Manual Book AII156154 PDF
Manual Book AII156154 PDF
GA 7
AII156154
Instruction book
Atlas Copco
GA 7
AII156154
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.
2016 - 01
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................6
2 General description...................................................................................................... 11
2.1 INTRODUCTION.................................................................................................................................11
3 Elektronikon I regulator.............................................................................................22
3.3 DISPLAY......................................................................................................................................... 24
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3.27 SETTINGS....................................................................................................................................... 42
4 Installation.....................................................................................................................44
4.4 PICTOGRAPHS................................................................................................................................. 50
5 Operating instructions................................................................................................. 52
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6 Maintenance.................................................................................................................. 60
7.5 COOLERS....................................................................................................................................... 67
8 Problem solving............................................................................................................70
9 Technical data...............................................................................................................73
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13 Declaration of conformity............................................................................................ 79
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1 Safety precautions
Explanation
Danger to life
Warning
Important note
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.
Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with
extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
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9. If compressed air is used in the food industry and more specifically for direct food contact, Atlas
Copco recommends, for optimal safety, the use of certified Class 0 compressors in combination with
appropriate filtration depending on the application. Please contact your Atlas Copco Customer Center
for advice on specific filtration.
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14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-
return valves (check valves) must not be relied upon for isolating pressure systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure relieving device or devices as required.
16. Piping or other parts with a temperature in excess of 70C (158F) 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.
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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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10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly. If removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged,
replace it by genuine material from the manufacturer to prevent the sound pressure level from
increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. Only if applicable, the following safety precautions are stressed when handling refrigerant:
Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
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2 General description
2.1 Introduction
General
GA 5, GA 7 and GA 11 are single-stage, oil-injected screw compressors driven by an electric motor. The
compressors are air-cooled and are enclosed in sound insulating bodywork.
The controller and the emergency stop button are integrated in the door panel of the electric cubicle. An
electric cabinet comprising the motor starter is located behind this panel.
Workplace compressors have no dryer, while Workplace Full-Feature (FF) compressors are provided
with an integrated air dryer.
GA 5 up to GA 11 are available with air receiver (tank-mounted version) as well as without air receiver
(Floor-mounted version)
Floor-mounted version
The compressors are installed directly on the floor.
Ref. Name
AF Air filter
AV Air outlet valve
Ca Air cooler
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Ref. Name
Co Oil cooler
Da Automatic condensate outlet
Dm1 Manual condensate drain valve
DR Dryer
FN1/2 Fan motors
M1 Drive motor
Flow diagrams
References
Ref. Description
A Intake air
B Air/oil mixture
C Hot compressed air
D Oil
E Dry 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 air receiver/oil separator (OT). Next, the compressed air flows
through minimum pressure valve (Vp) to air cooler (Ca).
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 when air delivery is
stopped.
On Full-Feature compressors the air flows through air dryer (DR) before reaching the outlet valve.
Flow diagram
Oil system
References Description
A Intake air
B Air/oil mixture
C Compressed air
D Oil
Description
The air/oil mixture coming from the compressor element flows into the oil separator/tank, where most of
the oil is separated by centrifugal action. The oil collects in the lower part of air receiver/oil separator (OT)
which serves as oil tank. The remaining oil is removed by oil separator (OS). A small pipe returns the
separated oil towards the compressor element.
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Air pressure forces the oil from oil separator/tank (OT) through oil cooler (Co) and filter (OF) towards
compressor element (E).
Flow diagram
Cooling system
References Description
A Intake air
B Compressed air/oil
C Compressed air
D Oil
Description
The cooling system comprises air cooler (Ca) and oil cooler (Co). The cooling air is generated by fans
(FN1 and FN2). The fan of the air system will run during loaded running and stop at unloading.
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Condensate drains
All floor-mounted versions are equipped with a condensate trap in the air outlet system. The trap is
equipped with a valve for automatic draining during operation, connected to automatic drain outlet (Da)
and to a manually operated valve (Dm) for draining after stopping the compressor.
Flow diagram
References Description
1 Oil separator tank
2 To air cooler
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Unloading
If the air consumption is less than the air output of the compressor, the net pressure increases. When the net
pressure reaches the unloading pressure, solenoid valve (Y1) is de-energised.
The control pressure present in the chambers of loading plunger (LP) and unloading valve (UV) is
vented to atmosphere via solenoid valve (Y1).
