompressor with DD filter

bar(e) 3.5 8.6 8.7

GA VSD 125 psi Full-Feature compressorwith DD filter

psig 51 125 126

GA VSD 10 bar Pack compressor bar(e) 6.0 9.5 10.0GA VSD 10 bar (145 psi) Pack compressor psig 87 138 145GA VSD 10 bar Full-Feature compressor bar(e) 6.0 9.5 9.8GA VSD 10 bar (145 psi) Full-Featurecompressor

psig 87 138 142

GA VSD 10 bar Full-Feature compressorwith DD filter

bar(e) 6.0 9.5 9.6

GA VSD 10 bar (145 psi) Full-Featurecompressor with DD filter

psig 87 138 139

GA VSD 150 psi (10.4 bar) Pack compressor bar(e) 6.0 10.4 10.9GA VSD 150 psi Pack compressor psig 87 150 158GA VSD 150 psi (10.4 bar) Full-Featurecompressor

bar(e) 6.0 10.4 10.7


bar(e) 6.0 10.4 10.5

GA VSD 150 psi Full-Feature compressorwith DD filter

psig 87 150 152

GA VSD 200 psi (13.8 bar) Pack compressor bar(e) 9.0 13.5 14.0GA VSD 200 psi Pack compressor psig 131 196 203

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Minimumsetting

Factorysetting

Maximumsetting

GA VSD 200 psi (13.8 bar) Full-Featurecompressor

bar(e) 9.0 13.5 13.8


bar(e) 6.0 10.4 13.6


psig 87 150 197

GA VSD 14 bar Pack compressor bar(e) 9.0 13.5 14.0GA VSD 14 bar (203 psi) Pack compressor psig 131 196 203GA VSD 14 bar Full-Feature compressor bar(e) 9.0 13.5 13.8GA VSD 14 bar (203 psi) Full-Featurecompressor

psig 131 196 200

GA VSD 14 bar Full-Feature compressorwith DD filter

bar(e) 6.0 10.4 13.6


psig 87 150 197

Indirect stop level bar 0.1 0.3 1.5Indirect stop level psi 1.45 4.4 21.8Direct stop level bar 0.1 1 1.5Direct stop level psi 1.45 14.5 21.8Proportional band % 10 15 20Integration time sec 1 10 20Minimum motor speed rpm 600 600 1500Maximum rpm reduction % 75 100 100

Parameters

Minimumsetting

Factorysetting

Maximumsetting

Minimum stop time: sec 0 15 255Permissive start time: sec 0 30 255Power recovery time (ARAVF) sec 15 15 3600Restart delay sec 0 3 255Communication time-out sec 10 20 60

Protections

Minimumsetting

Factorysetting

Maximumsetting

Compressor outlet temperature: Shut-down warning level ˚C 20 66 80Shut-down warning level ˚F 68 151 176

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Minimumsetting

Factorysetting

Maximumsetting

Shut-down level ˚C 20 80 80Shut-down level ˚F 68 176 176Compressor element outlet temperature: Shut-down warning level ˚C 80 114 120Shut-down warning level ˚F 176 237 248Shut-down level ˚C 80 120 120Shut-down level ˚F 176 248 248Cooling medium temperature: Air-cooled compressors (shut-down warninglevel)

˚C 0 50 55

Air-cooled compressors (shut-down warninglevel)

˚F 32 122 131

Air-cooled compressors, high ambientversion (shut-down warning level)

˚C 0 57 60

Air-cooled compressors, high ambientversion (shut-down warning level)

˚F 32 135 140

Air-cooled compressors (shut-down level) ˚C 0 55 55Air-cooled compressors (shut-down level) ˚F 32 131 131Air-cooled compressors, high ambientversion (shut-down level)

˚C 0 60 60

Air-cooled compressors, high ambientversion (shut-down level)

˚F 32 140 140

Water-cooled compressors (shut-downwarning level)

˚C 60 65 90

Water-cooled compressors (shut-downwarning level)

˚F 140 149 194

Water-cooled compressors (shut-downlevel)

˚C 60 75 90

Water-cooled compressors (shut-downlevel)

˚F 140 167 194

Delay at signal sec 0 20 60Ambient temperature: Shut-down warning level ˚C 0 50 55Shut-down warning level ˚F 32 122 131Shut-down warning level, high ambientversion

° C 0 57 60

Shut-down warning level, high ambientversion

° F 32 135 140

Shut-down level ˚C 0 55 55Shut-down level ˚F 32 131 131Shut-down level, high ambient version ° C 0 60 60Shut-down level, high ambient version ° F 32 140 140Delay at signal sec 0 255 255Oil separator temperature:

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Minimumsetting

Factorysetting

Maximumsetting

Shut-down warning level ˚C 0 120 120Shut-down warning level ˚F 32 248 248Shut-down level ˚C 0 120 120Shut-down level ˚F 32 248 248Delay at signal sec 0 1 3dp oil separator (shut-down warning level) mbar -- 850 1000dp oil separator (shut-down warning level) in WC -- 335 394dp oil separator (shut-down level) mbar -- 1000 1000dp oil separator (shut-down level) in WC -- 394 394Delay at signal sec 5 60 255On compressors with Energy Recoverysystem also:

Temperature Energy Recovery water inlet,warning level

°C 0 90 95

Temperature Energy Recovery water inlet,warning level

°F 32 194 203

Temperature Energy Recovery water inlet,shut-down level

°C 0 95 95

Temperature Energy Recovery water inlet,shut-down level

°F 32 203 203

Delay at start sec 0 0 0Delay at signal sec 0 5 10Temperature Energy Recovery water outlet,warning level

°C 0 90 95

Temperature Energy Recovery water outlet,warning level

°F 32 194 203

Temperature Energy Recovery water outlet,shut-down level

°C 0 95 95

Temperature Energy Recovery water outlet,shut-down level

°F 32 203 203

Delay at start sec 0 0 0Delay at signal sec 0 5 10

Service plans

Minimumsetting

Factorysetting

Maximumsetting

Service plan A (operating hours) hr See remark 4000 See remarkService plan B (operating hours) hr See remark 8000 See remarkService plan C (operating hours) hr See remark 16000 See remarkService plan D (operating hours) hr See remark 24000 See remarkService plan I (operating hours) hr See remark 2000 See remark

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Analogue signals Minimumsetting

Factorysetting

Maximumsetting

Dp of oil separator (shut-down warninglevel)

bar 0 0.8 1.0

Dp of oil separator (shut-down warninglevel)

psi 0 11.6 14.5

Delay at signal, Dp of oil separator sec 0 60 255Dp of air filter: Shut-down warning level mbar -85 -80 0Shut-down warning level psi -0.7 -0.7 -0.7Shut-down level mbar -85 -85 0Shut-down level psi -1.2 -1.2 -1.2Delay at signal, Dp of air filter sec 0 60 255Dp of DD filter mbar 100 350 350Dp of DD filter psi 1.45 1.45 1.45Delay at signal sec 0 60 255

Remark

A number of service operations are grouped (Level A, Level B, ...). Each level stands for a number of serviceoperations to be carried out at the programmed intervals. Consult your Atlas Copco Service Centre.

Terminology

Term ExplanationARAVF Automatic restart after voltage failure. See Elektronikon regulator.Required stopperiod/Minimumstop time

Once the compressor has automatically stopped, it will remain stopped for the minimumstop time (approx. 20 seconds), whatever the net air pressure. In automatic operation, thecompressor will not be stopped by the regulator until a standstill period of at least the sumof the minimum stop time and required stop period is expected. However, if the decreasein net air pressure should require a new start of the compressor, the regulator will start thecompressor after the minimum stop time.

Power recoverytime

Is the period within which the voltage must be restored to have an automatic restart. Isaccessible if the automatic restart is activated. To activate the automatic restart function,consult Atlas Copco.

Delay at shut-down signal

Is the time for which the signal must exist before the compressor is shut down. If it isrequired to program this setting to another value, consult Atlas Copco.

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4 Installation

4.1 Dimension drawing

Compressor dimensions

Dimension drawing of air-cooled Pack VSD compressors

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Dimension drawing of air-cooled Full-Feature VSD compressors

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Dimension drawing of water-cooled VSD compressors

Text on drawing

Reference Designation(1) Compressed air outlet(2) Cooling air outlet(3) Compressor air inlet(4) Cooling air inlet

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Reference Designation(5) Right hand side view(6) Left hand side view(7) Electric cable entry(8) Automatic drain, dryer(9) Rear side view(10) Manual drain(11) Automatic drain(12) Detail X(13) Energy recovery, water in(14) Energy recovery, water out(15) Front view(16) Top view(17) Slotted holes for horizontally pulling unit out of container(18) Manual drain, aftercooler(19) Automatic drain, aftercooler(20) z: height of compressor(21) Type(22) DD filter manual drain(23) EWD dryer drain(24) Cooling air inlet dryer(25) Compressed air outlet, Pack compressor(26) Compressed air outlet, with dryer(27) Cooling air inlet, dryer(28) Cooling air outlet, only for dryer(29) Cooling water out(30) Cooling water in(31) Cooling air outlet, VSD cubicle(32) VSD cubicle ventilation(33) Electric cable entry, VSD cubicle(34) Motor and canopy ventilation(35) Manual drain, dryer

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4.2 Installation proposal

Compressor room example

Compressor room example of GA VSD air-cooled compressor

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Compressor room example of air-cooled GA VSD Full-Feature compressor

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Compressor room example of GA VSD water-cooled compressor

Text on drawing

Reference Designation(1) Minimum free area to be reserved for compressor installation(2) Ventilation proposals(3) Cooling systems

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Reference Designation(4) Compressor air outlet, if dryer is by-passed(5) Compressor air outlet, Full-Feature compressors(6) Motor ventilation, air outlet(7) Motor ventilation, air inlet(8) Compressor air inlet(9) Cooling air outlet(10) Dryer cooling air outlet(11) Dryer and motor cooling air inlet(12) Compressor air inlet(13) Only C can be ducted(14) Only C and G can be ducted(15) Cubicle ventilation inlet(16) Cubicle ventilation outlet(17) C & F (if ducted) should be ducted separately(18) Cooling air inlet(19) Only C, F and G can be ducted(20) Motor ventilation, air inlet and dryer cooling air inlet(21) Only C, E and D can be ducted(22) C & E (if ducted) should be ducted separately(23) Only F, E and B can be ducted(24) F & E (if ducted) should be ducted separately

Description

Holes in the cubicle which are not used should be plugged.All electric screens in the control cubicle and drive cubicle have to be installed before start-up and remain installed during operation.

