Atlas Copco GA 7 VSD+ User manual

Atlas Copco
Oil-injected rotary screw compressors
GA 7 VSD+, GA 11 VSD+, GA 15 VSD+
Instruction book

Atlas Copco
Oil-injected rotary screw compressors
GA 7 VSD+, GA 11 VSD+, GA 15 VSD+
From following serial No. onwards: API 250 000
Instruction book
Original instructions
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.
2015 - 01
No. 2920 7109 23
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................5
1.1 SAFETY ICONS................................................................................................................................... 5
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................5
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................6
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 7
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 8
2 General description......................................................................................................10
2.1 INTRODUCTION.................................................................................................................................10
2.2 FLOW DIAGRAM................................................................................................................................14
2.3 CONDENSATE SYSTEM.......................................................................................................................16
2.4 REGULATING SYSTEM........................................................................................................................ 18
2.5 ELECTRICAL SYSTEM.........................................................................................................................18
2.6 AIR DRYER......................................................................................................................................20
3 Elektronikon® Graphic controller............................................................................... 22
3.1 ELEKTRONIKON® GRAPHIC CONTROLLER...............................................................................................22
3.2 CONTROL PANEL.............................................................................................................................. 24
3.3 ICONS USED.................................................................................................................................... 25
3.4 MAIN SCREEN..................................................................................................................................29
3.5 CALLING UP MENUS.......................................................................................................................... 33
3.6 INPUTS MENU...................................................................................................................................34
3.7 OUTPUTS MENU............................................................................................................................... 36
3.8 COUNTERS......................................................................................................................................38
3.9 CONTROL MODE SELECTION................................................................................................................40
3.10 SERVICE MENU................................................................................................................................ 41
3.11 MODIFYING THE SETPOINT..................................................................................................................45
3.12 EVENT HISTORY MENU.......................................................................................................................47
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3.13 MODIFYING GENERAL SETTINGS...........................................................................................................48
3.14 INFO MENU......................................................................................................................................50
3.15 WEEK TIMER MENU...........................................................................................................................51
3.16 TEST MENU..................................................................................................................................... 60
3.17 USER PASSWORD MENU.....................................................................................................................61
3.18 WEB SERVER.................................................................................................................................. 62
3.19 PROGRAMMABLE SETTINGS.................................................................................................................70
4 Installation.....................................................................................................................73
4.1 DIMENSION DRAWINGS.......................................................................................................................73
4.2 INSTALLATION PROPOSAL................................................................................................................... 76
4.3 ELECTRICAL CONNECTIONS.................................................................................................................78
4.4 PICTOGRAPHS................................................................................................................................. 81
5 Options.......................................................................................................................... 82
5.1 ENERGY RECOVERY.......................................................................................................................... 82
5.2 MAIN SWITCH.................................................................................................................................. 95
6 Operating instructions................................................................................................. 97
7 Maintenance................................................................................................................102
7.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................102
7.2 OIL SPECIFICATIONS........................................................................................................................105
7.3 DRIVE MOTOR ...............................................................................................................................106
7.4 AIR FILTER....................................................................................................................................106
7.5 OIL, OIL FILTER AND OIL SEPARATOR CHANGE...................................................................................... 107
7.6 COOLERS..................................................................................................................................... 109
7.7 DRYER MAINTENANCE INSTRUCTIONS..................................................................................................110
7.8 SAFETY VALVES............................................................................................................................. 111
7.9 DD/PD FILTERS SERVICE INTERVALS.................................................................................................111
7.10 SERVICE KITS................................................................................................................................ 112
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7.11 STORAGE AFTER INSTALLATION......................................................................................................... 112
7.12 DISPOSAL OF USED MATERIAL........................................................................................................... 112
8 Problem solving..........................................................................................................113
9 Technical data.............................................................................................................118
9.1 READINGS ON DISPLAY.................................................................................................................... 118
9.2 ELECTRIC CABLE SIZE AND FUSES......................................................................................................119
9.3 REFERENCE CONDITIONS AND LIMITATIONS.......................................................................................... 124
9.4 COMPRESSOR DATA........................................................................................................................125
9.5 TECHNICAL DATA ELEKTRONIKON® CONTROLLER..................................................................................127
10 Instructions for use.................................................................................................... 129
11 Guidelines for inspection...........................................................................................130
12 Pressure equipment directives................................................................................. 131
13 Declaration of conformity.......................................................................................... 132
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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
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.
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, the power isolating switch must be opened and locked.
The units are powered by a frequency converter, wait 10 minutes before starting any electrical repair.
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!
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 not allowed to walk or stand on the unit or on its components.
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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.
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.
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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
• 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
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• 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.
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.
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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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2920 7109 23 9