Loading plunger (LP) moves upwards and causes inlet valve (IV) to close the air inlet opening.
Unloading valve (UV) is opened by the pressure in the oil separator vessel. The pressure from the oil
separator vessel is released into atmosphere through the unloader (UA).
The pressure in the oil separator vessel stabilises at low value. A reduced amount of air is compressed
to guarantee a minimal pressure, required for lubrication during unloaded operation.
Air output is stopped (0%), the compressor runs unloaded.
Loading
When the net pressure decreases to the loading pressure, solenoid valve (Y1) is energised.
Control pressure is fed from the oil separator vessel via solenoid valve (Y1) to loading plunger (LP)
and unloading valve (UV).
Unloading valve (UV) closes the air blow-off opening. Loading plunger (LP) moves downwards and
causes inlet valve (IV) to open fully.
Air delivery is resumed (100%), the compressor runs loaded.
General
Also consult sections Electrical diagrams and Electrical connections.
Description
The electrical system comprises following components:
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Reference Designation
F1-F2 Fuses
F7-F8 Fuses
F21 Overload relay, compressor motor
K2 Contactor, air cooler
K5 Auxiliary relay
K11 Contactor, dryer
K21 Line contactor
T1 Transformer
1X0 Terminal strip (voltage supply)
X103-X108 Connectors
PE Earth terminal
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Service diagram for GA5 up to GA11C with Elektronikon I and star-delta starter
Reference Designation
(1) Customers installation
(2) Option
(3) Dryer
(4) All voltages (50 and 60 Hz) except: 440/460 V - 60 Hz
(5) 440/460 V - 60 Hz
(6) Oil cooler fan motor, clockwise rotation
(7) Air cooler fan motor, counter-clockwise rotation
(8) Remote start/stop
(9) Auxiliary relay K5
(10) Emergency stop
(11) Remote emergency stop
(12) Option Electronic Water drain (EWD)
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Reference Motors
M1 Drive motor
M4 Fan motor, oil cooler
M5 Fan motor, air cooler
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Flow diagram
Air dryer
Reference Name
A Refrigerant gas
B Refrigerant liquid
C Condensate
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Reference Name
AI Air inlet
AO Air outlet
1 Air/air heat exchanger
2 Air/refrigerant heat exchanger/evaporator
3 Condensate separator
4 Automatic drain / condensate outlet
5 Refrigerant compressor
6 Refrigerant condenser
7 Liquid refrigerant dryer/filter
8 Capillary
9 Bypass valve
10 Condenser cooling fan
11 Pressure switch, fan control
Refrigerant circuit
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 evaporating pressure.
The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further
evaporation at constant pressure. The heated refrigerant leaves the evaporator and is sucked in by the
compressor (5).
By-pass valve (9) regulates the refrigerant flow. Fan (10) is switched on or off by switch (11) depending on
the loading degree of the refrigerant circuit.
The refrigerant compressor motor has a built-in thermic protection. If the motor stops after
tripping of the thermic protection, it may take up to 2 hours for the motor windings to cool down
and before the motor can restart.
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3 Elektronikon I regulator
Control panel
Introduction
In general, the Elektronikon regulator has following functions:
Controlling the compressor
Protecting the compressor
Monitoring components subject to service
Automatic restart after voltage failure (made inactive)
Shut-down warning
A shut-down warning level is a programmable level below the shut-down level.
If one of the measurements exceeds the programmed shut-down warning level, this will also be indicated to
warn the operator before the shut-down level is reached.
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Service warning
If the service timer exceeds a programmed value, this will be indicated on display (1) to warn the operator
to carry out some service actions.
If activated, and provided the regulator was in the automatic operation mode, the
compressor will automatically restart when the supply voltage to the module is restored.
Elektronikon I regulator
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3.3 Display
Description
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Pictographs
Pictograph Description
Compressor status LOAD (during loaded running, the horizontal arrow flashes).
Running hours.
Dew-point temperature
Procedure
When the voltage is switched on, the Main screen is shown automatically, showing in short the operation
status of the compressor and the outlet pressure:
Main screen, typical example
bar
6.8
The screen shows that the compressor is running loaded (the horizontal arrow flashes) and that the outlet
pressure is 6.8 bar(e).