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Phase Description1 Install the compressor on a level floor suitable for taking its weight. For ventilation

alternative 1 (indicated as Alt. 1), the minimum distance between the top of the bodyworkand the ceiling is 1200 mm (47.2 in).

2 Remove the plastic plug (if provided) from the compressor air outlet pipe and fit the airoutlet valve (to be provided by the customer) to the pipe. Close the valve and connect itto the net.

3 The pressure drop over the air outlet pipe can be calculated as follows:For SI Units:dp = (L x 450 x Qc1.85) / (d5 x p)d = Inner diameter of the outlet pipe in mmdp = Pressure drop (recommended maximum = 0.1 bar)L = Length of outlet pipe in mp = Absolute pressure at the compressor outlet in bar(a)Qc = Free air delivery of the compressor in l/sFor British/American Units:dp = (L x Qc1.85) / (1470 x d5 x p)d = Inner diameter of the outlet pipe in indp = Pressure drop (recommended maximum = 1.45 psi)L = Length of outlet pipe in ftp = Absolute pressure at the compressor outlet in psigQc = Free air delivery of the compressor in cfmIt is recommended that the connection of the compressor air outlet pipe is made on top ofthe main air net pipe in order to minimize carry-over of possible condensate residue.As a rule of thumb, the following formula can be used to calculate the recommendedvolume of the air net:V = (30 x C x p x Q) / DpC = Correction factorDp = Pressure difference between unloading and loading pressures in bar (recommendedminimum = 0.6)p = Compressor inlet pressure in bar absoluteQ = Free air delivery of compressor in l/sV = Recommended air net volume in l

Correction factors

Air consumption divided by compressor free air delivery Correction factor C0.9 0.100.8 0.150.7 0.200.5 0.250.3 0.200.2 0.150.1 0.10

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Phase Description4 The inlet grids and ventilation fan should be installed in such a way that any recirculation

of cooling air to the compressor is avoided. The maximum air velocity through the grids is5 m/s (16.5 ft/s).The required ventilation to limit the compressor room temperature can be calculated asfollows:For SI Units:On air-cooled compressors: Qv = 0.92 N/dTOn water-cooled compressors: Qv = 0.1 N/dTQv = Required ventilation capacity in m3/sN = Shaft input of compressor in kW (for Pack compressors)N = Shaft input of compressor in kW + heat dissipated by dryer in KW (for Full-Featurecompressors)dT = Temperature increase in compressor roomFor British/American Units:On air-cooled compressors: Qv = 2618.5 N/dTOn water-cooled compressors: Qv = 284.5 N/dTQv = Required ventilation capacity in cfmN = Shaft input of compressor in hp (for Pack compressors)N = Shaft input of compressor in hp + heat dissipated by dryer in hp (for Full-Featurecompressors)dT = Temperature increase in compressor roomIf cooling air ducts are installed, the maximum allowable pressure drop over the ducts is30 Pa (0.12 in wc). The maximum pressure drop depends on the ambient temperature.The fan capacity should match the compressor fan capacity at a pressure head equal tothe pressure drop caused by the cooling air outlet ducts. Consult Atlas Copco.

5 Remove the plastic plugs (if provided) from the condensate outlets and fit the manualcondensate drain valve. Lay out the drain piping towards the condensate collector. Thedrain pipes must not dip into the water of the drain collector. It is recommended to providea funnel to allow visual inspection of the condensate flow.

6 Location of the Elektronikon regulator.7 See Electric cable size for the recommended size of the supply cables.

Check that the electrical connections correspond to the local codes. The installation mustbe earthed and protected against short circuits by fuses in all phases. An isolating switchmust be installed near the compressor.

- A water shut-off valve and water drain valve in the compressor water inlet pipe and outletpipe can be installed by the customer. If water shut-off valves are installed, a safety devicewith set pressure according to the maximum cooling water inlet pressure has to be installedbetween 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 the compressor water pipes and connect thepipes to the cooling water circuit.

For water-cooled compressors, the cooling water system installed outside the compressormust be protected by a safety device with set pressure according to the maximum coolingwater inlet pressure.

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4.3 Electric cable size and fuses

Cable size

All cables should be mounted on a horizontal ventilated tray.See table if cables need to be spaced!Connect cables in the cubicle with the correct cable lugs. There should be a space of 10 mmbetween naked cable parts.The cable size is stated for a maximum ambient temperature of 46 ˚C (115 ˚F).For IEC compressors, use 90 °C XLPE cables.

IEC 50 Hz compressors

Compressor type Voltage Cable size RemarkGA 110 VSD 380 2x(3x70mm2+35mm2) 2 cables, spacing required

GA 110 VSD 400 2x(3x70mm2+35mm2) 2 cables, spacing required








IEC 60 Hz compressors

Compressor type Voltage Cable size RemarkGA 110 VSD 380 2x(3x70mm2+35mm2) 2 cables, spacing required



GA 132 VSD 440 2x(3x120mm2+50mm2) 2 cables, no spacingrequired


GA 160 VSD 440 2x(3x120mm2+50mm2) 2 cables, no spacingrequired

CSA/UL 60 Hz compressors

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Compressor type Voltage Cable size RemarkGA 110 VSD 460 2x(3x AWG4/0+AWG3) 90 ˚C insulation cable at 46

˚C ambientGA 110 VSD 575 2x(3x AWG2/0+AWG4) 90 ˚C insulation cable at 46

˚C ambientGA 132 - 160 VSD 460 2x(MCM250+AWG2) 90 ˚C insulation cable at 46

˚C ambientGA 132 - 160 VSD 575 2x(AWG3/0+AWG4) 90 ˚C insulation cable at 46

˚C ambient

Maximum fuses

50 Hz IEC Pack compressors

Compressor typeVoltage

VFrequency

Hz ApprovalWater-Cooled Air-Cooled

Type

GA 110 VSD 380 50 IEC

3x315 A 3x315 A DIN 43 620size 3; highspeed fuse.Fuse type:

AR

GA 110 VSD 400 50 IEC


AR

GA 110 VSD 500 50 IEC


AR

GA 132 VSD 380 50 IEC 3x400 A 3x400 A

DIN 43 620size 3; highspeed fuse.Fuse type:

AR

GA 132 VSD 400 50 IEC 3x400 A 3x400 A


AR

GA 132 VSD 500 50 IEC 3x315 A 3x315 A


AR

GA 160 VSD 380 50 IEC 3x500 A 3x500 A


AR

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VFrequency


Type

GA 160 VSD 400 50 IEC 3x500 A 3x500 A


AR

GA 160 VSD 500 50 IEC 3x 355 A 3x 355 A


AR

60 Hz IEC Pack compressors


VFrequency


Type

GA 110 VSD 380 60 IEC


AR

GA 110 VSD 440 60 IEC


AR

GA 132 VSD 380 60 IEC 3x400 A 3x400 A


AR

GA 132 VSD 440 60 IEC 3x355 A 3x355 A


AR

GA 160 VSD 380 60 IEC 3x500 A 3x500 A


AR

GA 160 VSD 440 60 IEC 3x400 A 3x500 A


AR

60 Hz CSA/UL Pack compressors

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VFrequency


Type

GA 110 VSD 460 60 CSA/UL

3x315 A 3x315 A Class Tfuse; veryfast acting

fuse



fuse

GA 132 VSD 460 60 CSA/UL 3x315 A 3x355 A

Class Tfuse; veryfast acting

fuse

GA 132 VSD 575 60 CSA/UL 3x250 A 3x315 A


fuse

GA 160 VSD 460 60 CSA/UL 3x400 A 3x400 A


fuse

GA 160 VSD 575 60 CSA/UL 3x315 A 3x315 A


fuse

50 Hz IEC Full Feature compressors


VFrequency


Type

GA 110 VSD 380 50 IEC


AR

GA 110 VSD 400 50 IEC


AR

GA 110 VSD 500 50 IEC


AR

GA 132 VSD 380 50 IEC 3x500 A 3x500 A


AR

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VFrequency


Type

GA 132 VSD 400 50 IEC 3x400 A 3x500 A


AR

GA 132 VSD 500 50 IEC 3x315 A 3x315 A


AR

GA 160 VSD 380 50 IEC 3x500 A 3x500 A


AR

GA 160 VSD 400 50 IEC 3x500 A 3x500 A


AR

GA 160 VSD 500 50 IEC 3x 355 A 3x400 A


AR

60 Hz IEC Full Feature compressors


VFrequency


Type

GA 110 VSD 380 60 IEC


AR

GA 110 VSD 440 60 IEC


AR

GA 132 VSD 380 60 IEC 3x500 A 3x500 A


AR

GA 132 VSD 440 60 IEC 3x400 A 3x400 A


AR

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VFrequency


Type

GA 160 VSD 380 60 IEC 3x500 A 3x500 A


AR

GA 160 VSD 440 60 IEC 3x500 A 3x500 A


AR

60 Hz CSA/UL Full Feature compressors


VFrequency


Type



fuse



fuse

GA 132 VSD 460 60 CSA/UL 3x355 A 3x400 A


fuse

GA 132 VSD 575 60 CSA/UL 3x315 A 3x315 A


fuse

GA 160 VSD 460 60 CSA/UL 3x500 A 3x500 A


fuse

GA 160 VSD 575 60 CSA/UL 3x355 A 3x355 A


fuse

4.4 Electric connections

General instruction for the electrical installation of VSD compressors

• Electrical equipment from Atlas Copco Compressor is designed in accordance with the safety regulationsdescribed in IEC60204-1 and CENELEC EN60204.

