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Atlas Copco GA 37 VSD Instruction Book
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Atlas Copco GA 37 VSD Instruction Book

Atlas Copco GA 37 VSD Instruction Book

Oil-injected rotary screw compressors
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Oil-injected rotary screw compressors

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GRAEME SANDER
March 20, 2025

WHAT IS THE CAUSE OF THE CHECK VALVE/OIL STOP VALVE DISCHARGING EXCESSIVE OIL UP INTO THE AIR FILTER PIPE ON THE GA37VSD

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Summary of Contents for Atlas Copco GA 37 VSD

  • Page 1 Oil-injected rotary screw compressors...
  • Page 3 Oil-injected rotary screw compressors GA 37 VSD, GA 45 VSD Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. This instruction book is valid for CE as well as non-CE labelled machines. It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity.
  • Page 5 Instruction book SAFETY ICONS ........................6 SAFETY PRECAUTIONS, GENERAL ..................6 SAFETY PRECAUTIONS DURING INSTALLATION ..............7 SAFETY PRECAUTIONS DURING OPERATION ..............9 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ......... 10 INTRODUCTION ........................13 AIR FLOW ..........................17 OIL SYSTEM .......................... 19 COOLING SYSTEM .......................
  • Page 6 Instruction book ENERGY RECOVERY UNIT ....................82 ENERGY RECOVERY SYSTEMS..................83 OPERATION .......................... 84 MAINTENANCE ........................88 ENERGY RECOVERY DATA ....................88 DIMENSION DRAWINGS ....................... 90 INSTALLATION PROPOSAL ....................92 ELECTRICAL CONNECTIONS ....................95 COOLING WATER REQUIREMENTS ..................97 PICTOGRAPHS ........................102 BEFORE INITIAL START-UP ....................103 BEFORE STARTING ......................106 STARTING ..........................107...
  • Page 7 Instruction book 7.10 DRAINING CONDENSATE FROM THE OIL TANK ...............122 7.11 STORAGE AFTER INSTALLATION ..................123 7.12 DISPOSAL OF USED MATERIAL ..................123 READINGS ON DISPLAY .....................129 ELECTRIC CABLE SIZE AND MAIN FUSES ................129 PROTECTION SETTINGS ....................133 1904 0504 83...
  • Page 8 In addition to normal safety rules, which should be observed with stationary air compressor and equipment, the following safety directions and precautions are of special importance. Any modification on the compressor shall only be performed in agreement with Atlas copco and under stricter of the two shall apply The operator must employ safe working practices and observe all related work safety requirements and regulations.
  • Page 9 A compressor shall be lifted only with adequate equipment in conformity with local safety rules. Please consult Atlas Copco to check if a dedicated lifting devise is designed for this purpose. Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load.
  • Page 10 Instruction book electrical isolating switch is open, locked and labeled with a temporary warning before any maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine.
  • Page 11 Instruction book Verify that all tubes are secure in their fittings to insure that none might leak or come loose when the compressor is in operation. After inspection, the power can be put to the installed compressor. With the proper power applied, the rotation of the compressor and the cooling fan can be verified.
  • Page 12 Instruction book 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 •...
  • Page 13 Instruction book Before removing any pressurized component, effectively isolate the unit from all sources of pressure and relieve the entire system of pressure and electrical power. Take positive precaution to ensure that the unit cannot be started inadvertently. In addition, a warning sign bearing a legend such as shall be attached to the starting equipment...
  • Page 14 Instruction book Replace all consumables at recommended service intervals or sooner if operating conditions several / warrant or replace every 12 months. Make sure that all sound –damping material, e.g. on the bodywork and in the air inlet and outlet systems of the compressor, is in good condition.
  • Page 15 Instruction book GA 37 VSD up to GA 45 VSD are single-stage, oil-injected screw compressors driven by an electric motor. The compressors are enclosed in a sound-insulated bodywork and are available in air-cooled and water cooled version. The compressors are controlled by the Atlas Copco Elektronikon® Graphic regulator.
  • Page 16 Instruction book Air filter Air receiver Air outlet valve Air cooler Oil cooler CV/Vs Check valve/oil stop valve Automatic condensate outlet Compressor element Elektronikon® Graphic controller Cooling fan Drive motor Emergency stop button Vent plug Electric cabinet 1904 0504 83...