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Instruction book
Description
A shut-down warning will appear in the event of:
Too high a temperature at the outlet of the compressor element
Too high a dew-point temperature for Full-Feature compressors
If the outlet temperature of the compressor element exceeds the shut-down warning level (110 C /
230 F, not programmable), alarm LED (4) will light up and the related pictograph will appear
flashing.
Warning screen, element outlet temperature
flashing
bar
6.6
flashing
C
111
The screen shows that the temperature at the outlet of the compressor element is 111 C.
It remains possible to scroll through other screens (using keys 3 and 5) to check the actual status of
other parameters.
Press button (1) to stop the compressor and wait until the compressor has stopped.
Switch off the voltage, inspect the compressor and remedy.
The warning message will disappear as soon as the warning condition disappears.
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Dew-point temperature
For compressors with integrated dryer:
If the dew-point temperature exceeds the shut-down warning level (programmable), alarm LED (4)
will light up and the related pictograph will appear flashing.
Warning screen, dew-point temperature
flashing
bar
6.6
flashing
C
9
3.7 Shut-down
Description
The compressor will be shut down in case:
The temperature at the outlet of the compressor element exceeds the shut-down level
Of error of the outlet pressure sensor
Of overload of the drive motor
Of overload of the fan motor on air-cooled compressors
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If the outlet temperature of the compressor element exceeds the shut-down level (120 C / 248 F, not
programmable) the compressor will be shut-down, alarm LED (4) will flash, automatic operation
LED (5) will go out and the following screen will appear:
Shut-down screen, element outlet temperature
flashing
flashing
C
122
The screen shows that the temperature at the outlet of the compressor element is 122 C.
Switch off the voltage and remedy the trouble.
After remedying and when the shut-down condition has disappeared, switch on the voltage and restart
the compressor.
Motor overload
In the event of motor overload, the compressor will be shut-down, alarm LED (4) will flash,
automatic operation LED (5) will go out and the following screen will appear:
Shut-down screen, motor overload
flashing
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Description
A service warning will appear when the service timer has reached the programmed time interval.
If the service timer exceeds the programmed time interval, alarm LED (3) will light up.
Press arrow key (2): <r000> is shown (register 000). Press key (1), <S> (standing for <Service>
appears). Use key (2) to scroll to <r005> (register 005) and press enter key (1). The actual reading of
the service timer will be shown in <kHrs> (hours x 1000).
Example: <4.002> indicates that the compressor has run for 4002 hours since previous service.
Press enter key (1) and key (2) to scroll to <r001> (register 001). Press key (1) to check the running
hours which are shown in <kHrs> (hours x 1000)
Example of running hours screen
kHrs
8.000
The longer interval service actions must also include the shorter interval actions
In the example above, carry out all service operations belonging to the 8000
running hours interval as well as those belonging to the 4000 running hours
interval.
If using mineral oil instead of Atlas Copco Roto-injectfluid, the service timer has to
be decreased. See section Preventive maintenance schedule.
After servicing, reset the service timer. See section Calling up/resetting service timer.
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Control panel
Control panel
Scroll keys (2 and 3) can be used to scroll through all screens. The screens are divided into register screens
(numbered as <r001>, <r002>, ...) and parameter screens (numbered as <P001>, <P002>, ...)
During scrolling, the numbers of the screens appear consecutively. For most screens, the unit of
measurement and the related pictograph are shown together with the screen number.
In the event of a warning or a shut-down, an extra register screen <r000> is accessible.
Example
kHrs
r001
The screen shows the screen number <r001>, the unit used <kHrs> (hours x 1000) and the related
pictograph for running hours. Press enter key (1) to call up the actual running hours.
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Menu flow
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Control panel
bar
6.6
C
83
C
3
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Control panel
bar
6.6
Press arrow key (2) until <r001> is shown and then press enter key (1):
kHrs
2.381
The screen shows the unit used <kHrs> (hours x 1000) and the value <2.381>: the running hours of the
compressor are 2381 hours.
Control panel
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bar
6.6
Press arrow key (2) until <r002> is shown and then press enter key (1):
kHrs
1.755
The screen shows the unit used <kHrs> (hours x 1000) and the value <1.755>: the loading hours of the
compressor are 1755 hours.
Control panel
bar
6.6
Press arrow key (2) until <r003> is shown and then press enter key (1):
This screen shows the number of motor starts times 1000. Press enter key (1) to return to the register
screens.