• It is the responsibility of the customer to install the compressor unit according to the safety regulations inorder to protect people from electric shocks from direct or indirect contact.

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• In drives with frequency converters, leakage currents occur along the RFI filter and the cable capacities,especially during the motor start. Class A leakage detection protections would switch off the machine.Therefore it is not recommended to use class A detection systems on frequency converters.

Installation instructions for TN, TT, IT

In each network system (TN, TT or IT), the customer has to protect the installation using overcurrent protectionby means of fuses or automatic circuit breaker protection.

With respect to the power distribution system, additional installation instructions are given.

Network type TN (TN-S, TN-C and TN-C-S)

No additional protections need to be installed. If the customer wishes to or needs to install a leakage detectiondevice, it should be of type B and should comply with IEC755 Amendment 2 "General requirements forresidual current-operated protective devices". Atlas Copco advises customers to install the following earthleakage detection device: BENDER RCMA 470LY with external current transformer: http://www.bender.org/prod.html

Network type TT

In the case of TT-systems, safety regulations mostly stipulate the use of an earth leakage circuit breaker(e.l.c.b). In combination with frequency converters, type B residual current-operated protective devices shouldbe used. Atlas Copco advises customers to install the following earth leakage detection device: BENDERRCMA 470LY with external current transformer: http://www.bender.org/prod.html

Network type IT

In IT-network systems, it is permissible for the power supply to continue in the event of an initial earth leakagefault of a motor phase. However, the customer must detect the initial earth leakage fault. The fault must beindicated as an alarm. If this is not the case, the initial earth leakage fault must trigger automatic disconnectionof the power supply (EN 60204-1 par.: 6.3). However, the high frequency capacitive leakage currents causedby frequency converters cannot be detected by standard earth leakage detection systems. Atlas Copcorecommends that customers install: BENDER IRDH 275/435 http://www.bender.org/prod.html.

Atlas Copco strongly recommends that customers do not connect the neutral conductor from the power supplyto the compressor unit. The exposed conductive parts of the installation must be earthed locally. (EN 60204-1par.: 7.2.3)

Power distribution systems (TN, TT, IT)

According to IEC 60950, there are three main types of power distribution systems: TN, TT and IT. Theelectrical installation instructions depend on the type of network of the customer's power supply.

Network type TN (Terra Neutral) :

The TN power distribution system provides a direct earth to the exposed conductive parts of the installation.The connection is made through the PEN-conductor. Within the TN power distribution system, there are threesub-types: TN-S, TN-C and TN-C-S, identified according to neutral and protective earth conductors. Nearly85 % to 90 % of industrial networks are TN type.

Network type TN-S (Terra Neutral-Separate) :

The TN-S power distribution system provides separate neutral and direct earth conductors.

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A Power system earthB Exposed conductive parts

Network type TN-C (Terra Neutral-Combined) :

In the TN-C power distribution system, the neutral and the protective earth functions are combined in a singleconductor.


Network type TN-C-S (Terra Neutral-Combined-Separate) :

In the TN-C-S power distribution system, the neutral and the protective earth functions are combined to somedegree in a single conductor, a direct earth to the exposed conductive parts of the installation exists in part.The connection is achieved through the PEN conductor.

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Network type TT (Terra Terra) :

The TT power distribution system has one point that is directly earthed. In addition, the exposed conductiveparts of the installation are connected to earth electrodes that are independent from the power system's earth.


Network type IT (Impedance Terra) :

The IT power distribution system has no direct connection to Protective Earth (PE). It is earthed via a highohmic impedance, so that the network is effectively behaving like an unearthed floating network. The exposedconductive parts of the installation are directly connected to earth. In the event of an initial earth leakage faultof a motor phase, the power supply continues. However, the customer must detect the initial earth leakagefault. The fault must be indicated as an alarm.

A Power system earthB Exposed conductive partsC Impedance

Ambient conditions

The drive must only be used in a heated, indoor and controlled environment. Environmentallimits are listed below.

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OperationInstalled for stationary use

Air temperature No frost allowedRelative humidity 5 to 95 %

No condensation allowed. Maximum allowed relativehumidity is 60 % in the presence of corrosive gases.

Contamination levels No conducting dust allowed• Chemical gasses: Class 3C2• Solid particles: Class 3S2

Vibration I(IEC 60068-2) Maximum 1 mm (0.04 in) (5 to 13.2 Hz)Maximum 7 m/s2 (23 ft/s2 (13.2 to 100 Hz) sinusoidal

Shock (IEC 60068-2-29) Not allowed

Electric cabinet

Cabinet with VSD (Variable Speed Drive) unit of GA 132/160 VSD

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Electric diagram of GA 132/160 VSD

Ref. DesignationA1 RFI filterA11 Frequency converter, drive motorA21 Frequency converter, fan motors of air/oil cooler blockA31 Frequency converter, compressor motor of dryerF3/5 Circuit breakers, control circuitF17/47 Circuit breakers, condensate circuitK13 Auxiliary relay, motor running indicationK21 Contactor, emergency stopK40 Contactor, compressor motor of air dryerK41 Contactor, fan motor of air dryerK42 Contactor, fan motor of air dryerM Drive motorM25 Fan motor, air coolerM25 Fan motor, bodywork ventilationM26 Fan motor, air coolerM40 Compressor motor of air dryerM41 Fan motor of air dryerM42 Fan motor of air dryer

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Ref. DesignationQ1 Circuit breaker, control circuitQ2 Circuit breaker, circuit of fan motors and compressor motor of dryer

Circuit breaker, compressor motor of dryerQ20 Circuit breaker, supply circuit of cooler block fan motorsQ25 Circuit breaker, fan motor M25Q26 Circuit breaker, cooler fan motorQ40 Circuit breaker, compressor motor of air dryerQ41 Circuit breaker, fan motor of air dryerQ42 Circuit breaker, fan motor of air dryerT1/T2 Transformers1X1 Terminal strip1X3 Earthing connection1 Commutating coil(1) Customer's installation(2) Fan motor, air-cooled(3) Fan motor, air-cooled(4) Drive motor of dryer(5) Fan motor of dryer, air-cooled

Cable connection for GA 110 VSD, GA 132 VSD and GA 160 VSD

Always use cable glands.

A plate (1) has to be made by the customer to cover up the hole in the cubicle and to install cable glands.

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Cable section Cable diameter Cable gland size AC number50 8.0 16 0698 5140 7170 9.4 16 0698 5140 7195 11.0 20 0698 5140 72120 12.4 25 0698 5140 73150 13.8 25 0698 5140 73

4.5 Installation instructions for cubicle fan

Description

The fan must be installed on the cubicle roof with 8 bolts 0147 1963 08 as follows:

• Take off the top of the fan assembly (fan stays).• Mount the fan with 8 bolts to the roof as shown in figure A (the fan is made invisible to show the bolt

positions).• Reinstall the top.

Connect the cable as shown in figure B.

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Figure A

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Figure B

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Completed assembly of the cubicle fan

4.6 Installation instructions for heavy duty filter for VSD cubicle

Description

1. Remove the original filters (1). Remove the red plates (2).

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2. Place the seals (3) on the back side of the box, then install the box to the cubicle door using rivets. Theordering number for the seals is 1619 5188 00.

3. Install the heavy duty filters as shown below.

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Text on figure:

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(1) Cooling air flow(2) Compressor side(3) Outside

4.7 Installation instructions for dryer by-pass

Description

It is not required to connect a bypass, a blind flange is foreseen ex factory. If by-passing of the dryer is required,connect the compressor to the air net as shown below. The compressed air outlet temperature sensor (G3/8”)and the pressure transducer (1/4” -18 NPT) must be relocated to the delivery pipe upstream of the shut-offvalve. The new location is indicated by “x”. The temperature sensor and pressure transducer must be positionedperpendicular to the air flow at all time (as shown).

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V1 Shut-off valve, air netV2 By-pass valve, compressorV3 By-pass valve, dryerX New location for temperature sensor and pressure transducer1 Pipe towards air net2 Nipple

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4.8 Installation instructions GSM alarm

Hardware installation

Fix the Air contact module (1) to the rail as shown below.

Assemble the power supply cable, using:• connector X150.3 (ordering number 1088 0037 64)• two power wires (ordering number 0017 2010 40)• one earth wire (ordering number 0017 2070 40)• connector 12X14 (ordering number 1088 0037 62; the connector is supplied loose with the Air contact

module)

Install the power supply cable, plug the 3 pole connector (12X14) (4) in the Air contact module.