  • Page 17 Instruction book The Workplace Full Feature compressors are provided with an air dryer which is integrated in the sound insulated bodywork. The dryer removes condensate from the compressed air by cooling the air to near freezing point. 1904 0504 83...
  • Page 18 Instruction book Air outlet valve Air cooler Oil cooler CV/Vs Check valve/oil stop valve Automatic condensate outlet Manual condensate outlet Compressor element Elektronikon®/Elektronikon® Graphic controller Cooling fan Drive motor Unloader 1904 0504 83...
  • Page 19 Instruction book 1904 0504 83...
  • Page 20 Instruction book GA 37 VSD and GA 45 VSD Workplace Full-Feature Intake air Air/oil mixture Wet compressed air Condensate Dried compressed air (Full-Feature) The cooling fan (FN) is not provided on water-cooled compressors. Air drawn in through filter (AF) and check valve (CV) is compressed in compressor element (E).
  • Page 21 Instruction book Intake air Air/oil mixture Wet compressed air To the air outlet valve in case of a Workplace version. To the dryer in case of a Workplace Full-Feature version. The cooling fan (FN) is not provided on water-cooled compressors. In air receiver (AR) most of the oil is removed from the air/oil mixture by centrifugal action.
  • Page 22 Instruction book Intake air Air/oil mixture Wet compressed air Condensate The cooling system on air-cooled compressors comprises air cooler (Ca) and oil cooler (Co). The cooling air flow is generated by fan (FN). This cooling fan is switched on and off depending on the operating conditions according a specific algorithm 1904 0504 83...
  • Page 23 Instruction book Intake air Air/oil mixture Wet compressed air Water flow The cooling system on water-cooled compressors comprises air cooler (Cwa) and oil cooler (Cwo). They are connected to a cooling water circuit. The water flows through the inlet pipe, the coolers and the outlet pipe.
  • Page 24 Instruction book The compressors have an centrifugal water separator WSD25 (1). The condensate formed in the air cooler accumulates in the collector. When the condensate reaches a certain level, it is discharged through the automatic drain outlet (Da). Also, the condensate water can be discharged manually through the manual drain outlet (Dm).
  • Page 25 Instruction book If the consumption is less than the air output of the compressor, the net pressure increases. When the net pressure is higher than the set-point (desired net pressure), the regulator will decrease the motor speed. If the net pressure keeps on rising when the motor runs at minimum speed, the regulator stops the motor.
  • Page 26 Instruction book Air inlet Air outlet Air/air heat exchanger Air/refrigerant heat exchanger/evaporator Condensate separator Automatic drain / condensate outlet Refrigerant compressor Refrigerant condenser Liquid refrigerant dryer/filter Capillary Bypass valve Condenser cooling fan Pressure switch, fan control Liquid separator Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the incoming air starts to condense.
  • Page 27 Instruction book Refrigeration dryers of ID type contain high efficient refrigerant R410A of the HFC group Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most of the refrigerant condenses. The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to capillary tube (8). The refrigerant leaves the capillary tube at about evaporating pressure.
  • Page 28 Instruction book It is important to follow all regulations regarding the use of radio equipment, in particular regarding the possibility of radio frequency (RF) interference. Please follow the safety advice given below carefully. Respect restrictions on the use of radio equipment in fuel depots, chemical plants or other •...
  • Page 29 LINK Service rules out all uncertainties. Scheduling maintenance visits becomes as simple and easy as it should be; the service log book is always just one click away and the online link with Atlas Copco allows to request and quickly receive quotes for spare parts or additional services.
  • Page 30 Instruction book Controlling the compressor Protecting the compressor Monitoring components subject to service Automatic restart after voltage failure (made inactive) The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor (on compressors running at a fixed speed) or by adapting the motor speed (compressors with frequency converter).
  • Page 31 The regulator has a built-in function to automatically restart the compressor if the voltage is restored after voltage failure. For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. If activated and provided the regulator was in the automatic operation mode, the compressor will automatically restart if the supply voltage to the module is restored .
  • Page 32 Instruction book Shows the compressor operating condition and a number of icons Display to navigate through the menu. Pictograph Automatic operation Pictograph General alarm General Flashes if a shut-down warning condition exists. alarm LED Pictograph Service Service LED Lights up if service is needed Automatic Indicates that the regulator is automatically controlling the operation...
