Atlas Copco GA15 User manual

Atlas Copco
Oil-injected rotary screw compressors
GA 15, GA 18, GA 22
Instruction book

Atlas Copco
Oil-injected rotary screw compressors
GA 15, GA 18, GA 22
From following serial No. onwards: API 459 000
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.
2010 - 03
No. 2920 7083 31
Replaces No. 2920 7083 30
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................7
1.1 SAFETY ICONS...................................................................................................................................7
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................7
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................7
1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................9
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR.........................................................................10
2 General description......................................................................................................12
2.1 INTRODUCTION.................................................................................................................................12
2.2 AIR FLOW.......................................................................................................................................15
2.3 OIL SYSTEM....................................................................................................................................17
2.4 COOLING SYSTEM.............................................................................................................................19
2.5 CONDENSATE SYSTEM.......................................................................................................................20
2.6 REGULATING SYSTEM........................................................................................................................21
2.7 ELECTRICAL SYSTEM.........................................................................................................................22
2.8 ELECTRICAL DIAGRAMS......................................................................................................................23
2.9 AIR DRYER......................................................................................................................................25
3 Elektronikon® controller..............................................................................................26
3.1 ELEKTRONIKON® REGULATOR.............................................................................................................26
3.2 CONTROL PANEL..............................................................................................................................27
3.3 ICONS USED ON THE DISPLAY..............................................................................................................28
3.4 MAIN SCREEN..................................................................................................................................30
3.5 SHUT-DOWN WARNING.......................................................................................................................30
3.6 SHUT-DOWN....................................................................................................................................32
3.7 SERVICE WARNING............................................................................................................................33
3.8 SCROLLING THROUGH ALL SCREENS.....................................................................................................35
3.9 CALLING UP OUTLET AND DEWPOINT TEMPERATURES...............................................................................38
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3.10 CALLING UP RUNNING HOURS..............................................................................................................39
3.11 CALLING UP MOTOR STARTS...............................................................................................................40
3.12 CALLING UP MODULE HOURS...............................................................................................................41
3.13 CALLING UP LOADING HOURS..............................................................................................................41
3.14 CALLING UP LOAD RELAY...................................................................................................................41
3.15 CALLING UP/RESETTING THE SERVICE TIMER .........................................................................................42
3.16 SELECTION BETWEEN LOCAL, REMOTE OR LAN CONTROL........................................................................43
3.17 CALLING UP/MODIFYING CAN ADDRESS CONTROL..................................................................................43
3.18 CALLING UP/MODIFYING IP, GATEWAY AND SUBNETMASK........................................................................45
3.19 CALLING UP/MODIFYING PRESSURE BAND SETTINGS.................................................................................47
3.20 MODIFYING THE PRESSURE BAND SELECTION.........................................................................................48
3.21 CALLING UP/MODIFYING SERVICE TIMER SETTINGS...................................................................................49
3.22 CALLING UP/MODIFYING THE UNIT OF TEMPERATURE................................................................................49
3.23 CALLING UP/MODIFYING UNIT OF PRESSURE...........................................................................................50
3.24 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE......................................................................50
3.25 SELECTION BETWEEN Y-D OR DOL STARTING......................................................................................50
3.26 CALLING UP MODIFYING LOAD DELAY TIME.............................................................................................51
3.27 CALLING UP MODIFYING MINIMUM STOP TIME..........................................................................................51
3.28 ACTIVATING PASSWORD PROTECTION...................................................................................................52
3.29 ACTIVATE LOAD/UNLOAD REMOTE PRESSURE SENSING.............................................................................52
3.30 CALLING UP/MODIFYING PROTECTION SETTINGS......................................................................................53
3.31 TEST SCREENS................................................................................................................................55
3.32 WEB SERVER..................................................................................................................................56
3.33 PROGRAMMABLE SETTINGS.................................................................................................................64
4 Elektronikon® Graphic controller...............................................................................68
4.1 ELEKTRONIKON® GRAPHIC CONTROLLER...............................................................................................68
4.2 CONTROL PANEL..............................................................................................................................70
4.3 ICONS USED....................................................................................................................................71
4.4 MAIN SCREEN..................................................................................................................................74
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4.5 CALLING UP MENUS..........................................................................................................................76
4.6 INPUTS MENU...................................................................................................................................77
4.7 OUTPUTS MENU...............................................................................................................................78
4.8 COUNTERS......................................................................................................................................80
4.9 SERVICE MENU................................................................................................................................81
4.10 SETPOINT MENU...............................................................................................................................85
4.11 EVENT HISTORY MENU.......................................................................................................................87
4.12 MODIFYING GENERAL SETTINGS...........................................................................................................88
4.13 INFO MENU......................................................................................................................................89
4.14 WEEK TIMER MENU...........................................................................................................................90
4.15 TEST MENU.....................................................................................................................................99
4.16 USER PASSWORD MENU...................................................................................................................100
4.17 WEB SERVER................................................................................................................................101
4.18 PROGRAMMABLE SETTINGS...............................................................................................................109
5 Installation...................................................................................................................113
5.1 DIMENSION DRAWINGS.....................................................................................................................113
5.2 INSTALLATION PROPOSAL.................................................................................................................117
5.3 ELECTRICAL CONNECTIONS...............................................................................................................119
5.4 PICTOGRAPHS...............................................................................................................................120
6 Operating instructions...............................................................................................122
6.1 INITIAL START-UP............................................................................................................................122
6.2 BEFORE STARTING..........................................................................................................................125
6.3 STARTING ....................................................................................................................................125
6.4 DURING OPERATION........................................................................................................................126
6.5 CHECKING THE DISPLAY...................................................................................................................128
6.6 STOPPING ....................................................................................................................................129
6.7 TAKING OUT OF OPERATION..............................................................................................................130
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7 Maintenance................................................................................................................131
7.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................131
7.2 OIL SPECIFICATIONS........................................................................................................................133
7.3 STORAGE AFTER INSTALLATION.........................................................................................................134
7.4 SERVICE KITS................................................................................................................................134
7.5 DISPOSAL OF USED MATERIAL...........................................................................................................135
8 Adjustments and servicing procedures...................................................................136
8.1 DRIVE MOTOR ...............................................................................................................................136
8.2 AIR FILTER....................................................................................................................................136
8.3 OIL AND OIL FILTER CHANGE.............................................................................................................137
8.4 OIL SEPARATOR CHANGE.................................................................................................................138
8.5 COOLERS.....................................................................................................................................139
8.6 SAFETY VALVES.............................................................................................................................139
8.7 DRYER MAINTENANCE INSTRUCTIONS..................................................................................................140
9 Problem solving..........................................................................................................142
10 Technical data.............................................................................................................145
10.1 READINGS ON DISPLAY....................................................................................................................145
10.2 ELECTRIC CABLE SIZE AND MAIN FUSES..............................................................................................146
10.3 SETTINGS FOR MOTOR OVERLOAD RELAY............................................................................................148
10.4 DRYER SWITCHES...........................................................................................................................148
10.5 REFERENCE CONDITIONS AND LIMITATIONS..........................................................................................149
10.6 COMPRESSOR DATA FOR GA 15 UP TO GA 22..................................................................................149
10.7 TECHNICAL DATA ELEKTRONIKON® CONTROLLER..................................................................................154
11 Instructions for use....................................................................................................156
12 Guidelines for inspection...........................................................................................157
13 Pressure equipment directives.................................................................................158
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14 Declaration of conformity..........................................................................................159
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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.
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 roof of the compressor canopy.
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.
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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. 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.
3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead
to internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that the isolating switch is open and locked
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.
10. 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.
11. 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.
12. 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.
13. 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.
14. 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.
15. Piping or other parts with a temperature in excess of 80˚C (176˚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.
16. 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.
17. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
Also consult following safety precautions: Safety precautions during operation and 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.
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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 compressor during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make 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 compressors without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure-relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free
of wear or abuse
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. Do not remove any of, or tamper with, the sound-damping material.
11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be
protected by a pressure-relieving device or devices as required.
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.
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2920 7083 31 9