Plug the LAN cable (1622 0676 20) (3) into the Elektronikon (Mk4) and in the Aircontact module (5).

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The antenna must be led to the outside of the cubicle. The antenna cable can be led through a present conduitgland (preferably the gland which contains the Electronic drain cables) or a grommet can be used in a closedhole.

Once outside the cubicle, the wire can be brought to the outside (roof) of the machine.

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Software installation

For software installation please contact your local Atlas Copco service center.

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4.9 Pictographs

Explanation of Pictographs

Pictographs at other locations

Ref. Designation1 Start2 Scroll keys3 Tabulator key4 Function keys5 Voltage on6 Alarm7 Automatic operation8 Stop10 Automatic condensate drain12 Manual condensate drain13 Stop the compressor before maintenance or repair14 Warning: under tension15 Read Instruction book before starting the compressor16 Switch off the voltage and depressurise the compressor before maintenance or repair17 Before connecting the compressor electrically, consult the instruction manual for the motor

rotation direction18 Torques for steel (Fe) or brass (CuZn) bolts19 Consult the instruction manual before greasing20 Switch off the voltage before removing the protective cover inside the electric cabinet21 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)22 Consult the instruction manual before maintenance or repair23 Cooling water inlet24 Cooling water outlet25 Oil outlet26 Switch off the main isolating switch and wait 6 minutes before removing the screen

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Ref. Designation27 Arrow, rotation direction28 Disconnect from electrical supply before opening29 Do not mix oil brands

4.10 Cooling water requirements

Recommendations

The cooling water quality must meet certain minimum requirements.

No general recommendation can encompass the effects of all combinations of the various compounds, solidsand gases typically found in cooling water in interaction with different materials.

Only non-treated water must be used.

This recommendation is a general guide line for acceptable coolant quality.

Type of system

First, it is important to consider whether you are dealing with a closed system or an open system. In a closedsystem, the same cooling water circulates through a system without contact with air.

An open system is a pass-through system, or a circulating system with a cooling tower. In the latter case, thecomposition of the water that enters the cooler must be considered, and not the composition of the make-upwater. Due to the evaporative effect in the cooling tower, much higher concentrations of ions can be obtainedin the circulating water than in the make-up water.

Ryznar stability index (RSI)

The Ryznar Stability Index (RSI) is a parameter for predicting whether water will tend to dissolve or precipitatecalcium carbonate. The adhesion of scaling deposits and their effect are different on different materials, butthe equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by thesaturation 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 ExplanationpH Measured pH (at room temperature) of water samplepHs pH at saturation

The pHs is calculated by using :

pHs = (9.3 + A + B) - (C + D)

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Symbol ExplanationA Depends on the total solids concentration (mg/l)B Depends on the highest cooling water temperature (˚C/˚F), (T=75 ˚C/167 ˚F)C Depends on the calcium hardness (ppm CaCO3)

D Depends on the HCO3- concentration or M-alkalinity (mval/l)

The values of A, B, C and D can be found in the following table.

Total dissolvedsolids (mg/l)

A Temperature(˚C)

B Ca-hardness (ppmCaCO3)

C M-alkalinity (mval/l) D

50 - 300 0.1 0 - 1 2.6 10 - 11 0.6 0.20 - 0.22 1.0400-1000 0.2 2 - 6 2.5 12 - 13 0.7 0.24 - 0.26 1.1 7 - 9 2.4 14 - 17 0.8 0.28 - 0.34 1.2 10 - 13 2.3 18 - 22 0.9 0.36 - 0.44 1.3 14 - 17 2.2 23 - 27 1.0 0.46 - 0.54 1.4 18 - 21 2.1 28 - 34 1.1 0.56 - 0.70 1.5 22 - 27 2.0 35 - 43 1.2 0.72 - 0.88 1.6 28 - 31 1.9 44 - 55 1.3 0.90 - 1.10 1.7 32 - 37 1.8 56 - 69 1.4 1.12 - 1.38 1.8 38 - 44 1.7 70 - 87 1.5 1.40 - 1.76 1.9 45 - 50 1.6 88 - 110 1.6 1.78 - 2.20 2.0 51 - 56 1.5 111 - 138 1.7 2.22 - 2.78 2.1 57 - 63 1.4 138 - 174 1.8 2.80 - 3.54 2.2 64 - 71 1.3 175 - 220 1.9 3.54 - 4.40 2.3 72 - 80 1.2 230 - 270 2.0 4.6 - 5.4 2.4 280 - 340 2.1 5.6 - 7.0 2.5 350 - 430 2.2 7.2 - 8.8 2.6 440 - 550 2.3 9.0 - 11.0 2.7 560 - 690 2.4 11.2 - 13.8 2.8 700 - 870 2.5 14.0 - 17.6 2.9 880 - 1000 2.6 17.8 - 20.0 3.0

Interpretation of the value obtained

RSI Water condition ActionRSI<3.9 Very high scale formation Water cannot be used.4.0<RSI<5.5 High boiler scale formation Regular inspection and descaling operation

necessary.5.6<RSI<6.2 Slight boiler scale formation Water treatment not necessary.

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

temperatureWater treatment not necessary.Occasional inspection recommended.

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RSI Water condition Action7.6<RSI<9.0 Strong corrosion Regular inspection necessary, use of corrosion

inhibitor recommended.9.1<RSI<11 Very strong corrosion Regular inspection necessary, use of corrosion

inhibitor required.RSI>11 Very strong corrosion in

complete water systemWater should not be used.

The table indicates that distilled or demineralised water should never be used, as their RSI is > 11.

The RSI only indicates the equilibrium of scaling - descaling. A cooling water showing good RSI conditionscan still be unsuitable due to other factors.

From the table above, the RSI index should be between 5.6 and 7.5; otherwise, contact a specialist.

pH

The effect of pH is already calculated in the Ryznar index, but the pH itself has some additional limitations :6.8 < pH

Total dissolved solids (TDS)

This is the sum of all the ions in the water. It can be derived from the dry residue after evaporation (but notincluding suspended solids), or it can be estimated from the electrical conductivity.

In a closed system, the following limits apply : TDS < 3000 mg/l (< 3800 microS/cm)

For an open system, the following limits apply : TDS < 450 mg/l ( < 580 microS/cm)

Chlorides (Cl-)

Chloride ions will create pitting corrosion on stainless steel. Their concentration should 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

Open cooling system : sulphates < 150 ppm

Carbonate hardness

Closed cooling system : 50-1000 ppm CaCO3

Open cooling system : 50-500 ppm CaCO3

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HCO3- / SO4

2- should be > 1

Ammonia

< 0.5 ppm

Copper

< 1 ppm

Iron and manganese

< 1 ppm

Organics

No algae

No oil

Suspended solids

Non-soluble particles, size < 1 mm.

< 10 ppm

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5 Operating instructions

5.1 Initial start-up

Warning

The operator must apply all relevant Safety precautions.

Switch off the voltage before making any adjustment.

Outdoor/altitude operation

If the compressor is installed outdoors or if the air inlet temperature can be below freezing point, precautionsmust be taken. In this case, and also if operating at high altitude, consult Atlas Copco.

Moving/lifting

The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrudefrom the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Makesure that the beams cannot slide and that they protrude from the frame equally. The chains must be held parallelto the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment must beplaced in such a way that the compressor is lifted perpendicularly. Lift gently and avoid twisting.

General preparations for GA VSD compressors

Step Action1 Install the compressor, see the sections Dimension drawing, Installation proposal and

Electric cable size.2 Stick labels near the control panel to warn the operator that:

• the compressor may start automatically after a voltage failure• the compressor is automatically started and stopped• the compressor may be remotely controlled

3 A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork toprotect the compressor against corrosion. Remove the plates.

4 If the compressor has not run for the past 6 months, it is required to improve the lubricationof the compressor element before starting. Fill up the compressor element as describedin section Oil change (paragraph: Filling the compressor element with oil).

5 Check that the compressor is filled with oil; the pointer of the oil level indicator should bein the green range (see the section Oil change).

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Protection during transport

Transport fixtures of GA VSD compressors

Step Action1 The gear casing supports, motor support and air receiver supports are secured to the

frame, immobilizing the vibration dampers during transport.2 Remove the bolts (1) from the gear casing supports and the motor support.3 Remove the brackets fitted next to the air receiver supports.

Electric cabinet

Step Action1 Check that the electrical connections correspond to the local codes. The installation must

be earthed and protected by fuses in all phases. An isolating switch must be fitted.2 Check the wires on transformers for correct connection.3 Check the setting of the circuit breakers (see the section Settings of circuit breakers).

Water circuit

Step Action1 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.

Start up

On Full-Feature compressors, switch on the voltage 4 hours before starting in order toenergize the crankcase heater of the refrigerant compressor.

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Step Action1 Close the drain valves (see the section Cooling and condensate system).2 Switch on the voltage.3 Start the compressor and stop it immediately. Check the rotation direction of the drive

motor while the motor is coasting to a stop. To determine the rotation direction of the motor,look at the fan through the grating at the non-drive end of the motor. The correct rotationdirection is indicated by an arrow on the gear casing and on the fan cowl.On air-cooled compressors, check the rotation direction of the fan motor, the fan is visiblethrough the grating in the air inlet panel (see section Dimension drawing). The correctrotation direction is indicated by arrows on the fan inlet plate.On Full-Feature compressors, open the door of the dryer compartment and check therotation direction of the fan motors of the condenser. The correct rotation direction isindicated by an arrow.

4 If the rotation direction is wrong, press the emergency stop button, switch off the voltageand reverse two incoming electric lines.If the rotation direction of the fan motor is wrong, consult your Atlas Copco customer centre.

