Atlas Copco GA 55+ User manual

GA 55+, GA 75+, GA 90
Instruction book
Atlas Copco
Oil-injected rotary screw compressors

Atlas Copco
Oil-injected rotary screw compressors
2009 - 08
No. 9096 3313 00
www.atlascopco.com
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 meets the requirements for instructions specified by the machinery
directive 98/37/EC and is valid for CE as well as non-CE labelled machines
Instruction book
GA 55+, GA 75+, GA 90
From serial No. PNA922285

5
Instructionbook
9096331300
Table of contents
1 Safety precautions............................................................................................10
1.1 SAFETY ICONS........................................................................................................10
1.2 SAFETY PRECAUTIONS DURING INSTALLATION................................................................. 10
1.3 SAFETY PRECAUTIONS DURING OPERATION....................................................................12
1.4 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR.................................................... 13
2 Generaldescription............................................................................................. 15
2.1 INTRODUCTION ......................................................................................................... 15
2.2 AIR FLOW................................................................................................................ 19
2.3 OIL SYSTEM ............................................................................................................. 21
2.4 COOLING SYSTEM...................................................................................................... 22
2.5 CONDENSATE SYSTEM ................................................................................................ 24
2.6 REGULATING SYSTEM .................................................................................................. 25
2.7 ELECTRICAL SYSTEM .................................................................................................. 26
2.8 ELECTRICAL DIAGRAMS ............................................................................................... 28
2.9 AIR DRYER .............................................................................................................. 32
3 ElektronikonGraphiccontroller ......................................................................... 34
3.1 ELEKTRONIKON GRAPHIC REGULATOR ........................................................................... 34
3.2 CONTROL PANEL ...................................................................................................... 36
3.3 ICON USED ............................................................................................................. 37
3.4 MAIN SCREEN MENU .................................................................................................. 40
3.5 CALLING UP MENUS................................................................................................... 42
3.6 INPUTS MENU .......................................................................................................... 43
3.7 OUTPUTS MENU......................................................................................................45
3.8 COUNTERS .............................................................................................................. 47
3.9 SETTINGS MENU ....................................................................................................... 49
3.10 SERVICE MENU ......................................................................................................... 50
3.11 SETPOINT MENU ....................................................................................................... 54

6
Instructionbook
9096331300
3.12 EVENT HISTORY MENU ................................................................................................ 57
3.13 MODIFYING GENERAL SETTINGS ................................................................................... 58
3.14 INFO MENU .............................................................................................................. 60
3.15 WEEK TIMER MENU ................................................................................................... 61
3.16 TEST MENU.............................................................................................................. 65
3.17 USER PASSWORD MENU.............................................................................................. 66
3.18 PROGRAMMABLE SETTINGS .......................................................................................... 67
4 OSCi(optional)....................................................................................................71
4.1 INTRODUCTION ......................................................................................................... 71
4.2 OPERATIONAL ........................................................................................................... 72
4.3 PUTTING INTO OPERATION (COMMISSIONING) ................................................................... 77
4.4 PICTOGRAPHS .......................................................................................................... 78
4.5 ELEKTRONIKON DISPLAY AND WARNNGS.......................................................................... 78
4.6 DATA DISPLAYED DURING NORMAL OPETATION ................................................................... 79
4.7 WARNING ............................................................................................................... 80
4.8 MAINTENANCE .......................................................................................................... 82
4.9 SERVICES KITS ......................................................................................................... 85
4.10 PROBLEM SOLVING .................................................................................................... 85
5 Energy recovery(optional) ................................................................................. 88
5.1 ENERGY RECOVERY UNIT ............................................................................................ 88
5.2 ENERGY RECOVERY SYSTEMS ....................................................................................... 89
5.3 OPERATION .............................................................................................................. 90
5.4 MAINTENANCE .......................................................................................................... 93
5.5 ENERGY RECOVERY DATA ............................................................................................ 94
6 Installation ........................................................................................................... 96
6.1 DIMENSION DRAWINGS................................................................................................ 96
6.2 INSTALLATION PROPOSAL ............................................................................................. 98
6.3 ELECTRICAL CONNECTIONS.....................................................................................100
6.4 COOLING WATER REQUIREMENTS...............................................................................102

7
Instructionbook
9096331300
6.5 PICTOGRAPHS......................................................................................................105
7 Operating instructions....................................................................................107
7.1 BEFORE INITIAL START-UP........................................................................................107
7.2 INITIAL START-UP...................................................................................................108
7.3 BEFORE STARTING.................................................................................................111
7.4 STARTING............................................................................................................112
7.5 DURING OPERATION...............................................................................................114
7.6 CHECKING THE DISPLAY..........................................................................................116
7.7 STOPPING...........................................................................................................117
7.8 TAKING OUT OF OPERATION......................................................................................117
8 Maintenance..................................................................................................119
8.1 PREVENTIVE MAINTENANCE SCHEDULE........................................................................119
8.2 DRIVE MOTOR .....................................................................................................121
8.3 OIL SPECIFICATIONS..............................................................................................122
8.4 OIL AND OIL FILTER CHANGE....................................................................................122
8.5 DISPOSAL OF USED MATERIAL...................................................................................124
8.6 STORAGE AFTER INSTALLATION..................................................................................124
8.7 SERVICE KITS......................................................................................................125
9 Adjustments and servicing procedures ..........................................................126
9.1 AIR FILTER..........................................................................................................126
9.2 COOLERS ..........................................................................................................127
9.3 SAFETY VALVES.....................................................................................................128
10 Problem solving.............................................................................................129
10.1 PROBLEM SOLVING.................................................................................................129
11 Technical Data ................................................................................................132

8
Instructionbook
9096331300
11.1 READINGS ON DISPLAY............................................................................................132
11.2 ELECTRIC CABLE SIZE AND MAIN FUSES...................................................................... 133
11.3 SETTINGS OF FAN MOTOR CIRCUIT BREAKER................................................................ 134
11.4 SETTINGS FOR MOTOR OVERLOAD RELAY..................................................................... 134
11.5 DRYER SWITCHES................................................................................................ 135
11.6 RERERENCE CONDITIONS AND LIMITATIONS.................................................................. 135
11.7 COMPRESSOR DATA.............................................................................................. 136
11.8 TECHNICAL DATA ELEKTRONIKON CONTROLLER............................................................ 141
12 Instruction for use of air receiver....................................................................143
12.1 INSTRUCTIONS FOR USE.........................................................................................143
13 Guideline for instruction.................................................................................144
13.1 GUIDELINES FOR INSPECTION................................................................................. 144

10
Instructionbook
9096331300
1 Safety precautions
1.1 Safety icons
Explanation
1.2 Safetyprecautionsduringinstallation
General 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
shallapply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained,
specialised 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 depressurise the compressor. In addition,
the power isolating switch must be opened and locked.
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.
Danger for file
Warning
Important note
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.