Atlas Copco GA 37 VSD User manual

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Oil-injected rotary screw compressors

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Oil-injected rotary screw compressors
GA 37 VSD, GA 45 VSD
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as identified
in the Declaration of Conformity.
2015 - 01
            
www.atlascopco.com

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Instruction book
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1904 0504 83 ϯ
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                                                    
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1.1SAFETY ICONS ....................................................................................................................... 6
1.2SAFETY PRECAUTIONS, GENERAL ...................................................................................... 6
1.3SAFETY PRECAUTIONS DURING INSTALLATION................................................................ 7
1.4SAFETY PRECAUTIONS DURING OPERATION .................................................................... 9
1.5SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR......................................... 10
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                                              
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2.1INTRODUCTION.................................................................................................................... 13
2.2AIR FLOW .............................................................................................................................. 17
2.3OIL SYSTEM.......................................................................................................................... 19
2.4COOLING SYSTEM ............................................................................................................... 20
2.5CONDENSATE SYSTEM ....................................................................................................... 22
2.6REGULATING SYSTEM......................................................................................................... 23
2.7ELECTRICAL SYSTEM.......................................................................................................... 23
2.8AIR DRYER............................................................................................................................ 24
2.9SMARTBOX AND SMARTLINK.............................................................................................. 25
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          !     "                                                                                          
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3.1ELEKTRONIKON® GRAPHIC CONTROLLER ....................................................................... 28
3.2CONTROL PANEL ................................................................................................................. 30
3.3ICONS USED ......................................................................................................................... 31
3.4MAIN SCREEN....................................................................................................................... 35
3.5CALLING UP MENUS ............................................................................................................ 39
3.6INPUTS MENU....................................................................................................................... 40
3.7OUTPUTS MENU................................................................................................................... 43
3.8COUNTERS ........................................................................................................................... 45
$
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Instruction
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1904 0504 83 
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4.1ENERGY RECOVERY UNIT .................................................................................................. 82
4.2ENERGY RECOVERY SYSTEMS.......................................................................................... 83
4.3OPERATION .......................................................................................................................... 84
4.4MAINTENANCE ..................................................................................................................... 88
4.5ENERGY RECOVERY DATA................................................................................................. 88
)
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*                                            + ,
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5.1DIMENSION DRAWINGS....................................................................................................... 90
5.2INSTALLATION PROPOSAL.................................................................................................. 92
5.3ELECTRICAL CONNECTIONS .............................................................................................. 95
5.4COOLING WATER REQUIREMENTS.................................................................................... 97
5.5PICTOGRAPHS ....................................................................................................................102
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6.1BEFORE INITIAL START-UP................................................................................................103
6.2BEFORE STARTING.............................................................................................................106
6.3STARTING ............................................................................................................................107
6.4DURING OPERATION ..........................................................................................................108
6.5CHECKING THE DISPLAY....................................................................................................110
6.6STOPPING............................................................................................................................111
6.7TAKING OUT OF OPERATION.............................................................................................112
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7.1PREVENTIVE MAINTENANCE SCHEDULE.........................................................................113
7.2OIL SPECIFICATIONS ..........................................................................................................116
7.4AIR FILTER ...........................................................................................................................117
7.5OIL AND OIL FILTER CHANGE ............................................................................................118
7.6COOLERS.............................................................................................................................120
7.7SAFETY VALVES..................................................................................................................121
7.8DRYER MAINTENANCE INSTRUCTIONS............................................................................121
7.9SERVICE KITS......................................................................................................................122