5 Run the compressor for a few minutes and check that it is operating normally.

5.2 Before starting

Warning

Step ActionThe operator must apply all relevant safety precautions. See the section Safetyprecautions.If the water system was drained (see the section Stopping), close the drain valves.Switch off your mobile phone when in the vicinity of a GA VSD compressor which is undertension.

Procedure

Step Action- Switch on the voltage. The voltage-on LED lights up.- Close condensate drain valves.

Full-Feature compressors have two condensate traps and two drain valves.- Open the air outlet valve.- Check the oil level. The pointer of the oil level gauge should be in the green range or orange

range.If the compressor has only just stopped, wait one minute before checking the level.

- On Full-Feature compressors, make sure that the dryer shut-off valves are open and thatthe dryer by-pass valve is closed (customer’s installation).

- On water-cooled compressors, open the water shut-off valves (customer's installation) andregulating valve (located inside the compressor next to the oil/water coolers) and checkfor water flow.

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5.3 Starting

Procedure

Step Action• When the compressor is stopped and the automatic operation LED (3) is lit, the

compressor may start automatically.• If the start/stop timer is active, the compressor may start automatically, even if it was

stopped manually. See the section Programming clock functions.

Control panel

Step Action- Press start button (1). The compressor starts running and automatic operation LED (3)

lights up.- On water-cooled compressors, regulate the cooling water flow with the compressor

running loaded at maximum speed.Adjust the water flow to obtain the most suitable air temperature at the outlet of thecompressor element, i.e. between 2 and approx. 7 degrees Celsius above the relevanttemperature in the figure below.Consult the section Compressor specifications for the cooling water consumption.

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Cooling water temperature

Minimum allowable air temperature at compressor element outlet of water-cooled compressors

• (A): Air inlet temperature• (B): Condensation temperature• (C): Working pressure• (D): Relative air humidity

5.4 During operation

Description

When automatic operation LED (3) is lit, the Elektronikon regulator is automatically controlling thecompressor: the speed will continuously vary to match the air delivery to the air consumption, and thecompressor will start and stop whenever necessary.

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Keep all doors closed during operation.

Example of the main screen

“Compressor Outlet” 6.6 bar . “Compressor Speed” 2100 rpm“Menu” F1 F2 F3

5.5 Checking the display

Warning

Before carrying out any maintenance, repair work or adjustment, stop the compressor,press the emergency stop button and switch off the voltage. Close the air outlet valve andopen the manual condensate drain valve.

Control panel

Step Action1 Regularly check the display for readings and messages. Normally, the main display is

shown, indicating the compressor outlet pressure, the status of the compressor and thefunctions 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 serviceactions of the indicated service plans or replace the component and reset the relevanttimer.

4 Regularly check the actual compressor status by pressing the arrow down key from themain screen.

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Example of the main menu

“Status data”“Measured Data”“Counters”“Mainscreen”F1 F2 F3

Example of the main display

Example of Main screen of GA 110 VSD up to GA 160 VSD compressors


5.6 Stopping

Procedure

Control panel of GA 11 VSD up to GA 160 VSD

Step Action- Press stop button (1): the compressor will stop and LED (2) will go out.- To stop the GA 110 VSD up to GA 160 VSD compressor in the event of an emergency,

press the emergency stop button (S2).- Close air outlet valve.- Open condensate drain valve.- On water-cooled compressors, close the water shut-off valves (customer’s installation).- 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 thewater inlet and outlet pipes (customer's installation).

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Step Action- Switch off the voltage.

5.7 Taking out of operation

Disconnecting the compressor

At the end of the service life of the compressor, proceed as follows:

Step Action1 Stop the compressor and close the air outlet valve.2 Switch off the voltage and disconnect the compressor from the mains.3 Depressurize the compressor by opening the drain valve and loosening the oil filler plug

one turn.4 Shut off and depressurize the part of the air net which is connected to the outlet valve.

Disconnect the compressor air outlet pipe from the air net.5 Drain the oil and condensate circuits.

On water cooled compressors, drain the water circuits.6 Disconnect the compressor condensate piping from the condensate drain net.7 On water cooled compressors, disconnect the cooling water pipes from the compressor.

5.8 Use of air receiver

Instructions

Step Action1 This equipment can contain pressurised air and oil; be aware of its potential danger if used

improperly.2 This equipment must only be used as compressed air/oil separator and must be operated

within the specified limits.3 No alterations must be made to this equipment by welding, drilling, grinding or other

methods of mechanical working without written permission of the manufacturer. If there isdamage to a part under pressure from any cause, the complete part must be replaced.

4 For the oil separator vessel: original bolts have to be used after opening for insideinspection. The bolts must be removed and fitted with the correct tool. The bolts must betightened with a torque of 355 Nm (+/- 85 Nm). Damaged bolts must not be re-used. O-rings must be replaced.

5 The safety valve is designed in such a way that the pressure will not permanently exceedthe maximum allowable operating pressure of the vessel, except for short pressure surgesup to 1.1 times the design pressure.

6 Only use oil specified by the manufacturer.7 Make sure the vessel is fully depressurised before opening the drain plug or fill plug.

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Step Action8 This vessel and other parts under pressure have been designed and built to guarantee an

operational lifetime in excess of 20 years and an infinite number of pressure load cycles.A visual inspection (for damage, non-authorised alterations,...) of the vessel (at the outsideand inside) is recommended every 5 years. Make sure the vessel is fully depressurisedand isolated before carrying out an internal inspection.

9 At every inspection, also check the oil drain flexible. Replace if there is any wear ordamage.

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6 Maintenance

6.1 Preventive maintenance schedule

Warning

Before carrying out any maintenance, repair work or adjustment, proceed as follows:• Stop the compressor.• Press emergency stop button (S2).• Close the air outlet valve and open the manual condensate drain valves.• Switch off the voltage.• Open and lock the isolating switch.• Repairs inside the start and speed regulation cabinet may only be carried out by Atlas

Copco.• Wait at least 6 minutes before starting any electrical repairs as hazardous high voltage

remains on the condensers of the start and speed regulation unit for 6 minutes after thevoltage is switched off.


Warranty - Product Liability

Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not coveredby Warranty or Product Liability.

General

When servicing, replace all removed gaskets, O-rings and washers.

Preventive maintenance schedule

Period Running hours OperationDaily 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 -- Check the cleanliness of the cubicle filters. Replace or clean if dusty.Weekly -- Drain condensate from air receiver, if installed3-Monthly -- Clean compressor.3-Monthly -- Check for possible leaks.3-Monthly 500 Check the coolers; clean them if necessary. See the section Coolers.3-Monthly -- Remove air filter elements and inspect.Yearly -- Have safety valve tested.Yearly -- Have all flexibles inspected.Yearly 4000 If Roto-Inject Fluid is used, change oil.Yearly 4000 On compressor with high ambient option, replace oil filters.

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Period Running hours OperationYearly 4000 On compressor with high ambient option, if Roto-Xtend Duty Fluid is

used, change oil.Yearly 8000 Replace oil filters.Yearly 8000 If Roto-Xtend Duty Fluid is used, change oil.Yearly 8000 Replace air filter element.Yearly -- Regrease motor, for the interval and quantity, see section Motors.2-Yearly 8000 Have oil separator element replaced.When displayed -- Carry out service action according to the displayed service plans.

When operating in a dusty atmosphere, inspect the air filters more frequently.Use always Atlas Copco filters.The separator element must also be replaced when the pressure difference over the elementexceeds 0.8 bar (12 psi). Check the pressure drop when the compressor is running loadedand preferably with a stable working pressure.Damaged flexibles must be replaced immediately.

Service agreements

Atlas Copco Customer Centres have a range of service agreements to suit your needs:

• An 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 operationalefficiency, minimize 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 anumber of service actions to be carried out at the time intervals programmed in the Elektronikon regulator.

When a level is reached, a message will appear on the screen. After carrying out all service actions, the intervaltimers must be reset using the “Reset” key in the “Service” menu. Consult your Atlas Copco Service Centre.

6.2 Motors

Warning

Stop the compressor and switch off the voltage. The operator must apply all relevant Safetyprecautions.

Never mix greases of different brands or types.

Fan motors

The bearings of the fan motors are greased for life. The bearings of the fan motor must be replaced after 24000operating hours.

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ABB drive motor

Compressor type Power IntervalD end

AmountD end

IntervalND end

AmountND end

GA 110 VSD 132 kW 4000 h 20 gr (0.71oz)

4000 h 20 gr (0.71oz)

GA 132 VSD 132 kW 4000 h 20 gr (0.71oz)

4000 h 20 gr (0.71oz)

GA 160 VSD 160 kW 4000 h 20 gr (0.71oz)

4000 h 20 gr (0.71oz)

6.3 Oil specifications

Atlas Copco Roto-Inject Fluid

Roto-Inject Fluid is a high-quality lubricant for single-stage, oil-injected rotary screw compressors. See thesection Service kits.

Atlas Copco Roto-Xtend Duty Fluid

Atlas Copco Roto-Xtend Duty Fluid is a high-quality synthetic lubricant for oil-injected scroll and screwcompressors which keeps the compressor in excellent condition. Roto-Xtend Duty Fluid can be used forcompressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F) (see section Servicekits).

Important

Never mix oils of different brands or types.

6.4 Oil change

Warning


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Control panel

Control panel of MkIV regulator

Procedure

1. Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage.Wait a few minutes and depressurize by unscrewing the vent plug on top of the air receiver to permit anypressure in the system to escape. Wait until all the pressure in the system is released.

