Atlas Copco GA 55+ User manual

Atlas Copco
GA 55+
API603130
Instruction book

Atlas Copco
GA 55+
API603130
Instruction book
Original instructions
Manufacturing Date: 24/10/2006
Copyright notice
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.
2016 - 02
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................6
1.1 SAFETY ICONS................................................................................................................................... 6
1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................7
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 FLOW....................................................................................................................................... 13
2.3 OIL SYSTEM.................................................................................................................................... 14
2.4 COOLING SYSTEM.............................................................................................................................15
2.5 CONDENSATE SYSTEM.......................................................................................................................16
2.6 REGULATING SYSTEM........................................................................................................................ 17
2.7 ELECTRICAL SYSTEM.........................................................................................................................18
2.8 ELECTRICAL DIAGRAMS......................................................................................................................19
2.9 AIR DRYER......................................................................................................................................22
3 Elektronikon II regulator.............................................................................................. 24
3.1 ELEKTRONIKON® II REGULATOR.......................................................................................................... 24
3.2 CONTROL PANEL.............................................................................................................................. 26
3.3 FUNCTION KEYS............................................................................................................................... 27
3.4 SCROLL KEYS.................................................................................................................................. 28
3.5 EMERGENCY STOP BUTTON................................................................................................................ 28
3.6 CONTROL PROGRAMS........................................................................................................................28
3.7 MAIN SCREEN MENU......................................................................................................................... 30
3.8 CALLING UP MENUS.......................................................................................................................... 31
3.9 QUICK LOOK AT THE ACTUAL COMPRESSOR STATUS................................................................................ 32
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3.10 STATUS DATA MENU..........................................................................................................................33
3.11 MEASURED DATA MENU..................................................................................................................... 36
3.12 COUNTERS MENU............................................................................................................................. 36
3.13 TEST MENU..................................................................................................................................... 37
3.14 MODIFY PARAMETERS MENU............................................................................................................... 38
3.15 MODIFYING PARAMETERS................................................................................................................... 38
3.16 MODIFYING PROTECTION SETTINGS...................................................................................................... 39
3.17 MODIFYING SERVICE PLANS................................................................................................................ 40
3.18 PROGRAMMING CLOCK FUNCTION.........................................................................................................42
3.19 MODIFYING CONFIGURATION SETTINGS..................................................................................................47
3.20 PROGRAMMING COMPRESSOR CONTROL MODES..................................................................................... 47
3.21 SERVICE MENU................................................................................................................................ 48
3.22 SAVED DATA MENU........................................................................................................................... 50
3.23 PROGRAMMABLE SETTINGS.................................................................................................................51
4 Installation.....................................................................................................................53
4.1 DIMENSION DRAWINGS.......................................................................................................................53
4.2 INSTALLATION PROPOSAL................................................................................................................... 55
4.3 ELECTRICAL CONNECTIONS.................................................................................................................57
4.4 PICTOGRAPHS................................................................................................................................. 60
5 Operating instructions................................................................................................. 62
5.1 INITIAL START-UP..............................................................................................................................62
5.2 BEFORE STARTING............................................................................................................................64
5.3 STARTING ...................................................................................................................................... 65
5.4 DURING OPERATION..........................................................................................................................66
5.5 CHECKING THE DISPLAY.....................................................................................................................69
5.6 STOPPING ......................................................................................................................................70
5.7 TAKING OUT OF OPERATION................................................................................................................71
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6 Maintenance..................................................................................................................72
6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................72
6.2 OIL SPECIFICATIONS..........................................................................................................................74
6.3 STORAGE AFTER INSTALLATION........................................................................................................... 75
6.4 SERVICE KITS.................................................................................................................................. 75
6.5 DISPOSAL OF USED MATERIAL............................................................................................................. 75
7 Adjustments and servicing procedures..................................................................... 76
7.1 DRIVE MOTOR .................................................................................................................................76
7.2 AIR FILTER......................................................................................................................................76
7.3 OIL AND OIL FILTER CHANGE...............................................................................................................77
7.4 COOLERS....................................................................................................................................... 79
7.5 SAFETY VALVES............................................................................................................................... 80
7.6 DRYER MAINTENANCE INSTRUCTIONS....................................................................................................80
8 Problem solving............................................................................................................82
9 Technical data...............................................................................................................85
9.1 READINGS ON DISPLAY...................................................................................................................... 85
9.2 ELECTRIC CABLE SIZE AND MAIN FUSES................................................................................................ 86
9.3 SETTINGS OF FAN MOTOR CIRCUIT BREAKER.......................................................................................... 87
9.4 MOTOR OVERLOAD RELAY SETTINGS.................................................................................................... 87
9.5 DRYER SWITCHES.............................................................................................................................88
9.6 REFERENCE CONDITIONS AND LIMITATIONS............................................................................................ 88
9.7 COMPRESSOR DATA..........................................................................................................................88
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10 Instructions for use...................................................................................................... 90
11 Guidelines for inspection.............................................................................................91
12 Pressure equipment directives................................................................................... 92
13 Declaration of conformity............................................................................................ 93
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 General safety precautions
1. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel. The personnel should apply safe working practices by use of personal
protection equipment, appropriate tools and defined procedures.