Press arrow key (2) until <r004> is shown and then press enter key (5):
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226
This screen shows the number of motor starts to be added to the reading in register <r003>. In this
example, the number of motor starts is 3226.
Control panel
bar
6.6
Press arrow key (3) until <r005> is shown and then press enter key (2):
kHrs
1.191
This screen shows the unit used <kHrs> (hours x 1000) and the value <1.191>: the compressor has run
1191 hours since the previous service.
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Control panel
bar
6.6
Press arrow key (2) until <r005> is shown and then press enter key (1):
If <0> appears, the function automatic restart after voltage failure is not active.
If <1> appears, the function automatic restart after voltage failure is active.
Control panel
bar
6.6
Press arrow key (2) until <r007> is shown and then press enter key (1): the number shown indicates the set
of parameters which are programmed ex-factory.
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Control panel
bar
6.6
Press arrow key (2) until <P001> is shown and then press enter key (1):
bar
7.0
The screen shows the setting of the unloading pressure: 7.0 bar(e)
Use arrow keys (2 and 3) to modify this setting.
Press enter key (1) to program the new value and to return to the parameter screens.
Control panel
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bar
6.6
Press arrow key (2) until <P002> is shown and then press enter key (1):
bar
6.4
The screen shows the setting of the loading pressure: 6.4 bar(e)
Use arrow keys (2 and 3) to modify this setting.
Press enter key (1) to program the new value and to return to the parameter screens.
Control panel
bar
6.6
Press arrow key (2) until <P003> is shown and then press enter key (1):
C
8
The screen shows the warning setting for the dew-point temperature: 8 C
Use arrow keys (2 and 3) to modify this setting.
Press enter key (1) to program the new value and to return to the parameter screens.
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Control panel
bar
6.6
Press arrow key (2) until <P004> is shown and then press enter key (1): the setting of the service
timer is shown in <kHrs> (hours x 1000). Example: <4.000> means the timer is set at 4000 running
hours.
Use arrow keys (2 and 3) to modify this setting.
Press enter key (1) to program the new value and to return to the parameter screens.
Control panel
bar
6.6
Press arrow key (2) until <P005> is shown and then press enter key (1): the possible settings are
shown: <Mpa>, <psi>, and <bar>; the actually used unit is flashing.
Use arrow keys (2 and 3) to select another unit of pressure.
Press enter key (1) to program the new unit of pressure and return to the parameter screens.
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Control panel
bar
6.6
Press arrow key (2) until <P006> is shown and then press enter key (1): the possible settings are
shown: <C> and <F>; the actually used unit is flashing.
Use arrow keys (2 and 3) to select another unit of temperature.
Press enter key (1) to program the new unit of temperature and return to the parameter screens.
Control panel
bar
6.6
Press arrow key (2) until <P007> is shown and then press enter key (1). The actually used starting
mode is flashing <1> for Y-D (star-delta) or <0> for DOL (direct-on line).
Use arrow keys (2 and 3) to select another starting mode.
Press enter key (1) to program the new starting mode and to return to the parameter screens.
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Description
This parameter, accessible in screen <P008>, can only be modified after entering a password. Consult
Atlas Copco if this function should be activated.
Control panel
bar
6.6
Press arrow key (2) until <P009> is shown and then press enter key (1). The actually used starting
mode is flashing <0> for local control mode or <1> for remote control mode.
Use arrow keys (2 and 3) to select another mode.
Press enter key (1) to program the new control mode and to return to the parameter screens.
Description
This parameter, accessible in screen <P010>, can only be modified after entering a password.
3.27 Settings
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Dew-point temperature
The nominal warning setting is 8 C (46.4 F)
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4 Installation
Drawings
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Reference Designation
1 Compressor and motor cooling air inlet
2 Motor and dryer cooling air outlet
3 Cooling air outlet
4 Cooling air inlet
5 Dryer air inlet
6 Compressed air outlet
7 Compressor air inlet
8 Manual drain
9 Automatic drain
10 Weight
11 Electrical cable entry
12 Rear view
Outdoor/altitude operation
If the compressor is installed where the ambient temperature can be below 0 C (32 F), precautions must
be taken. In this case, and also if operating above 1000 m (3300 ft), consult Atlas Copco.