  • Page 33 Instruction book When the compressor is stopped, the icon stands Stopped / Running still. When the compressor is running, the icon is rotating. Compressor status Motor stopped Running unloaded Running loaded Machine control mode Local start / stop Remote start / stop Network control Automatic restart after voltage Automatic restart after voltage failure is active...
  • Page 34 Instruction book Service Service required Main screen display Value lines display icon Chart display icon General icons No communication / network problem Not valid Pressure temperature Digital input Special protection Compressor element (LP, HP, ...) Dryer 1904 0504 83...
  • Page 35 Instruction book Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Inputs Outputs Alarms (Warnings, shutdowns) Counters Test Settings Service 1904 0504 83...
  • Page 36 Instruction book Saved data Access key / User password Network Setpoint Info Down 1904 0504 83...
  • Page 37 Instruction book Scroll keys Enter key Escape key The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed. Typically, 5 different main screen views can be chosen: 1.
  • Page 38 Instruction book Text on figures Compressor Outlet Flow Load, shutdown, ... (text varies upon the compressors actual condition) Menu Unload, ES,...(text varies upon the compressors actual condition) Text on figures Compressor Outlet Flow Off, Shutdown,... (text varies upon the compressors actual condition) Menu Running hours Element outlet...
  • Page 39 Instruction book • shows the Action buttons. These buttons are used: • To call up or program settings • To reset a motor overload, service message or emergency stop • To have access to all data collected by the regulator The function of the buttons depends on the displayed menu.
  • Page 40 Instruction book When the Chart (Low Resolution) is selected, the chart shows the variation of the selected input per day. The screen shows the evolution over the last 10 days. To change between the different screen layouts, select the far right icon in the control icons line (see value lines display icon or chart display icon in section Icons used) and press the Enter key.
  • Page 41 Instruction book Scroll keys Enter key Escape key When the voltage is switched on, the main screen is shown automatically. To go to the Menu screen, select <Menu> (3), using the Scroll keys Press the Enter key to select the menu. Following screen appears: 1904 0504 83...
  • Page 42 Instruction book • The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings (Regulation) icon is selected. The status bar shows the name of the menu that corresponds with the selected icon. •...
  • Page 43 Instruction book Starting from the Main screen (see Main screen): Move the cursor to the action button Menu and press the enter key , following screen appears: Text on figure Menu Regulation Using the scroll keys, move the cursor to the inputs icon (see above, section Menu icon) Press the enter key, a screen similar to the one below appears: Inputs Compressor outlet...
  • Page 44 Instruction book The first item in the list is highlighted. In this example, the Net Pressure is selected (chart icon). To change, press the Enter button again: a pop-up window opens: Press Enter again to remove this input from the chart. Another confirmation pop-up opens: Select Yes to remove or No to quit the current action.
  • Page 45 Instruction book To call up information regarding the actually measured data and the status of some inputs such as the motor overload protection. Starting from the Main screen (see Main screen): Move the cursor to the action button Menu and press the enter key (2), following screen appears: 1904 0504 83...
  • Page 46 Instruction book Text on figure Menu Regulation Move the cursor to the outputs icon (see above, section Menu icon, using the scroll keys (1) Press the enter key (2), a screen similar to the one below appears: Outputs Fan motor contact Blow-off contact General shutdown Automatic operation...
  • Page 47 Instruction book Scroll keys Enter key Escape key To call up: The running hours The loaded hours The number of motor starts The number of hours that the regulator has been under tension The number of load cycles 1904 0504 83...
  • Page 48 Instruction book Starting from the Main screen (see Main screen): Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Menu Regulation Using the scroll keys , move the cursor to the counters icon (see above, section Menu icon) Press the enter key, following screen appears: Text on figure Counters...
  • Page 49 Instruction book Scroll keys Enter key Escape key To select the control mode, i.e. whether the compressor is in local control, remote control or controlled via a local area network (LAN). Starting from the main screen, make sure the button Menu (1) is selected: 1904 0504 83...
  • Page 50 Instruction book Next, use the scroll buttons to go to the regulation icon (2) and press the enter button: There are 3 possibilities: • Local control • Remote control • LAN (network) control After selecting the required regulation mode, press the enter button on the controller to confirm your selection.
  • Page 51 Instruction book Scroll keys Enter key Escape key • To reset the service plans which are carried out. • To check when the next service plans are to be carried out. • To find out which service plans were carried out in the past. •...