2. Drain the oil by removing the drain plug of the flexible fixed to the bottom of the air receiver.

Draining the oil cooler on air-cooled compressors:

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1. Take off the side panels of the compressor and remove the stays.2. Open the cooler compartment and disconnect the cooler inlet pipe (1).

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3. Disconnect the cooler outlet pipe (4) and roll out the oil cooler (2).4. Remove the three bolts at the left side of the cooler.5. Lift the oil cooler and fix the safety support. Remove the vent plug at the left side of the cooler. The oil

is drained via the cooler drain plug at the inlet connection.6. After draining, remove the safety support and bring the oil cooler back to its original position. Fix the

cooler.7. Drain the compressor element as described below.8. Reconnect the cooler inlet (1) and oulet pipe (4).9. Reinstall the stays and side panels of the compressor.

Draining the oil cooler on water-cooled compressors:

1. Take off the side panels of the compressor.2. Remove the drain plugs (1) and the interconnecting pipe of the oil coolers.3. Reinstall the plugs after draining.4. Reinstall the side panels of the compressor.

Draining the compressor element, oil filter housing and oil stop valve

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1. Remove the drain plug (3) to drain the oil stop valve.2. Remove the drain plug of the flexible to drain the oil from the gearbox.3. Reinstall the drain plugs after draining.4. Disconnect the flexible from the bypass valve (5) to drain the oil from the oil filter housing.5. Reinstall the flexibles to the bypass valve after draining.

Oil filter change

1. Use an oil pan to avoid oil spillage. Unscrew the oil filters (6).2. Clean the filter seats on the manifold.3. Oil the gaskets of the new filters and screw the filters into place until the gaskets contact their seats. Then

tighten by hand.

Filling the compressor element with oil

On GA VSD compressors, disconnect the air inlet hose from the compressor element and pour 10 l (2.64 USgal, 2.20 Imp gal, 0.35 cu.ft) of oil into the compressor element. Reinstall the inlet hose after filling.

Filling the air receiver with oil

1. Reinstall and tighten the oil drain plug of the air receiver.2. Remove filler plug (FC).3. Fill the air receiver with oil until the level reaches the filler opening.4. Refit and tighten filler plug (FC) and tighten the vent plug on top of the air receiver.5. Run the compressor loaded for a few minutes.6. Stop the compressor and wait a few minutes.7. Depressurize the system by unscrewing the vent plug on top of the air receiver.8. Remove the filler plug and fill the air receiver with oil until the level reaches the filler opening.9. Tighten filler plug (FC).10. Tighten the vent plug on top of the air receiver.

Resetting the Elektronikon regulator

After carrying out all service actions in the relevant “Service Plan”, reset the service warning as follows:

1. Press the “Menu” key (3).2. Press key (1) until “Service” is followed by an arrow pointing to the right. Activate the menu by pressing

key (2).3. Press key (1) until the related “Service Plan” is followed by an arrow pointing to the right and activate by

pressing key (2).4. Press the “Reset” key (3); the timer is reset to 0.

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6.5 Storage after installation

Run the compressor, e.g. twice a week, until warm.

If the compressor is going to be stored without running from time to time, protective measures must be taken.Consult Atlas Copco.

6.6 Service kits

General

Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copcoparts while keeping the maintenance budget low. All service kits are indicated in the relevant Parts Lists.

Atlas Copco Roto-Inject Fluid

Roto-Inject Fluid can be ordered in the following quantities:

• 20-litre can: 2901 0522 00• 209-litre drum: 2901 0045 01

See the section Oil specifications.

Atlas Copco Roto-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.

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7 DD filter

7.1 Maintenance

When maintaining the filter, keep in mind the following:

• On filters with manual drain valve, open the latter at regular intervals to evacuate collected dust or liquid• Change the filter element yearly or when the pressure drop reaches approx. 0.35 bar• In case an automatic drain valve is installed, manual draining can be carried out by turning the connection

nipple of the automatic drain valve counterclockwise.•

When the filter has to process air with a temperature higher than the specified maximumtemperature, the filter's lifetime will be reduced considerably!

7.2 Filter element change

Procedure

When maintaining the filter, keep in mind the following:

1. Isolate the filter from the air net.2. Depressurize the filter by turning the connection nipple of the automatic drain valve counterclockwise or

by opening the manual drain valve.3. Unscrew the bowl. A whistling noise will warn you if the bowl is not fully depressurized. If this occurs,

the bowl should be screwed back and the venting should be repeated.4. Discard the old filter element.5. Remove the O-ring from the bowl and clean the bowl with isopropanol. Cleaning cloths of Kimtech are

recommended. Position a new O-ring on the bowl.6. Open the sealed bag at the topcap side of the filter cartridge.7. Take the cartridge and lower the plastic until the middle of the cartridge.8. Position the cartridge under the filter head and push it in place. Only touch the plactic bag. Avoid contact

of the filter cartridge with the hands.

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9. Remove the plastic bag and reposition the bowl.

A small amount of paint compatible lubricant ( e.g . FOODLUBE EXTREME) may be appliedto screw threads and O-rings to facilitate the assembly.

7.3 Service intervals

The following service intervals should be observed:

• For filters operating less than 4000 hours per year: 12 months.• For filters operating 8000 hours per year: 4000 hours or 6 months, whichever comes first.

7.4 Filter disposal

Used filters must be disposed of in an environmentally friendly and safe manner, and in line with the localrecommendations and environmental legislation.

7.5 Reference conditions

Air inlet pressure 7 bar(e) 102 psigAir inlet temperature 20˚C 68 ˚FAmbient temperature 20˚C 68 ˚F

7.6 Principal data

Maximum compressed air inlet pressure 16 bar(e) 232 psigMinimum compressed air inlet pressure 1 bar(e) 15 psigMinimum compressed air inlet temperature 1˚C 34˚FMaximum compressed air inlet temperature 65˚C 149 ˚FMaximum compressed air inlet pressure 16 bar(e) 232 psigMinimum ambient temperature 1˚C 34 ˚FMaximum ambient temperature 65˚C 149 ˚FMaximum recommended pressure drop 0.35 bar(e) 5 psig

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8 Integrated dryer

8.1 Condensate drain system

Description

The condensate enters the Electronic Water Drain (EWD) via inlet (1) and accumulates in the water separatorof the heat exchanger and in collector (2). A capacitive sensor (3) continuously measures the liquid level. Assoon as the collector is filled up to a certain level, a drain delay timer is started. As soon as the delay time hasexpired, pilot valve (4) is activated and diaphragm (5) opens outlet (6), discharging the condensate.

When the collector has been emptied, the outlet closes quickly without wasting compressed air.

When the controller registers a malfunction, the red alarm LED starts flashing, a warning appears on thedisplay of the regulator and the electronic drain valve will automatically change to the alarm mode, openingand closing the valve according to a sequence as shown below. This condition continues until the fault isremedied. If the fault is not remedied automatically, maintenance is required.

Electronic water drain

Drain frequency during alarm condition

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Testing the Electronic water drain

Control panel, EWD

Briefly press the TEST button and check that the valve opens for condensate discharge.

Checking the alarm signal

• Press and hold the test button for at least 1 minute.• Check that the alarm LED flashes.• Check that a warning is generated on the display of the regulator.• Release the test button.

8.2 Maintenance instructions

Important

Cooling dryers of the ID type contain refrigerant HFC.

Safety precautions

When handling refrigerant R404a, all applicable safety precautions must be observed. The followingpoints are stressed:

• Contact of refrigerant with the skin will cause freezing. Special gloves must be worn and, if there is contactwith the skin, the skin should be rinsed with water. On no account may clothing be removed.

• Fluid refrigerant will also cause freezing of the eyes; therefore, safety glasses must be worn.• Refrigerant R404a is poisonous. Do not inhale refrigerant vapours. Check that the working area is

adequately ventilated.

Local legislation

Local legislation may impose that:

• Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its functionmust be carried out by an authorised control body.

• The installation should be checked once a year by an authorised control body.

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Warranty and product liability

Use only Atlas Copco authorised genuine parts. Any damage or malfunction caused by the use of unauthorisedparts is not covered by Warranty or Product Liability.

General

The following remarks should be kept in mind:

• Keep the dryer clean.• On air-cooled dryers, brush or blow off the finned surface of the condenser regularly.

On water-cooled dryers, regularly check for water leaks.• Regularly test the EWD.

8.3 Problem solving

Faults and remedies

Condition Fault Remedy- Pressure dew-point too high Ambient temperature too high Check and correct; if necessary, draw

cooling air via a duct from a coolerplace or relocate dryer

Shortage of refrigerant Have circuit checked for leaks andrecharged

Refrigerant compressor doesnot run

See below

Evaporator pressure too high See below Condenser pressure too high See below Automatic drain system

cloggedHave the system cleaned

- Condenser pressure too highor too low

Cooling water system clogged Have cooling water system cleaned

Cooling water temperature toohigh

Check and correct as necessary

- Compressor stops or does notstart

Electric power supply tocompressor is interrupted

Check and correct as necessary

Motor overload protection ofrefrigerant compressor motorhas tripped

Have motor checked

High-pressure switch tripped See above- Condensate drain remains

inoperativeAutomatic drain systemclogged

Have system inspected

- Condensate trap continuouslydischarges air and water

Automatic drain system out oforder

Have system checked

- Evaporator pressure is too highor too low at unload

Hot-gas by-pass valveincorrectly set or out of order

Have hot-gas by-pass valve adjusted

Condenser pressure too highor too low

See above

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Condition Fault Remedy Shortage of refrigerant Have circuit checked for leaks and

recharged

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9 Adjustments and servicing procedures

9.1 Air filters

Warning

Stop the compressor, close the air outlet valve, press the emergency stop button andswitch off the voltage. The operator must apply all relevant Safety precautions.