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Installation proposal
Text on drawing
Reference Designation
(1) Ventilation proposals
(2) Minimum free area to be reserved for the compressor installation
(3) Compressor
(4) Front
(5) Top view
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Installation guidelines
1. Install the compressor unit on a solid, level floor suitable for taking its weight. The recommended
minimum distance between the top of the unit and the ceiling is 900 mm (35 in). The air receiver
must not be bolted to the floor. The minimum distance between the wall and the back of the
compressor must be 500 mm (19.5 in).
2. Position of the compressed air outlet valve.
To facilitate the access to the dryer during maintenance operations, provide a flexible connection
between the air outlet valve and the air net.
Close the valve.
Connect to the air net
3. The pressure drop over the air delivery pipe can be calculated from:
p = (L x 450 x Qc1.85) / (d5 x P), with
d = Inner diameter of the pipe in mm
p = Pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi))
L = Length of the pipe in m
P = Absolute pressure at the compressor outlet in bar
Qc= Free air delivery of the compressor in l/s
It is recommended that the connection of the compressor air outlet pipe is made on top of the main air
net pipe in order to minimise carry-over of possible condensate residue.
4. Ventilation: the inlet grids and ventilation fan should be installed in such a way that any recirculation
of cooling air to the compressor or dryer is avoided. The maximum air velocity through the grids is 5
m/s (16.5 ft/s).
The maximum allowable pressure drop over the cooling air ducts is 30 Pa (0.12 in water column).
If it is greater than this value, a fan is needed at the outlet of the ducts. Consult Atlas Copco.
For alternatives 1 and 3, the required ventilation capacity to limit the compressor room
temperature can be calculated as follows:
Qv = (1.16 N + 0.6)/T for units with optional dryer
Qv = Required ventilation capacity in m3/s
N = Shaft input of compressor in kW
T = Temperature increase in the compressor room in C
For alternatives 2 and 4: the fan capacity should match the compressor fan capacity at a pressure
head equal to the pressure drop across the air ducts.
5. Position of control panel.
6. Mains cable
To preserve the protection degree of the electric cubicle and to protect its components from
dust from the environment, it is mandatory to use a proper cable gland when connecting the
supply cable to the compressor.
7. Filter, type DD for general purposes (optional). The filter traps solid particles down to 1 micron with
a max. oil carry-over of 0.5 mg/m3. A high-efficiency filter, type PD (optional), may be installed
downstream of a DD filter. This filter traps solid particles down to 0.01 micron with max. oil carry-
over of 0.01 mg/m3. If oil vapours and odours are undesirable, a QD type filter should be installed
downstream of the PD filter.
It is recommended to provide by-pass pipes and valves across the filters in order to isolate the filters
during maintenance without disturbing the compressor.
8. Safety valve
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Important remark
To preserve the protection degree of the electric cubicle and to protect its components from
dust from the environment, it is mandatory to use a proper cable gland when connecting the
supply cable to the compressor.
Electrical connections
1. Provide an isolating switch nearby the compressor.
2. Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals.
3. Check the fuses and the setting of the overload relay. See section Settings of overload relay and fuses
4. Connect the power supply cables to terminals L1, L2, L3 of terminal strip (1X0).
5. Connect the earth conductor to earth bolt (1X3).
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Reference Designation
(1) Customers installation
(2) Option
(3) Dryer
(4) All voltages except: 440/460 V - 60 Hz
(5) 440/460 V - 60 Hz
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Reference Designation
(6) Oil cooler fan motor, clockwise rotation
(7) Air cooler fan motor, counter-clockwise rotation
(8) Supply of dryer, oil cooler and air cooler
(9) All other voltages
4.4 Pictographs
Description
Pictographs
Reference Designation
1 Manual condensate drain
2 Automatic condensate drain
3 Warning: voltage
4 Warning: switch off the voltage and depressurize compressor before repairing
5 Warning: before connecting compressor electrically, consult Instruction book for motor
rotation direction
6 Torques for steel (Fe) or brass (CuZn) bolts
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Reference Designation
7 Consult instruction book before greasing
8 Lightly oil gasket of oil filter, screw it on and tighten by hand (approx. half a turn)
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5 Operating instructions
Safety
Procedure
For the position of the air outlet valve and the drain connections, see sections Introduction
and Condensate system.
1. Consult the sections Electric cable size,Installation proposals and Dimension drawings
2. The following transport fixtures, painted red, must be removed:
Bolts (1)
Bushes (2)
Transport fixtures
For a voltage supply other than 230V or 400V+N, a transformer (T3) is provided. See Electrical
connections.