Instruction book
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1904 0504 83 ϱ
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7.10DRAINING CONDENSATE FROM THE OIL TANK...............................................................122
7.11STORAGE AFTER INSTALLATION ......................................................................................123
7.12DISPOSAL OF USED MATERIAL .........................................................................................123
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9.1READINGS ON DISPLAY .....................................................................................................129
9.2ELECTRIC CABLE SIZE AND MAIN FUSES ........................................................................129
9.3PROTECTION SETTINGS ....................................................................................................133
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Instruction
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1904 0504 83 
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4 5 6 7 8 9 8 : ; < 9
Danger for life
Warning
Important note
= > 9> ? 8 7 6 ?>@8 A : ; < 9 B
C D
To be read attentively and acted accordingly before installing, operating, repairing or
decommissioning the unit
E D
These recommendations apply to machinery processing or consuming air or insert gas.
F D
Processing of any other gas requires additional safety precautions typical to the application,
which are not included herein.
G D
In addition to normal safety rules, which should be observed with stationary air compressor and
equipment, the following safety directions and precautions are of special importance.
HD
Any modification on the compressor shall only be performed in agreement with Atlas copco and
under stricter of the two shall apply
I D
The operator must employ safe working practices and observe all related work safety
requirements and regulations.
JD
If any of the following statements does not comply with the applicable legislation, the stricter of
the two shall apply.
K D
Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
L D
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.
C M D
Before any maintenance, repair work, adjustment or any other non-routine checks:
•Stop the compressor.
•Press the emergency stop button.
•Switch off the voltage.
•Depressurize the compressor.
•Lock Out – Tag Out (LOTO):
- Open the power isolating switch and lock it with a personal lock.
- Tag the power isolating switch with the name of the service technician.
•On units are powered by a frequency converter, wait 10 minutes before starting any
electrical repair.
•Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
C C D
The units are powered by a frequency converter, wait 10 minutes before starting any electrical
repair.

Instruction book
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1904 0504 83 ϳ
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In a domestic environment, this product may cause radio interference in which
case supplementary mitigation measures are required.
If the machine is equipped with an automatic restart after voltage failure function
and if this function is active, be aware that the machine will restart automatically
when the power is restored if it was running when the power was interrupted
C E D
Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean equipment,
do so with extreme caution and wear eye protection.
C F D
The owner is responsible for maintaining the unit in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
C G D
It is not allowed to walk or stand on the roof of the compressor canopy.
All responsibility for any damage or injury resulting from neglecting these
precautions, or non observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated,
will be disclaimed by the manufacturer .
N?>@8 A : ; < 9 B O A ?;9P <6> ? 8 : ; < 9
C D
Apart from general engineering practice in conformity with the local safety regulations, the
following directives are specially stressed:
E D
In proposals/quotes to the customer it should be mentioned mandatory to ask for lockable
isolators at customer installation, the same has to be added in AIB for commissioning/servicing
of the machine. Need of lockable isolators to be clearly communicated to customers.
F D
A compressor shall be lifted only with adequate equipment in conformity with local safety rules.
Please consult Atlas Copco to check if a dedicated lifting devise is designed for this purpose.
Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or
stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within
safe limits.
G D
The units is designed for indoor use . If the unit is installed outdoors, special precautions must
be taken; consult your supplier.
HD
In case the devise is a compressor, place the machine where the ambient air is as cool and
clean as possible if necessary, install a suction duct. Never obstruct the air inlet. Care must b
taken to minimize the entry of moisture at the inlet air
I D
Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the
pipes.
JD
Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
K D
In case the devise is a compressor, the aspirated air must be free of flammable fumes, vapours
and particles, e.g. paint solvents, that can lead to internal fire or explosion.
L D
In case the dives is a compressor, arrange the air intake so that loose clothing worn by people
cannot be drawn in.
C M D
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.
C C D
No external force may be exerted on the air outlet valve; the connected pipe must be free of
strain.
C E D
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 depressurized and that the