2 General description
2.1 Introduction
Introduction
GA 7 VSD+ up to GA 15 VSD+ are single-stage, oil-injected screw compressors driven by an interior
permanent magnet motor (iPM motor).
The compressors are controlled by the Atlas Copco Elektronikon® Graphic regulator (ER).
The regulator is fitted to the front panel. An electric cabinet (1) comprising fuses, transformers, relays, etc.
is located behind this panel.
The compressors use VSD (Variable Speed Drive) technology. This means: automatic adjustment of the
motor speed, depending on the compressed air demand.
The compressors are air-cooled and are enclosed in a sound-insulated bodywork.
GA Workplace
Front view, GA VSD+ Workplace
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Open side view, GA VSD+ Workplace
GA Workplace Full-Feature
The Workplace Full Feature compressors have 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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Front view, GA VSD+ Workplace Full-Feature
Open side view, GA VSD+ Workplace Full-Feature
Reference Name
AF Air filter
AR Air receiver
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Reference Name
AV Air outlet
Ca Air cooler
Co Oil cooler
Da Automatic condensate outlet
Dm Manual condensate outlet
DR Refrigerant dryer
E Compressor element
ED Electronic water drain
ER Elektronikon® Graphic controller
FN Cooling fan
IPM Drive motor
OF Oil filter
OS Oil separator
S3 Emergency stop button
1 Electric cabinet
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2.2 Flow diagram
GA 7 VSD+ up to GA 15 VSD+ Workplace
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GA 7 VSD+ up to GA 15 VSD+ Workplace Full-Feature
Reference Description
A Air inlet
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate
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Reference Description
F Dry compressed air (Full-Feature)
Air flow
Air comes in through filter (AF) and inlet valve (IV) and is compressed in the compressor element (E).
A mixture of compressed air and oil flows into the air receiver/oil separator (AR).
The air flows through the minimum pressure valve (Vp), the air cooler (Ca) and the condensate trap (MT)
to the outlet valve (AV).
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 have a dryer (DR) after the air cooler.
Oil circuit
The air receiver (AR) removes most of the oil from the air/oil mixture by centrifugal action. The oil
separator (OS) removes the remaining oil. The oil collects in the lower part of the air receiver (AR) which
serves as oil tank.
The oil system has a thermostatic bypass valve (BV).
When the oil temperature is below 71 ˚C (160 ˚F), the bypass valve shuts off the oil supply from the oil
cooler (Co).
Air pressure forces the oil from air receiver (AR) through the oil filter (OF). The oil cooler (Co) is
bypassed.
When the oil temperature has increased up to 71˚C (160 ˚F), bypass valve (BV) starts opening the supply
from the oil cooler (Co). At approximately 85˚C (185 ˚F), all the oil flows through the oil cooler.
The filtered oil flows through the cooling channels of the interior permanent magnet (iPM) motor to the
compressor element (E).
Cooling
The cooling system has an air cooler (Ca) and an oil cooler (Co).
The fan (FN) blows air over the coolers. This fan is set on and off, depending on the operating conditions,
according to a specific algorithm.
2.3 Condensate system
Drain connections
The compressors have an electronic water drain (ED).
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Location of electronic water drain (Workplace)
Location of electronic water drain (Workplace Full-Feature)
On GA Workplace units, the water in the air condenses and collects in the collector of the air cooler.
On a GA Workplace Full-Feature, the water in the air collects in the water separator of the heat exchanger/
evaporator.
When the condensate in the electronic drain (ED) reaches a certain level, it is drained via the automatic
drain outlet (Da).
Condensate drain connections, GA Workplace
Reference Designation
Da Automatic drain connection
Dm Manual drain connection
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Electronic water drain (ED), typical example
To test the electronic water drain, press the Test button (2) on top of the device.
2.4 Regulating system
Description
When the compressor is started and the net pressure is below the setpoint, the motor speed increases until
the net pressure reaches the setpoint or until the maximum motor speed is reached.
If the air consumption is less than the air delivery of the compressor, the net pressure increases further.
When the net pressure reaches the setpoint (desired net pressure) and continues to rise, the regulator
decreases the motor speed.
When the pressure continues to increase although the motor already operates at minimum speed, the
regulator stops the motor as soon the net pressure reaches a value, equal to the setpoint plus the indirect
stop level (typically 0.3 bar above the setpoint, see section Programmable settings).
Should the net pressure rise very quickly to a value equal to the setpoint plus the direct stop level (typically
1 bar above the setpoint, see section Programmable settings), the compressor is stopped immediately
(without first decreasing the motor speed).
No compressed air is lost when the compressor is stopped in automatic operation, thus saving valuable
energy.
If the compressor was stopped in automatic operation and the net pressure approaches the setpoint, the
regulator starts the motor again. The quicker the net pressure drops, the quicker the compressor will restart.
The pressure in the oil separator vessel is only released to atmosphere when the
compressor is stopped manually or in case of an emergency stop (see chapter Stopping
in section Operating Instructions).
2.5 Electrical system
Electric components
The electrical system has following components:
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