3. Check that the electrical connections correspond to the local codes and that all wires are clamped tight
to their terminals.
The installation must be earthed and protected against short circuits by fuses of the inert type in all
phases. An isolating switch must be installed near the compressor.
4. Check transformer (T1) for correct connection.
Check the settings of drive motor overload relay (F21).
Check that the motor overload relay is set for manual resetting.
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5. Fit the air outlet valve (AV); see section Introduction for the position of the valve.
Close the valve.
Connect the air net to the valve.
6. Fit the manual condensate drain valve(s) (Dm). Close the valve. Connect the valve to a drain
collector.
7. Connect the automatic drain outlet (Da) to a drain collector.
The drain pipes to the drain collector must not dip into the water. If the pipes have been fitted outside
the room where freezing is possible, they must be insulated.
8. Check the oil level.
The oil level sight-glass should be between 1/4 and 3/4 full.
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If the rotation direction of the drive motor is incorrect, switch off the voltage and reverse two
incoming electric lines.
On air-cooled compressors, check also the rotation direction of the fan motor.
11. On compressors equipped with an Elektronikon I regulator, check the settings; see section Settings.
12. Start and run the compressor for a few minutes. Check that the compressor operates normally.
Procedure
- Check the oil level, top up if necessary. See section Initial start-up.
5.3 Starting
Procedure
For the position of the air outlet valve and the drain connections, see sections
Introduction and Condensate system.
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Step Action
- Switch on the voltage. Check that voltage on LED (6) lights up.
- Open the air outlet valve.
- Close the condensate drain valve(s) (Dm).
- Press start button (1) on the control panel. The compressor starts running and the
automatic operation LED (8) lights up. After the motor running time in star (Y-time, see
Parameters in section Programmable settings) has elapsed, the drive motor switches
over from star to delta and the compressor starts running loaded.
Procedure
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Regularly check the oil level: Approximately three minutes after stopping, sight-glass (Gl) should be
between 1/4 and 3/4 full. If the level is too low, stop the compressor, wait until the compressor has stopped,
depressurise the oil system by unscrewing oil filler plug (FC) one turn and wait a few minutes. Remove the
plug and top up oil, until the sight-glass is full. Fit and tighten the plug (FC).
When automatic operation LED (8) is lit, the regulator is automatically controlling the compressor, i.e.
loading, unloading, stopping of the motors and restarting.
If provided, regularly check that condensate is discharged by the automatic drain(s) during operation. See
section Condensate system. The amount of condensate depends on environmental and working conditions.
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Procedure
On compressors equipped with an Elektronikon I regulator, check the display (2) regularly: the compressor
status is indicated by pictographs; see section Pictographs used on the screen. Remedy the trouble if alarm
LED (7) is lit or flashes, see sections Service warning, Shut-down warning and Shut-down.
5.6 Stopping
Elektronikon regulator
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Procedure
Step Action
- Press stop button (9). Automatic operation LED (8) goes out and the compressor stops after
30 seconds of unloaded operation.
- To stop the compressor in the event of an emergency, press emergency stop button (10).
Alarm LED flashes (7).
On compressors with Elektronikon I: after remedying the problem cause, unlock the button by
pulling it out and press the reset key (14) before restarting.
Do not use emergency stop button (10) for normal stopping!
- Close the air outlet valve (AV).
- Open the condensate drain valve of the compressor (Dm) to drain the water trap completely.
See section Condensate system.
If maintenance or repair work is necessary, consult Problem solving for all relevant safety precautions.
Procedure
Step Action
- Stop the compressor and close the air outlet valve.
- Switch off the voltage and disconnect the compressor from the mains.
- Depressurise the compressor by opening plug (FC). Consult section Oil and oil filter change to
locate the filler plug.
- Open the condensate drain valve(s) (Dm). Consult section Condensate system to locate the
drain valve.
- Shut off and depressurise the part of the air net which is connected to the outlet valve.
Disconnect the compressor air outlet pipe from the air net.
- Drain the oil.
- Drain the condensate circuit and disconnect the condensate piping from the condensate net.
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6 Maintenance
Warning
Service kits
For overhauling or carrying out preventive maintenance, service kits are available (see section Service
kits).
Service contracts
Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work.
Consult your Atlas Copco Customer Centre.