  • Page 52 Instruction book Text on image Service Overview Service plan Next service History • Scroll through the items to select the desired item and press the Enter key to see the details as explained below. Text on image Overview Running Hours Real Time hours Reset Example for service level (A):...
  • Page 53 Instruction book From the Service menu above, select Service plan (3) and press Enter. Following screen appears: Text on image Service plan Level Running hours Real time hours Modify Dependant on the operating conditions, it can be necessary to modify the service intervals. To do so, use the Scroll keys to select the value to be modified.
  • Page 54 Instruction book Text on image Next service Level Running hours Actual In the example above, the A Service level is programmed at 4000 running hours, of which 0 hours have passed. The History screen shows a list of all service actions done in the past, sorted by date. The date at the top is the most recent service action.
  • Page 55 Instruction book Scroll keys Enter key Escape key , it is possible to program two different setpoints. This menu is also used to select the active setpoint. Starting from the Main screen, • Highlight the action key Menu using the Scroll keys and press the Enter key. Following screen appears: Text on image Menu...
  • Page 56 Instruction book Text on image Regulation Setpoint 1 Indirect stop level 1 Direct stop level 1 Setpoint 2 Modify • The screen shows the actual settings. To modify the settings, move the cursor to the action button Modify and press the Enter key.
  • Page 57 Instruction book Scroll keys Enter key Escape key To call up the last shut-down and last emergency stop data. Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: 1904 0504 83...
  • Page 58 Instruction book • Using the Scroll keys, move the cursor to the Event History icon (see above, section Menu icon) • The list of last shut-down and emergency stop cases is shown. • Scroll through the items to select the desired shut-down or emergency stop event. •...
  • Page 59 Instruction book To display and modify a number of settings. Starting from the Main screen, • Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Next, move the cursor to the Settings icon (see above, section menu icon).using the Scroll keys. •...
  • Page 60 Instruction book Text on image General Language used Time Date Date format Modify • To modify, select the Modify button using the Scroll keys and press the Enter key. • A screen similar to the one above is shown, the first item (Language) is highlighted. Use the key of the Scroll keys to select the setting to be modified and press the Enter key.
  • Page 61 • Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon). • Press the Enter key. The Atlas Copco internet address appears on the screen. Scroll keys...
  • Page 62 Instruction book • To program time-based start/stop commands for the compressor • To program time-based change-over commands for the net pressure band • Four different week schemes can be programmed. • A week cycle can be programmed, a week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week schemes can be chosen.
  • Page 63 Instruction book Week Timer Week Action Schemes Week Cycle Status Week Timer Inactive Remaining Running Time The first item in this list is highlighted in red. Select the item requested and press the Enter key on the controller to modify. •...
  • Page 64 Instruction book Friday Saturday Sunday • A new window opens. The Modify action button is selected. Press the enter button on the controller to create an action. Monday Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller.
  • Page 65 Instruction book Monday Start Save Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. Monday Start Save Modify • A pop-up window opens. Use the key of Scroll keys to modify the values of the hours. Use the Scroll keys to go to the minutes.
  • Page 66 Instruction book • Press the Escape key on the controller. The action button Modify is selected. Use the Scroll keys to select the action Save. Monday Start Save Modify • A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions.
  • Page 67 Instruction book Week Action Scheme 1 Monday - Start Tuesday Wednesday Thursday Friday Saturday Sunday Press the Escape key on the controller to leave this screen. A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week schemes can be chosen.
  • Page 68 Instruction book Week 2 Week 3 Week 4 Modify Press twice the Enter key on the controller to modify the first week. • A new window opens. Select the action, example: Week Action Scheme 1 Week Cycle Week 1 Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Modify...
  • Page 69 Instruction book Week Timer Week Week Timer Inactive Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active. Week Timer Week Action Schemes Week Cycle Status Remaining Running Time •...
  • Page 70 Instruction book Week Timer Week Action Schemes Week Cycle Status Remaining Running Time • This timer is used when the week timer is set and for certain reasons the compressor must continue working, for example, 1 hour, it can be set in this screen. This timer is prior to the Week Timer action.
  • Page 71 Instruction book • To carry out a display test, i.e. to check whether the display and LEDs are still intact. Starting from the Main screen, • Move the cursor to the action button Menu and press the enter key (2), following screen appears: •...