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Position of air filter

Procedure

Step Action1 Remove panel (4) from the compressor.2 Remove the filter element.3 Fit the new filter element.4 Reinstall panel (4)5 Reset the message and service timer:

• 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 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.

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9.2 Coolers

Checking the coolers for cleanliness on air-cooled compressors

Activate the "Cleanlinesstest" option in the Elektronikon regulator as follows:

• Starting from the main screen, press the "Menu" key.• Press the arrow down key (1) until "Test" is followed by a horizontal arrow.• Activate the menu by pressing the tabulator key (2).• Press the arrow down key (1) until the option "Cleanliness" is followed by a horizontal arrow.• Activate the menu by pressing the tabulator key (2).

Measure the pressure drop by the water column in mmWG. The condition of the cooler cleanliness can beanalyzed by comparing this value with the value in the table below depending on the compressor model.Substract 3 mm WG from the values in the table when ducting is installed.

The values are given at maximum fan speed as activated by the cleanliness test. Mild clogging means that25% of the section is blocked. Heavy clogging means that 50% of the section is blocked. The values shouldonly be used as guideline. Depending on the local (ambient) conditions the limits can be different. Readingson the compressor should be observed on a regular basis to avoid high temperatures. Regular cleaning isanyhow advised since clean coolers will reduce fan speed and thus power consumption.

Clean Mild clogging Heavyclogging

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HOYCsandoval

Line

Maximum fanspeed (rpm)

No action Cleaningadvised

Cleaningnecessary

GA 110 VSD Pack and Full-Feature

1500 46 58 73

GA 132 VSD Pack 1200 56 65 80GA 132 VSD Full-Feature 1500 85 102 124GA 160 VSD Pack and Full-

Feature1500 85 102 124

Cleaning the coolers

Stop the compressor, press the emergency stop button and switch off the voltage. Theoperator must apply all relevant Safety precautions.

Procedure

Coolers of air-cooled compressors

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Coolers of water-cooled compressors

Keep the cooler block clean to maintain the cooling efficiency.

On air-cooled compressors proceed as follows:

Step Action1 Take off the side panels of the compressor and remove the stays.2 Open the two inside doors.3 Remove any dirt form the coolers with a fibre brush, brush in the direction of the fins. Also

remove any dirt from the fans.4 Clean the coolers with an air jet in the reverse direction to normal flow. Use low pressure

air; if necessary, the pressure may be increased up to 6 bar (e) (87 psig)5 If it is necessary to clean the coolers with a cleaning agent, consult Atlas Copco.6 Close the inside doors.7 Reinstall the stays and side panels of the compressor.

On water-cooled compressors, consult the Atlas Copco Customer Centre if it is necessary to clean the coolers.

9.3 Safety valve

Warning

Stop the compressor and switch off the voltage. The operator must apply all relevant Safetyprecautions.

Never run the compressor without safety valves. No adjustments are allowed.

Testing

The valve can be tested on a separate compressed air line.

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Consult the Atlas Copco Customer Centre if the valve does not open at the correct pressure (see the sectionSettings of safety valve).

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10 Problem solving

10.1 Problem solving

Warning

Before carrying out any maintenance, repair work or adjustment, stop the compressor,press the emergency stop button and switch off the voltage. Close the air outlet valve andopen the manual condensate drain valves.

Open and lock the isolating switch. The operator must apply all relevant Safety precautions.

Control panel

Faults and remedies

A service message appears on the displayStop 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 displayThe alarm LED will light up indicating that the temperature at the outlet of the compressor elements is toohigh. The message disappears as soon as the cause of the problem is remedied.

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Unit is shut downThe alarm LED will flash indicating either that the outlet temperature is too high or that the motor overloadrelay has tripped. Remedy the problem. It may be necessary to reset the display after remedying the fault:press the “Reset” key (2), the message “All protection functions are OK” will appear, after which thecompressor can be restarted.

Excessive oil consumptionHave the compressor inspected by the Atlas Copco Customer Centre.

Condition Fault RemedyCondensate is not discharged fromcondensate traps during loading.

Discharge pipe of condensate trapclogged.

Check and correct as necessary.

Float valve of condensate trapsmalfunctioning.

Remove float valve assembly,clean and check.

EWD (electronic water drain)malfunctioning.

Consult Atlas Copco.

Condition Fault RemedyCompressor air delivery or pressurebelow normal.

Air consumption exceeds airdelivery of compressor.

Check equipment connected.

Choked air filters. Replace filters.Air leakage. Check and correct.

Condition Fault RemedyCompressor element outlettemperature or delivery airtemperature above normal.

Oil level too low. Check and correct.

Oil coolers clogged. Consult the section Coolers. Air cooler clogged. Consult the section Coolers. On air-cooled compressors,

insufficient cooling air or coolingair temperature too high.

Check and correct as necessary.

On water-cooled compressors,cooling water flow too low.

Increase flow.

On water-cooled compressors,restriction in cooling water system.

Consult Atlas Copco CustomerCentre.

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11 Technical data

11.1 Readings on display

General

Control panel

Reference Units ReadingOutlet pressure bar(e) Depends on pressure set-pointSpeed rpm Varies (controlled by regulator)Maximum working pressure bar(e) See Compressor data.

At pressure set-point

Reference Units 4 bar(e)60 psig

7 bar(e)100 psig

9.5 bar(e)140 psig

13.5 bar(e)196 psig

Dp of air filter, approx. bar < 0.05 < 0.05 < 0.05 < 0.05Dp of air filter, approx. psi < 0.73 < 0.73 < 0.73 < 0.73Dp of oil separator bar < 0.8 < 0.8 < 0.8 < 0.8Dp of oil separator psi <11.6 <11.6 <11.6 <11.6Oil injection pressure,approx.

bar 3.1 4.9 6.5 9.0

Oil injection pressure,approx.

psi 45 70 95 130

Compressor outlettemperature

˚C < 55 < 55 < 55 < 55

Compressor outlettemperature

˚F <131 <131 <131 <131

Element out temperature ˚C < 100 < 100 < 100 < 100Element out temperature ˚F <212 <212 <212 <212Cooling mediumtemperature

˚C < 46 < 46 < 46 < 46

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Reference Units 4 bar(e)60 psig

7 bar(e)100 psig

9.5 bar(e)140 psig

13.5 bar(e)196 psig

Cooling mediumtemperature

˚F <115 <115 <115 <115

Dew-point temperature ˚C 3 3 3 3Dew-point temperature ˚F 37 37 37 37

11.2 Reference conditions

Reference conditions

Absolute inlet pressure bar(a) 1Absolute inlet pressure psi 14.5Relative air humidity % 0Air inlet temperature ˚C 20Air inlet temperature ˚F 68Nominal working pressure See Compressor dataCooling medium inlet temperature ˚C 20Cooling medium inlet temperature ˚F 68Cooling water temperature rise °C 10Cooling water temperature rise °F 18

11.3 Limits

Limits

Maximum air inlet/ambient temperature, GA Pack, high ambienttemperature version

˚C 55


˚F 131


˚C 55


˚F 131

Maximum air inlet/ambient temperature, GA 110 VSD up to GA160 VSD

˚C 46

Maximum air inlet/ambient temperature, GA 110 VSD up to GA160 VSD

˚F 115

Maximum air inlet/ambient temperature, GA 110 VSD up to GA160 VSD, high ambient version

˚C 50

Maximum air inlet/ambient temperature, GA 110 VSD up to GA160 VSD, high ambient version

˚F 122

Minimum air inlet/ambient temperature ˚C 0

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Minimum air inletambient temperature ˚F 32Maximum cooling air temperature, GA Pack, high ambienttemperature variant

˚C 55

Maximum cooling air temperature, GA Pack, high ambienttemperature variant

˚F 131

Maximum cooling air temperature, GA Full-Feature and Full-Feature with DD filter, high ambient temperature variant

˚C 50

Maximum cooling air temperature, GA Full-Feature and Full-Feature with DD filter, high ambient temperature variant

˚F 122

Maximum cooling air temperature, GA 110 VSD up to GA 160VSD

˚C 46

Maximum cooling air temperature, GA 110 VSD up to GA 160VSD

˚F 115

Minimum cooling air temperature ˚C 0Minimum cooling air temperature ˚F 32Maximum working pressure See section Compressor

dataMaximum cooling water inlet temperature ˚C 40Maximum cooling water inlet temperature ˚F 104Maximum cooling water outlet temperature (open systems) ˚C 50Maximum cooling water outlet temperature (open systems) ˚F 122Maximum cooling water outlet temperature (recirculatingsystems)

˚C 60

Maximum cooling water outlet temperature (recirculatingsystems)

˚F 140

Maximum cooling water inlet pressure bar(e) 10Maximum cooling water inlet pressure psig 145

11.4 Settings of safety valve

Compressor type SettingFor GA compressors with a maximum working pressure of 8.5, 10 or 14 bar 15 bar (e)For GA compressors with a maximum working pressure of 5.2, 6.9, 8.6, 10.4 or 13.8bar

15 bar (e)

For GA compressors with a maximum working pressure of 75, 100, 125, 150 or 200psi

218 psig

Instruction book

2920 1728 05 149

11.5 Settings of circuit breakers

IEC

Networksystem

Supplyvoltage

(V)