Instruction
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1904 0504 83 
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electrical isolating switch is open, locked and labeled with a temporary warning before any
maintenance or repair. As a further safeguard, 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 start equipment.
C F D
Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted air does not recirculate to the compressor air inlet or cooling
air inlet.
C G D
The electrical connections must correspond to the applicable codes. The machines must be
earthed and protected against short circuits by fuses in all phases. A lockable power isolating
switch must be installed near the compressor.
CHD
On machines with automatic start/stop system or if the automatic restart function after voltage
failure is activated, a sign stating "This machine may start without warning" must be affixed near
the instrument panel.
C I D
In multiple compressor systems, manual valves must be installed to isolate each compressor.
Non-return valves (check valves) must not be relied upon for isolating pressure systems.
CJD
Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure relieving device or devices as required.
C K D
Piping or other parts with a temperature in excess of 70°C (158°F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other high
temperature piping must be clearly marked.
C L D
For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet
pressure.
E M D
If the ground is not level or can be subject to variable inclination, consult the manufacturer.
E C D
If the device is a dryer and no free extinguishing system is present in the air close to the dryer,
safety valves must be installed of the dryer.
E E D
Never Drill holes in an electrical cabinet. Small metallic burrs can cause short-circuits in
electrical components
E F D
Make sure to avoid condensation on electrical components (e.g. cubicle, Elektronikon and
frequency converter)
E G D
To preserve the protection of the electric cabinet and to protect its components from dust from
the environment and the entry of moisture in the electrical cabinet. It is absolutely necessary to
use a proper cable gland when connecting the power supply cable to the compressor.
Q B >< R 8 9 ; S 6 ?< 6 > ? @ 8 T 7 >P 7 8 9 O @8 9 ? > B A 7 : ; 9 O 8 S 8 P >: < < ?R 8 ; 7 A ? > < R : U > > V A ; 6 S >9 : W X U ; B
@< A 7 O 8 7 B < ? > B A 7 : ; 9 R ; ? > 8 9 O R 8 : 8 7 ; : ; >B W
EHD
Avoid contact with sharp edges hot surfaces to prevent damage to cable insulation.
E I D
Before initial start-up and after service interventions, make sure the following final inspection
checks are made:
a. Inspect all electrical connections to verify there are no loose connections and all are
tightened correctly
b. Check for strain relief on the (main) power cables.
c. Verify that the power requirement for the unit has been provided for by referencing to the unit
power label on the inside of the electrical cabinet door of the unit
d. The branch circuit protection and supply cable size for the compressor must be sized to
meet the power requirement per local electrical codes
e. Verify that the unit is correctly grounded using the proper size of wire connected to a tested
earth ground
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X U ; B @< A 7 O 8 7 B < ? > B A 7 : ; 9 R ; ? > 8 9 O R 8 : 8 7 ; : ; >B W
EJD
Before initial start-up and after service inventions , make sure the following final mechanical
inspection check are made:
a. Inspect all connections to make sure they are tight, sealed and secured.
b. Visually inspect metal or nylon tubing located in the compressor. Tubes can come loose or
get damaged in shipping. Verify the flexibility of the nylon tubes while inspecting for damage.

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c. Verify that all tubes are secure in their fittings to insure that none might leak or come loose
when the compressor is in operation.
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After inspection, the power can be put to the installed compressor. With the proper power
applied, the rotation of the compressor and the cooling fan can be verified.
Also consult following safety precautions: Safety precautions during operation
and Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert
gas. Processing of any other gas requires additional safety precautions typical
to the application which are not included herein.
Some precautions are general and cover several machine types and
equipment; hence some statements may not apply to your machine.
All responsibility for any damage or injury resulting from neglecting these
precautions, or non observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated,
will be disclaimed by the manufacturer.
N?>@8 A : ; < 9 B O A ?;9P <6> ? 8 : ; < 9
C D
Air hoses shall be of correct size and suitable for the working pressure. Never use frayed
damaged or deteriorated houses. Use only the correct type and size of hose end fittings and
connections. When blowing through a hose or airline, ensure that the open end is held securely.
A free end will whip and may cause injury. Make sure that a hose is fully depressurized before
disconnecting it.
E D
Never play with compressed air. Do not apply it to your skin or direct an air stream at people.
Never use it to clean dirt from clothes. When using it to clean equipment, do so with extreme
caution and use eye protection.
F D
The compressor is not considered as capable of producing air for breathing quality. For
breathing air quality, the compressed air must be adequately purified according to local
legislation and standards.
G D
Never operate the unit at pressures below or in excess of its limit ratings as indicated on the
Principal Data sheet.
Never touch any piping or components of the compressor during operation.
HD
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 remote start equipment.
I D
Never operate the machine when there is a possibility of taking in flammable or toxic fumes,
vapors or particles.
JD
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.
K D
On compressor without bodywork, wear ear protection in the vicinity of the machines.
L D
People staying in environments or rooms where the sound pressure level reaches or exceeds
80 dB(A) shall wear ear protectors.
C M D
Periodically check that:

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• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• No leaks occur
• 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 abuse
• Air cooling filters of the electrical cabinet are not clogged
C C D
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.
C E D
On water-cooled compressors using open circuit cooling towers, protective measures must be
taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
C F D
Do not remove any of, or tamper with, the sound-damping material.
C G D
Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure shall be protected by a pressure relieving device or devices as required.
CHD
Yearly inspect air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during
installation and Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert
gas. Processing of any other gas requires additional safety precautions
typical to the application which are not included herein.
Some precautions are general and cover several machine types and
equipment; hence some statements may not apply to your machine.
All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for
installation, operation, maintenance and repair, even if not expressly stated,
will be disclaimed by the manufacturer.
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Maintenance and repair work shall only be carried out under supervision of someone qualified for the
job
To maintain warranty and to insure the compressor operates correctly and safety, genuine parts must
be used. Use of non-genuine parts, failure to correctly install equipment or perform recommended
scheduled maintenance will void warranty and result in damage to or failure of the equipment. This
could also result in fire and fatalities.
Always use the correct safety equipment such as safety glasses, gloves, safety shoes, etc.
Before performing any maintenance, stop the compressor, close the shut-off valve at the unit
discharge, remove all electrical power from the equipment, verify the receiver tank on the unit is at zero
pressure and let the machine cool down. Take positive precaution to ensure that the unit cannot be
started inadvertently by following a lock-out tag-out procedure. In addition, a warning sign bearing a
legend such as
^
]<? _ ; 9 6 ?< P ? > B B ` O < 9 < : B : 8 ?: a
shall be attached to the starting equipment

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C D
Before removing any pressurized component, effectively isolate the unit from all sources of
pressure and relieve the entire system of pressure and electrical power. Take positive
precaution to ensure that the unit cannot be started inadvertently. In addition, a warning sign
bearing a legend such as
^
]<? _ ; 9 6 ?< P ? > B B ` O < 9 < : B : 8 ?: a
shall be attached to the starting
equipment
E D
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 remote start equipment.
F D
Protect hands to avoid injury from hot machine parts, e.g during draining of oil
G D
Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
HD
Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapours of cleaning liquids.
Never use caustic solvents, which can damage materials of the air net, e.g polycarbonate
bowls.
I D
Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering
the parts and exposed openings with a clean cloth, paper or tape. Make sure that no tools,
loose parts or range are left on or the unit.
JD
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.
Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapour when air is admitted.
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6? > BBA ? > c > BB>7d > :@W
K D
Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam-cleaning. Or due to condensation of humid ambient air.
L D
If the branch circuit is provided using a fused disconnect to supply power to the compressor,
and then verify that all the fuses are of the same type and properly sized. If a circuit breaker is
used to supply power, verify that it is properly sized.
C M D
Visually inspect and verify that the connections at the branch circuit protection device are tight
and the wire insulation Is not degraded.
C C D
Visually inspect the wire from the branch circuit protection devise to the compressor starter to
verify that it is sized correctly and in good order.
C E D
Verify that the power wire and ground connections at the compressor starter are tight and in
good order.
C F D
Verify that the wire connections from the compressor starter to the compressor motor are tight
and in good order
C G D
Replace filters in the electrical cabinet when they are saturated with dust.
CHD
Check if the sealing of the electrical cabinet is in perfect condition. If not replace it.
C I D
Inspect all tubing in the compressor for possible leaks or normal aging and replace with genuine
parts if needed
CJD
Verify if all tube fitting are tight and tubes are securely held in the fittings.
C K D
Also check all nylon for chaffing, cracks and flexibility and replace with genuine parts to insure
safe operation.
C L D
Drain any condensate that may have collected in the receiver tank.
E M D
Take oil samples for evaluation and be sure to mark with customer name, compressor model,
compressor serial number and running hours of the compressor. Respect oil service intervals.
Oxidized oil will result in higher compressor temperatures that could result in fire.
E C D
Replace oil with genuine compressor oil of the same type when needed.