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.
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 before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify,
pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, 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.
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. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use
breathing protection.
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• 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 7083 31 11

2 General description
2.1 Introduction
GA 15 up to GA 22 are single-stage, oil-injected screw compressors driven by an electric motor. The
compressors are air-cooled.
The compressors are controlled by an Elektronikon® controller.
GA Pack
GA Pack are enclosed in a sound-insulated bodywork. The compressors are controlled by an Elektronikon®
controller (standard version) or by an Elektronikon® Graphic controller (optional). The controller module is
fitted to the door on the front side. An electric cabinet comprising the motor starter is located behind this
panel.
Floor-mounted compressors are directly installed on the floor:
Front view, GA 15 up to GA 22 Floor-mounted Pack
Tank-mounted compressors are mounted on a large air receiver (AR) of 500 l (125 gal, 4.5 cu.ft):
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Front view, GA 15 up to GA 22 Tank-mounted Pack
GA Full-Feature
GA Full-Feature (FF) are controlled by an Atlas Copco Elektronikon® controller (standard version) or by an
Elektronikon® Graphic controller (optional). They are provided with an air dryer, integrated in the sound-
insulated bodywork. The dryer removes condensate from the compressed air by cooling the air to near freezing
point and automatically draining the condensate.
Floor-mounted compressors are directly installed on the floor:
Front view, GA 15 up to GA 22 Floor-mounted Full-Feature
Tank-mounted compressors are mounted on a large air receiver (AR) of 500 l (125 gal, 4.5 cu.ft):
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Front view, GA 15 up to GA 22 Tank-mounted Full-Feature
Reference Name
AF Air filter
AR Air receiver
AV Air outlet valve
Ca Air cooler
Co Oil cooler
Dm1 Manual drain, air receiver
DR Dryer
ER1 Elektronikon® controller (standard) or Elektronikon® Graphic controller (optional)
M1 Motor
MT Condensate trap (GA Pack)
OF Oil filter
OS Oil separator cartridge
OT Oil separator tank
S3 Emergency stop button
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2.2 Air flow
Flow diagrams
Flow diagram, GA Pack
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Flow diagram, GA 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.
Compressed air and oil flow into the oil tank (OT). The air is discharged through outlet valve (AV) via
minimum pressure valve (Vp) and air cooler (Ca).
During loaded operation, minimum pressure valve (Vp) keeps the pressure in the separator tank (OT) 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, inlet valve (IV) closes, preventing compressed air and oil to be vented into
the air filter.
A condensate trap (MT) downstream the air cooler is included.
On Full-Feature compressors, the air flows through air dryer (DR) before it is discharged through outlet valve
(AV). Also see section Air dryer .
2.3 Oil system
Flow diagram
Oil system
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References Description
1 Compressed air flow towards the condensate trap (Pack units).
Compressed air flow to the air dryer (compressors with integrated dryer)
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
Description
In oil tank (OT) most of the oil is removed from the air/oil mixture by centrifugal action. The rest is removed
by oil separator (OS). The oil collects in the lower part of oil tank (OT).
Air pressure forces the oil from oil tank (OT) through oil cooler (Co) and filter (OF) to compressor element
(E).
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.
Thermostatic 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.
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