  • Page 72 Instruction book Scroll keys Enter key Escape key If the password option is activated, it is impossible for not authorized persons to modify any setting. Starting from the Main screen (see Main screen), • Move the cursor to <Menu> and press the Enter key (2). Following screen appears: •...
  • Page 73 Instruction book • Move the cursor to the Password icon (see above, section Menu icon) • Select <Modify> using the Scroll keys and press the Enter key. Next, modify the password as required. All Elektronikon controllers have a built-in web server that allows direct connection to the company network or to a dedicated PC via a local area network (LAN).
  • Page 74 Instruction book • Go to My Network places (1). • Click on View Network connections (1). • Select the Local Area connection (1), which is connected to the controller. • Click with the right button and select properties (1). 1904 0504 83...
  • Page 75 Instruction book • Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked. After selecting TCP/IP, click on the Properties button (2) to change the settings. • Use the following settings: •...
  • Page 76 Instruction book • Click on the Connections tab (1) and then click on the LAN settings button (2). • In the Proxy server Group box, click on the Advanced button (1). 1904 0504 83...
  • Page 77 Instruction book • In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given but they must be separated with semicolons (;). Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2).
  • Page 78 Instruction book All screen shots are indicative. The number of displayed fields depends on the selected options • Open your browser and type the IP address of the controller you want to view in your browser (in this example http://192.168.100.100). The interface opens: •...
  • Page 79 Instruction book All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and cannot be removed from the main screen. Lists all current analog input values.
  • Page 80 Instruction book Lists all Digital outputs and their status. Lists all special protections of the compressor. Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours. It is also possible to show the current status of the service interval. If an ESi license is provided, the ES button is displayed in the navigation menu.
  • Page 81 Instruction book Set-point 1 and 2, Workplace compressors bar(e) Set-point 1 and 2, Workplace compressors psig Set-point 1 and 2, Workplace Full-Feature bar(e) 12.8 compressors Set-point 1 and 2, Workplace Full-Feature psig compressors Indirect stop level Indirect stop level 1.45 4.35 14.5 Direct stop level...
  • Page 82 The built-in service timers will give a Service warning message after their respective preprogrammed time interval has elapsed. For specific data, see section Preventive Maintenance. Consult Atlas Copco if a timer setting needs to be changed. The intervals must not exceed the nominal intervals and must coincide logically. See section Modifying general settings.
  • Page 83 Minimum stop time The settings for the Proportional band and integration time are determined by Proportional experiment band and integration time Altering these settings may damage the compressor. Consult Atlas Copco. 1904 0504 83...
  • Page 84 The Atlas Copco energy recovery (ER) systems are designed to recover most of the above- mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance.
  • Page 85 The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor. Consult Atlas Copco for installing and connecting the energy recovery unit. The energy recovery systems can be applied as low temperature rise/high water flow systems or as high temperature rise/low water flow systems.
  • Page 86 Consult section Cooling water requirements to minimise problems due to bad water quality. If in any doubt, consult Atlas Copco. Add an anti-freeze product such as ethylene-glycol to the water in proportion to the expected temperature to avoid freezing.
  • Page 87 Instruction book Thermostatic bypass valve of Oil filter unit Oil/water heat exchanger (ER unit) Oil separator vessel Thermostatic bypass valve in Compressor element filter housing Oil cooler (compressor) Aftercooler (compressor) Water inlet Water outlet BV2 starts closing the bypass line over the heat exchanger (HE) at the lower limit of its temperature range.
  • Page 88 Instruction book Attention: It is only allowed to turn the handle completely in or out. No in- between position is allowed. The oil cooler bypass valve (BV1) starts closing the bypass line and opening the oil supply line from the main oil cooler (Co) at the lower limit of its temperature range.
  • Page 89 Instruction book When the compressor is started up from cold, the oil temperature will be low. Bypass valve (BV2) shuts off the oil supply from the heat exchanger (HE) and bypass valve (BV1) shuts off the oil supply from the oil cooler (Co) to prevent the compressor oil from being cooled.
  • Page 90 To clean the oil side, soak the heat exchanger in a degreasing solution. To remove scale formation in the water compartment, a proper descaling process should be applied. Consult Atlas Copco. See section Reference conditions and limitations.