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@< A 7 O ? > B A 7 : ; 9 R ; ? > W
E E D
Replace all consumables at recommended service intervals or sooner if operating conditions
several / warrant or replace every 12 months.
E F D
Make sure that all sound –damping material, e.g. on the bodywork and in the air inlet and outlet
systems of the compressor, is in good condition. If damaged, replace it by genuine material to
prevent the sound pressure level from increasing.
E G D
Every time the separator element is renewed, examine the discharge pipe and the inside of the
oil separator vessel for carbon deposits; if excessive, the deposits should be removed.
EHD
Before clearing the machine for use after maintenance or overhaul, check that operating
pressures, temperatures and time settings are correct and that the control and shut-down
devices function correctly. If removed, check that the coupling guard of the compressor drive
shaft has been reinstalled.
f g h
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a. Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if
required, use breathing protection.
b. Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the
latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away;
then seek medical first aid.
c. Always wear safety glasses.
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? > B A 7 : ; 9 R ; ? > d
EJD
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.
E K D
Customer to check all the safety / protection devices once in a month, Check function of
following components and maintain the record of the same.
• Overload relay - set at min setting and check trip+ manual trip
• Safety valve - raise the pressure and check the opening at set press - even Elektronikon
have SV test function.
• Temp switch - open the contacts (make NO) and check trip.
• PSR - reverse any 2 phase and check the trip.
Also consult following safety precautions: Safety precautions during
installation and Safety precautions during operation.
These precautions apply to machinery processing or consuming air or inert
gas. Processing of any other gas requires additional safety precautions
typical to the application which are not included herein.
Some precautions are general and cover several machine types and
equipment; hence some statements may not apply to your machine.

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GA 37 VSD up to GA 45 VSD are single-stage, oil-injected screw compressors driven by an electric
motor.
The compressors are enclosed in a sound-insulated bodywork and are available in air-cooled and
water cooled version.
The compressors are controlled by the Atlas Copco Elektronikon® Graphic regulator.
The electronic control module is fitted to the door at the right side. An electric cabinet comprising
fuses, transformers, relays, etc. is located behind this panel.
Atlas Copco's integrated VSD (Variable Speed Drive) technology mirrors air usage, automatically
adjusting the motor speed depending on the compressed air demand.
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AF Air filter
AR Air receiver
AV Air outlet valve
Ca Air cooler
Co Oil cooler
CV/Vs Check valve/oil stop valve
Da Automatic condensate outlet
E Compressor element
ER Elektronikon® Graphic controller
FN Cooling fan
M1 Drive motor
S3 Emergency stop button
VP Vent plug
1 Electric cabinet

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The Workplace Full Feature compressors are provided with an air dryer which is integrated in the
sound insulated bodywork. The dryer removes condensate from the compressed air by cooling the air
to near freezing point.
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>R>?>9@ > b 8 S >
AV Air outlet valve
Ca Air cooler
Co Oil cooler
CV/Vs Check valve/oil stop valve
Da Automatic condensate outlet
Dm Manual condensate outlet
E Compressor element
ER Elektronikon®/Elektronikon® Graphic controller
FN Cooling fan
M1 Drive motor
UA Unloader

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GA 37 VSD and GA 45 VSD Workplace Full-Feature
>R>?>9@ > B [ >B@ ? ; 6 : ; < 9
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate
F Dried compressed air (Full-Feature)
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The cooling fan (FN) is not provided on water-cooled compressors.
[>B@ ? ; 6 : ; < 9
Air drawn in through filter (AF) and check valve (CV) is compressed in compressor element (E).
A mixture of compressed air and oil flows into the air receiver/oil separator (AR). The air is discharged
through
the outlet valve via minimum pressure valve (Vp), air cooler (Ca) and condensate trap (MT).
Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum
pressure and
includes a check valve which prevents blow-back of compressed air from the net.
Full-Feature compressors are provided with a dryer (DR).