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 machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
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!
6. 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.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
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9. If compressed air is used in the food industry and more specifically for direct food contact, Atlas
Copco recommends, for optimal safety, the use of certified Class 0 compressors in combination with
appropriate filtration depending on the application. Please contact your Atlas Copco Customer Center
for advice on specific filtration.
1.3 Safety precautions during installation
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.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept
within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. In case the device 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 be taken to
minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the
working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors and
particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people cannot
be drawn in.
8. 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.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. 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 electrical
isolating switch is open, locked and labelled with a temporary warning before any maintenance or
repair. As a further safeguard, persons switching on or off 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.
11. 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.
12. 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.
13. 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.
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14. 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.
15. 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.
16. 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.
17. 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.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the dryer,
safety valves must be installed in the vessels of the dryer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
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.
1.4 Safety precautions during operation
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.
Precautions during operation
1. Never touch any piping or components of the machine 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
sure that a hose is fully depressurized before disconnecting it.
3. 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.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
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 machines 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
• No leaks occur
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• 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
9. 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. 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.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the 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.
1.5 Safety precautions during maintenance or repair
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.
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 for maintenance or repair. The manufacturer will disclaim all damage or
injuries caused by the use of non-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 remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor 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 vapors of cleaning liquids.
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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, 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 vapor 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
that they function correctly. If removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
17. 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.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material 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 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. Only if applicable, the following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
• 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.
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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2 General description
2.1 Introduction
GA 55+ up to GA 90 are single-stage, oil-injected screw compressors driven by an electric motor. The
compressors are available in air-cooled and water-cooled version.
The compressors are controlled by an Elektronikon® regulator.
GA Workplace Full-Feature
GA Workplace Full-Feature compressors are enclosed in a sound-insulated bodywork. The Elektronikon
control module is fitted to the door on the right side. An electric cabinet comprising the motor starter is
located behind this panel. The compressors are provided with an air dryer.
The dryer is integrated in the sound-insulated bodywork. The dryer removes water from the compressed air
by cooling the air to near freezing point. The condensate is automatically drained.
Front view, GA 55+ up to GA 90 Workplace Full-Feature
Reference Name
1 Electric cubicle
AF Air filter
AR Air receiver (oil separator vessel)
AV Air outlet valve
Ca Air cooler
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Reference Name
Co Oil cooler
Da Automatic condensate outlet
Da1 Automatic condensate outlet, dryer
DR Dryer
ER Elektronikon® II regulator
FN Fan
M1 Compressor drive motor
VP Vent plug (oil cooler)
S3 Emergency stop button
OF Oil filter housing
Rear view, GA 55+ up to GA 90 Workplace Full-Feature
Reference Name
E Compressor element
CV/Vs Check valve/oil stop valve
FN Cooling fan
M1 Compressor drive motor
MT Condensate trap
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Reference Name
AV Compressed air outlet valve
DR Dryer
AF Air filter
Co Oil cooler
Ca Air cooler
UA Unloader
2.2 Air flow
Flow diagrams
Flow diagram, GA Workplace Full-Feature
Reference Description
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate
F Dried compressed air
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Description
Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. A mix
of compressed air and oil flows into the air receiver/oil separator (AR) via check valve (CV). The air is
discharged through outlet valve (AV) via minimum pressure valve (Vp) and air cooler (Ca).
The air cooler is provided with a moisture trap (MT).
On Full-Feature compressors, the air flows through air dryer (DR) before it is discharged through outlet
valve (AV). Also see section Air dryer.