  • Page 91 Instruction book If the programmed warning settings for the water temperatures are exceeded, a warning indication is shown on the Elektronikon: Water inlet temperature of energy recovery ˚C Water inlet temperature of energy recovery ˚F Energy recovery water outlet temperature ˚C Depends on application...
  • Page 92 Instruction book 1904 0504 83...
  • Page 93 Instruction book Centre of gravity GA 37 VSD GA 37 VSD GA 45 VSD GA 45 VSD Dimensions +/- 50 mm (1.97 in) Weight GA 37 VSD 1227 1142 GA 37 VSD 2705 2518 GA 45 VSD 1290 1200 GA 45 VSD...
  • Page 94 Instruction book Air cooling Water cooling The direction of the cooling flows may never be inverted 1904 0504 83...
  • Page 95 Instruction book Install the compressor unit on a solid, level floor suitable for taking the weight. Position of the compressed air outlet valve. The pressure drop over the air delivery pipe can be calculated from: p = (L x 450 x Qc ) / (d5 x P), with 1.85 d = inner diameter of the pipe in mm...
  • Page 96 The drain pipes to the drain collector must not dip into the water of the drain collector. Atlas Copco has oil/water separators (type OSD or OSCi) to separate the oil from the condensate to ensure that the condensate meets the requirements of the environmental codes.
  • Page 97 In this case, and also if operating above 1000 m (3300 ft), consult Atlas Copco. The compressor can be moved by a lift truck using the slots in the frame. Take care not to damage the bodywork during lifting or transport.
  • Page 98 Instruction book Customer's installation Option dryer Star connection: All other voltages Delta connection: 200-230V 50/60 Hz (see motor data plate for correct connection) For Modbus communication The complete electrical diagram can be found in the electrical cubicle. Provide an isolating switch. Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals.
  • Page 99 Stop the compressor and switch off the voltage before connecting external equipment. Only potential-free contacts are allowed • The compressor is controlled via a local network. Consult Atlas Copco. Cooling water needs to fulfill certain requirements in order to avoid problems of scaling, fouling, corrosion or bacterial growth.
  • Page 100 Instruction book monitoring of concentrations and properties, prevention of sludge formation and maintenance of the system. This applies also to treatment with antifreeze products. They must be provided with suitable stabilizers and inhibitors. Specifications are also depending on the type of cooling circuit (open, once through / recirculating with tower / closed) and on the application (Standard –...
  • Page 101 Instruction book The Ryznar Stability Index is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate. The adhesion of scaling depositions and their effect are different on different materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by the saturation pH value (pH ).
  • Page 102 Instruction book • RSI < 6: boiler scale formation • 6 < RSI < 7: neutral water • RSI > 7: corrosive water As a general rule, the RSI index should be between 5.6 and 7.5. If that is not the case, contact a specialist Disinfecting with chlorine is not done in closed systems, neither in energy recovery systems.
  • Page 103 Instruction book Single pass < 1 < 0.2 Recirculating (with tower) < 1 not applicable Closed loop < 1 < 0.2 The limit of is a rejection limit. The limitation only applies for copper containing systems. Large particles (size > 10 µm) should not be present as they can be filtered out.
  • Page 104 Instruction book Switch off the voltage and depressurize the compressor before starting maintenance or repairs Keep the doors closed during operation Switch off the voltage before removing protecting cover inside electric cubicle Warning, voltage Automatic condensate drain Stop the compressor before cleaning the coolers Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx.
  • Page 105 Instruction book The operator must apply all applicable Safety precautions. For the location of the air outlet valve and the drain connections, see sections Introduction Condensate system Important note. 1. Consult the sections Electrical cable size, Installation proposal Dimension drawings. •...
  • Page 106 9. On water-cooled compressors, drain valves, shut-off valves and a regulating valve should be fitted by the customer in the cooling water piping. • The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco). • The compressor is automatically controlled and may be restarted automatically.
  • Page 107 Instruction book If the compressor has not run for the past 6 months, it is strongly recommended to improve the lubrication of the compressor element before starting. To do so: Loosen the hose clip (2) and disconnect the inlet hose (3). Remove the unloader (1) 3.
  • Page 108 Instruction book 2. On water-cooled compressors, close the cooling water drain valves. Open the cooling water inlet valve and the regulation valve. 3. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of drive motor (M1) while the motor is coasting to a stop. The correct rotation direction of the drive motor is indicated by an arrow shown on the motor fan cowl.