Frequency(Hz) Approval Q1 (A)

STDQ1 (A)HAT

Q20(A)

STD

Q20(A)

HAT

Q2(A)

Q40(A)

Q41(A)

TT/TN 380 50 IEC 2.3 2.3 28 31 59 20 9TT/TN 400 50 IEC 2.22 2.22 28 31 59 - 9TT/TN 500 50 IEC 1.78 1.78 20 25 48 20 9

TT/TN 380 60 IEC 2.3 2.3 28 31 59 - 9TT/TN 440 60 IEC 2.02 2.02 28 31 59 20 9

IT 380 50 IEC 2.3 2.3 28 31 59 20 9IT 400 50 IEC 2.22 2.22 28 31 59 - 9IT 500 50 IEC 1.78 1.78 20 25 48 20 9

IT 380 60 IEC 2.3 2.3 28 31 59 - 9IT 440 60 IEC 2.02 2.02 28 31 59 20 9

CSA/UL

Networksystem

Supplyvoltage

(V)

Frequency(Hz) Approval Q1 (A)

STDQ1 (A)HAT

Q20(A)

STD

Q20(A)

HAT

Q2(A)

Q40(A)

Q41(A)

TT/TN 460 60 CSA/UL 2.5 2.5 28 31 59 - 9TT/TN 575 60 CSA/UL 2.5 2.5 17 17 36 20 9

IT 460 60 CSA/UL 2.,5 2.5 28 31 59 - 9IT 575 60 CSA/UL 2.5 2.5 17 17 36 20 9

11.6 Compressor data

Data for GA 8.5 bar (123.3 psi) 50 Hz compressors

Units GA 110 VSD GA 132 VSD GA 160 VSDMaximum working pressure, GA Pack bar(e) 8.5 8.5 8.5Maximum working pressure, GA Pack psig 123 123 123Maximum working pressure, GA Full-Feature

bar(e) 8.3 8.3 8.3

Maximum working pressure, GA Full-Feature

psig 120 120 120

Instruction book

150 2920 1728 05

Units GA 110 VSD GA 132 VSD GA 160 VSDMaximum working pressure, GA Full-Feature with DD filter

bar(e) 8.1 8.1 8.1

Maximum working pressure, GA Full-Feature with DD filter

psig 118 118 118

Nominal working pressure bar(e) 8.0 8.0 8.0Nominal working pressure psig 116 116 116Motor shaft speed for: Pack compressors r/min 1923 2413 2862Full-Feature compressors 1919 2385 2832Full-Feature compressors with DDfilter

1917 2379 2823

Air-cooled compressors designed forhigh ambient temperature

-- 2218 2635

Water-cooled compressors designedfor high ambient temperature

-- 2198 2616

Power input, GA Pack kW 133 168 205Power input, GA Pack hp 178 225 275Power input, GA Full-Feature kW 139 176 214Power input, GA Full-Feature hp 186 236 287Power input, GA Full-Feature with DDfilter

kW 139 176 214

Power input, GA Full-Feature with DDfilter

hp 186 236 287

Power input, air-cooled compressorsdesigned for high ambienttemperature

kW -- 159 194


hp -- 213 260

Power input, GA W Pack kW 131 166 202Power input, GA W Pack hp 176 223 271Power input, GA W Full-Feature kW 135 169 205Power input, GA W Full-Feature hp 181 227 275Power input, GA W Full-Feature withDD filter

kW 135 169 205

Power input, GA W Full-Feature withDD filter

hp 181 227 275

Power input, water-cooledcompressors designed for highambient temperature

kW -- 157 192


hp -- 211 257

Oil capacity, GA l 87 87 87Oil capacity, GA US gal 23 23 23Oil capacity, GA Imp gal 19.1 19.1 19.1

Instruction book

2920 1728 05 151

Units GA 110 VSD GA 132 VSD GA 160 VSDOil capacity, GA cu.ft 3.07 3.07 3.07Oil capacity, GA W l 75 75 75Oil capacity, GA W US gal 19.6 19.6 19.6Oil capacity, GA W Imp gal 16.3 16.3 16.3Oil capacity, GA W cu.ft 2.61 2.61 2.61Sound pressure level, GA dB(A) 68 68 68Sound pressure level, GA W dB(A) 68 68 68Maximum cooling water flow l/s 2.7 3.6 4.4Maximum cooling water flow cfm 5.7 7.6 9.3Minimum cooling water flow l/s 1.9 1.5 1.8Minimum cooling water flow cfm 4.0 3.18 3.8



bar(e) 9.8 9.8 9.8


psig 142 142 142


bar(e) 9.6 9.6 9.6


psig 139 139 139


1780 2213 2638


-- 2054 2448


-- 2037 2429


kW 140 175 213


hp 187 235 286

Instruction book

152 2920 1728 05

Units GA 110 VSD GA 132 VSD GA 160 VSDPower input, air-cooled compressorsdesigned for high ambienttemperature

kW -- 159 193


hp -- 213 259


kW 136 169 205


hp 182 227 275


kW -- 157 191


hp -- 211 256

Oil capacity, GA l 87 87 87Oil capacity, GA US gal 23 23 23Oil capacity, GA Imp gal 19.1 19.1 19.1Oil capacity, GA cu.ft 3.07 3.07 3.07Oil capacity, GA W l 74 74 74Oil capacity, GA W US gal 19.6 19.6 19.6Oil capacity, GA W Imp gal 16.3 16.3 16.3Oil capacity, GA W cu.ft 2.61 2.61 2.61Sound pressure level, GA dB(A) 68 68 69Sound pressure level, GA W dB(A) 68 68 69Maximum cooling water flow l/s 2.7 3.6 4.4Maximum cooling water flow cfm 5.7 7.6 9.3Minimum cooling water flow l/s 1.9 1.5 1.8Minimum cooling water flow cfm 4.0 3.18 3.8



bar(e) 13.8 13.8 13.8


psig 200 200 200

Instruction book

2920 1728 05 153


bar(e) 136 13.6 13.6


psig 197 197 197


1479 1846 2224


-- 1709 2058


-- 1702 2049


kW 141 175 212


hp 189 235 284


kW -- 159 192


hp -- 213 257


kW 137 168 203


hp 184 225 272


kW -- 157 190


hp -- 211 255


Instruction book

154 2920 1728 05


Data for GA 125 psi (8.6 bar) 60 Hz compressors


bar(e) 8.9 8.9 8.9


psig 129 129 129


bar(e) 8.7 8.7 8.7


psig 126 126 126


1854 2311 2748


-- 2146 2558


-- 2126 2538


kW139

176 214


hp186

236 287

Instruction book

2920 1728 05 155


kW

--

159 194


hp

--

213 260


kW135

169 205


hp181

227 275


kW

--

157 191


hp

--

211 256



Units GA 110 VSD GA 132 VSD GA 160 VSDMaximum working pressure, GA Pack bar(e) 10.9 10.9 10.9Maximum working pressure, GA Pack psig 158.1 158.1 158.1Maximum working pressure, GA Full-Feature

bar(e)10.7

10.7 10.7


psig155

155 155

Instruction book

156 2920 1728 05


bar(e)10.5

10.5 10.5


psig152

152 152


1703

2120 2534


--

1963 2345


--

1949 2328


kW

--

159 193


hp

--

213 259


kW140

175 213


hp188

235 286


kW136

169 204


hp183

227 274


kW

--

157 191


hp

--

211 256


Instruction book

2920 1728 05 157



Units GA 110 VSD GA 132 VSD GA 160 VSDMaximum working pressure, GA Pack bar(e) 14 14.0 14.0Maximum working pressure, GA Pack psig 203 203 203Maximum working pressure, GA Full-Feature

bar(e)13.8

13.8 13.8


psig200

200 200


bar(e)13.6

13.6 13.6


psig197

197 197


1479

1846 2224


-- 1709 2058


-- 1702 2049


kW141

175 212


hp189

235 284

Instruction book

158 2920 1728 05


kW -- 159 192


hp -- 213 257


kW137

168 203


hp184

225 272


kW 157 190


hp 211 255


Instruction book

2920 1728 05 159

12 Pressure equipment directives

Category IV

Product:

• GA 110 VSD• GA 132 VSD• GA 160 VSD

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 under the exclusion of articleI, section 3.6.

The following pressure bearing parts are of category higher than I :

Oil separator vessel : Cat IV

Design pressure 15 bar(e), content 290 l

Design standard : ASME section VIII div. 1.

Safety valve : Cat IV

Design code : AD-Merkblätter, A2

Instruction book

160 2920 1728 05

13 Documentation

Declaration of conformity

Typical example of a Declaration of Conformity document

Instruction book

2920 1728 05 161

No.

292

0 17

28 0

5 / 2

011

- 07

What sets Atlas Copco apart as a company is our conviction thatwe can only excel in what we do if we provide the best possibleknow-how and technology to really help our customers produce,grow and succeed.

There is a unique way of achieving that - we simply call it the AtlasCopco way. It builds on interaction, on long-term relationshipsand involvement in the customers’ process, needs and objectives.It means having the flexibility to adapt to the diverse demands ofthe people we cater for.

It’s the commitment to our customers’ business that drives oureffort towards increasing their productivity through bettersolutions. It starts with fully supporting existing products andcontinuously doing things better, but it goes much further, creatingadvances in technology through innovation. Not for the sake oftechnology, but for the sake of our customer’s bottom line andpeace-of-mind.

That is how Atlas Copco will strive to remain the first choice, tosucceed in attracting new business and to maintain our positionas the industry leader.

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