During loaded operation, minimum pressure valve (Vp) keeps the pressure in the separator tank (AR)
above a minimum value, required for lubrication. An integrated check valve prevents the compressed air
downstream the valve from being vented to atmosphere during unloaded operation. When the compressor
is stopped, check valve (CV) and inlet valve (IV) close, preventing compressed air (and oil) to be vented
into the air filter.
2.3 Oil system
Flow diagram
Oil system
References Description
1 Compressed air flow to the air dryer (compressors with integrated dryer)
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate
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Description
In air receiver/oil separator (AR), most of the oil is removed from the air/oil mixture by centrifugal action.
The remaining oil is removed by oil separator (OS). The oil collects in the lower part of air receiver/oil
separator (AR), which serves as an oil tank.
The oil system is provided with a thermostatic bypass valve (BV). When the oil temperature is below its set
point, bypass valve (BV) shuts off the supply to oil cooler (Co) and the oil cooler is bypassed.
Air pressure forces the oil from air receiver/oil separator (AR) through oil filter (OF) and oil stop valve
(Vs) to compressor element (E).
Bypass valve (BV) starts opening the supply from cooler (Co) when the oil temperature has increased to
the set point. At approx. 15 ˚C (27 ˚F) above the set point, all the oil flows through the oil cooler.
Oil stop valve (Vs) prevents the compressor element from flooding with oil when the compressor is
stopped. The valve is opened by element outlet pressure when the compressor is started.
2.4 Cooling system
Flow diagram
Cooling system, air-cooled compressors
References Description
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate
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Description
The cooling system comprises air cooler (Ca) and oil cooler (Co).
On air-cooled compressors, the cooling air flow is generated by fan (FN).
2.5 Condensate system
Water drains
Condensate drains, typical example
Reference Designation
Da Automatic drain connection
Da1 Automatic drain connection of the dryer (only on Full-Feature units)
Next to each automatic drain outlet is a manual condensate drain connection for manually draining of the
condensate.
Electronic condensate drains, typical example
The compressors have an electronic water drain (EWD). The condensate from the air cooler accumulates in
a collector. When the condensate reaches a certain level, it is discharged through the automatic drain outlet
(Da).
On Full-Feature compressors, an additional electronic water drain (EWD1) is provided. The condensate
trap of the heat exchanger is drained by EWD1 and discharged through automatic drain outlet (Da1).
Also see section Air flow.
Testing the electronic water drain can be done by briefly pressing the test button (1) on top of the drain.
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2.6 Regulating system
Flow diagram
Regulating system (loaded condition)
Loading
When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results:
• The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank
pressure (1) via the solenoid valve.
• Unloading valve/blow-off valve (UV) moves downwards, closing off the connection to channels (2)
and (3).
• Underpressure from the compressor element causes loading plunger (LP) to move downwards and
inlet valve (IV) to open fully.
Air delivery is 100%, the compressor runs loaded.
Unloading
If the air consumption is less than the air output of the compressor, the net pressure increases. When the net
pressure reaches the unloading pressure, solenoid valve (Y1) is de-energised. Results:
• The pressure above unloading valve/blow-off valve (UV) is released to atmosphere and the space
above valve (UV) is no longer in connection with the oil separator tank pressure (1).
• Unloading valve/blow-off valve (UV) moves upwards, connecting the oil separator tank pressure (1)
with channels (2) and (3).
• The pressure in channel (2) causes the loading plunger (LP) to move upwards, causing inlet valve
(IV) to close, while the pressure is gradually released to atmosphere.
• The pressure in the separator tank stabilises at low value. A small amount of air is kept drawn in to
guarantee a minimal pressure, required for lubrication during unloaded operation.
Air output is stopped, the compressor runs unloaded.
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2.7 Electrical system
General
Also consult sections Electrical diagrams and Electrical connections.
Electrical components
The electrical system comprises following components:
Electric cubicle, typical example
Reference Designation
F1/2/3 Fuses
(F3 is only provided in case a phase sequence relay is provided)
F4/5/6 Fuses
F7/F8/F9 Fuses (only on Full-Feature)
F10/11/12 Fuses
F21 Overload relay, compressor motor
Q15 Circuit breaker, fan motor (on air-cooled compressors)
K5 Auxiliary relay
K11 Auxiliary contactor for dryer (only on Full-Feature)
K21 Line contactor
K22 Star contactor
K23 Delta contactor
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