  • Page 109 100° C, this will lead to more rapid oil deterioration, which will have an impact on oil service intervals. Consult Atlas Copco for best practices in this case. Also consult Atlas Copco in case condensate should form in the oil.
  • Page 110 Instruction book (A): Air inlet temperature (B): Condensation temperature (C): Working pressure (D): Relative air humidity If operating at a pressure of 10 bar(e) in an ambient temperature of 20 °C and at a relative air humidity of 100%, the minimum temperature to prevent condensate from forming is 68 °C.
  • Page 111 Instruction book Regularly check the oil level. To do so: 1. Press stop button (9). 2. A few minutes after stopping, the oil level should be between the oil filler neck (FC) and the top of the sight glass (Gl). 3.
  • Page 112 Instruction book Regularly check the service indicator. If the coloured part of service indicator (VI) shows full out, replace the air filter element. Reset the service indicator by pushing the knob in the extremity of the indicator body. Regularly check that condensate is discharged during operation. See section Condensate system.
  • Page 113 Instruction book The display (2) will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded. Carry out the service actions of the indicated plans or replace the component and reset the relevant timer, see section Service warning.
  • Page 114 Instruction book The operator must apply all relevant Safety precautions . Stop the compressor and close the air outlet valve. Open the manual drain valve. Switch off the voltage and disconnect the compressor from the mains. Unscrew the oil filler plug only one turn to permit any pressure in the system to escape.
  • Page 115 Instruction book Only pressing the emergency stop button is not sufficient to make the compressor voltage free. 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.
  • Page 116 For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits). Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work.Consult your Atlas Copco Customer Centre. When servicing, replace all removed gaskets, O-rings and washers.
  • Page 117 On water-cooled units: check for possible water leakage 8000 (2) If Atlas Copco Roto-Xtend Duty Fluid is used, change oil and oil filter. Have the oil separator element replaced. The oil separator element must also be replaced when the pressure drop over it exceeds 1 bar (14.5 psi).
  • Page 118 It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of field experience and research in our labs. See section...
  • Page 119 Instruction book Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a brush and/ or compressed air jet. The bearing at the non-drive end side is greased for life. The bearing at the drive end side is lubricated by the oil system. 1.
  • Page 120 Instruction book The operator must apply all relevant Safety precautions. Always drain the compressor oil at all drain points. Used oil left in the compressor can contaminate the oil system and can shorten the lifetime of the new oil. Never mix lubricants of different brands or types as they may not be compatible and the oil mix will have inferior properties.
  • Page 121 Instruction book Run the compressor until warm. Stop the compressor after 3 minutes of unloaded operation. Close the air outlet valve and switch off the voltage. Wait a few minutes and depressurise by unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape.
  • Page 122 • Next, clean with an air jet in the reverse direction to normal flow. Use low pressure air. If necessary, the pressure may be increased up to 6 bar(e) (87 psig). • If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco. • Remove the cover used during cleaning.
  • Page 123 Instruction book Before removing the valve, depressurise the compressor. See section Problem solving. Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure stamped on the valve, it needs to be replaced. No adjustments are allowed.
  • Page 124 Instruction book Be aware that certain components such as the refrigerant compressor and the discharge pipe can become quite hot (up to 110 °C - 230 °F). Therefore, wait until the dryer has cooled down before removing the panels. Before starting any maintenance or repair work, switch off the voltage and close the air inlet and outlet valves.
  • Page 125 Instruction book Before draining condensate it is obligatory to stop the machine and disconnect it from the power mains Proceed as follows: Stop the machine, turning in “OFF” position the isolating switch. • Press the button switch (on the dryer if fitted). •...
  • Page 126 Instruction book Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped (approx. 30 seconds) and close the air outlet valve. Press the test button on top of the electronic water drain unit the air system between the air receiver and outlet valve is fully depressurized.
  • Page 127 Avoid recirculating of cooling air. If installed, check capacity of compressor room fan On water-cooled compressors, Increase flow cooling water flow too low On water-cooled compressors, Consult Atlas Copco Customer restriction in cooling water system Centre 1904 0504 83...
  • Page 128 Thermostatic valve malfunctioning Have valve tested. Replace if necessary. Air cooler clogged Clean cooler Compressor element out of order Consult Atlas Copco Customer Centre Excessive oil consumption; oil Incorrect oil causing foam Change to correct oil carry-over through discharge line Oil level too high Check for overfilling.
  • Page 129 If a problem is detected by the converter, a specific code (Main motor converter alarm) will appear on the Elektronikon display, together with a fault code. Below table lists the most important error codes. If another code appears, please contact Atlas Copco. Shutdown Navigate to the Stop icon or to the Protections icon and press Enter.
  • Page 130 Main Motor Converter Alarm Fault Too low voltage. The voltage on the Check the supply voltage. converter is below the specifications. Contact Atlas Copco. Too high voltage. The voltage on the Check the supply voltage. converter is above the specifications. Contact Atlas Copco.
  • Page 131 Instruction book The readings mentioned below are valid Reference conditions and limitations). under the reference conditions (see condition) Air outlet pressure Depends on the setpoint (desired net pressure). Compressor element Approx. 60 ˚C (108 ˚F) above ambient temperature. outlet temperature Dewpoint temperature Approx.
  • Page 132 Always double-check the fuse size versus the calculated cable size. If required, reduce fuse size or enlarge cable size. Cable length should not exceed the maximum length according to IEC60204 table 10 GA 37 VSD 73.4 GA 37 VSD 76.8 81.6...
  • Page 133 Instruction book I: current in the supply lines at maximum load and nominal voltage (1): compressors without integrated dryer (2): compressors with integrated dryer are done according to 60364-4-43 electrical installations of buildings, part 4: protection for safety- section 43: protection against overcurrent. Fuse sizes are calculated in order to protect the cable against short circuit.
  • Page 134 Instruction book Maximum allowed current in function of the ambient temperature for installation method C 4 mm² < 32 A < 28 A < 25 A < 23 A < 20 A 6 mm² < 41 A < 36 A <...
  • Page 135 Instruction book • For supply cables larger than 35 mm²: half the size of the supply wires Always check the voltage drop over the cable (less than 5 % of the nominal voltage is recommended). = 89 A, maximum ambient temperature is 45 °C, recommended fuse = 100 A •...
  • Page 136 ˚F Maximum altitude operation (1) 1000 m above sea level Maximum altitude operation (1) 3281 ft above sea level (1): For operation at higher altitude: contact Atlas Copco Maximum cooling water outlet temperature ˚C Maximum cooling water outlet temperature ˚F...
  • Page 137 Instruction book All data specified below apply under reference conditions, see section Reference conditions and limitations Frequency Number of compression stages Normal effective working pressure bar(e) 12.5 Normal effective working pressure psig Maximum effective working pressure, Workplace bar(e) Maximum effective working pressure, Workplace psig Maximum effective working pressure, Workplace Full- bar(e)
  • Page 138 Instruction book Oil capacity, air-cooled Oil capacity, air-cooled US gal 5.55 5.55 5.55 Oil capacity, air-cooled Imp gal 4.62 4.62 4.62 Oil capacity, water-cooled 17.9 17.9 17.9 Oil capacity, water-cooled US gal 4.73 4.73 4.73 Oil capacity, water-cooled Imp gal 3.94 3.94 3.94...
  • Page 139 Instruction book Temperature of air leaving the outlet valve (approx.), ˚C Workplace Full-Feature Temperature of air leaving the outlet valve (approx.), ˚F Workplace Full-Feature Nominal motor power Nominal motor power Dryer power at full load, Workplace Full-Feature units 50 Hz 1.34 1.34 1.34...
  • Page 140 Instruction book Supply voltage 24 V AC /16 VA 50/60Hz (+40%/-30%) 24 V DC/0.7 A Type of protection IP54 (front) IP21 (back Ambient and temperature IEC60068-2 conditions • Operating temperature • -10°C…..+60°C (14 °F ..140 °F) range • -30°C…..+70°C (-22 °F ..158 °F) Storage temperature •...
  • Page 141 Instruction book This vessel can contain pressurized air; this can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator and must be operated within the limits specified on the data plate. No alterations must be made to this vessel by welding, drilling or other mechanical methods without the written permission of the manufacturer.
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  • Page 146 In order to be First in Mind-First in Choice ® for all your quality compressed air needs, Atlas Copco delivers the products and services that help to increase your business’ efficiency and profitability. Atlas Copco's pursuit of innovation never ceases,...

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