General
When servicing, replace all removed gaskets, O-rings and washers.
Intervals
The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service
intervals, depending on the environmental and working conditions of the compressor.
The longer interval actions and checks must also include the shorter interval actions and checks.
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Period Operation
Daily Check oil level.
Check readings on display.
Check that condensate is discharged during loaded operation of the compressor.
Check the pressure dew-point temperature (compressors with integrated dryer).
3-monthly (1) Check coolers, clean if necessary.
On Full-Feature units: check condenser of dryer and clean if necessary.
Remove the air filter element and inspect. If necessary, clean using an air jet. Replace
damaged or heavily contaminated elements.
Check the filter element of the electric cabinet (if applicable). Replace if necessary
Frequency Operation
(running hours)
4000 (1) If Atlas Copco Roto-Inject Fluid is used, change oil and oil filter.
Replace the air filter element.
Replace the oil separator element.
Replace the filter element of the electric cabinet (if applicable).
Clean coolers.
Check pressure and temperature readings.
Carry out a LED/display test.
Check for leakages.
If provided, remove, dismantle and clean float valve of condensate trap. See section
Condensate system.
Clean the condenser of the dryer (Full-Feature compressors)
Yearly Test temperature shut down function.
Test safety valve(s).
8000 (2) Replace V-belts.
Have air inlet valve and minimum pressure valve inspected by Atlas Copco.
Important
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Avoid mixing lubricants of different brands or types as they may not be compatible and
the oil mix may have inferior properties. A label, indicating the type of oil filled ex factory,
is stuck on the air receiver/oil tank.
Roto-Inject Fluid
Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw
compressors. Its specific composition keeps the compressor in excellent condition. Roto-Inject Fluid can be
used for compressors operating at ambient temperatures between 0 C (32 F) and 40 C (104 F). If the
compressor is regularly operating in ambient temperatures above 35 C (95 F), oil lifetime is reduced
significantly. In such case it is recommended to use Roto-Xtend Duty Fluid.
Procedure
Run the compressor regularly, e.g. twice a week, until warm. Load and unload the compressor a few times.
If the compressor is going to be stored without running from time to time, protective
measures must be taken. Consult your supplier.
Service kits
For overhauling and for preventive maintenance, a wide range of service kits is available. Service kits
comprise all parts required for servicing the component and offer the benefits of genuine Atlas Copco parts
while keeping the maintenance budget low.
Also a full range of extensively tested lubricants, suitable for your specific needs is available to keep the
compressor in excellent condition.
Consult the Spare Parts List for part numbers.
Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must
be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations
and environmental legislation.
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Electronic components are subject to the EU Directive 2012/19/EC for Waste Electrical and Electronic
Equipment (WEEE). As such, these parts must not be disposed of at a municipal waste collection point.
Refer to local regulations for directions on how to dispose of this product in an environmental friendly
manner.
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General
Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a brush
and/or compressed air jet.
Bearing maintenance
The motor bearings do not need to be regreased during their normal service life.
Air filter
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Recommendations
1. Never remove the filtration element while the compressor is running.
2. For minimum downtime, replace the dirty element by a new one.
3. Discard the element when damaged.
Procedure
1. Stop the compressor. Switch off the voltage.
2. Remove the cover of air filter (AF) by turning it anti-clockwise. Remove the filter element. If
necessary, clean the cover.
3. Fit the new element and the cover.
4. Reset the air filter service warning.
Consult section Calling up/resetting service timer to reset the service warning on Elektronikon I
regulators.
1. Stop the compressor. Switch off the voltage.
2. Remove the side panel.
3. Remove the cover of air filter (AF) by turning it anti-clockwise. Remove the filter element. If
necessary, clean the cover.
4. Fit the new element and the cover.
5. Reset the air filter service warning.
Warning
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Procedure
1. Run the compressor until warm. Stop the compressor. Close the air outlet valve and switch off the
voltage. Depressurise the compressor by opening manual drain valve(s) (Dm, Dm1). Wait a few
minutes and depressurise the air receiver/oil tank (OT) by unscrewing oil filler plug (FC) just one turn
to permit any pressure in the system to escape.
2. Remove oil drain plug (DP1). Drain the oil by opening valve (Vd). Close the valve and fit the plug
after draining.
3. Collect the oil and deliver it to the local collection service. Refit and tighten the drain and vent plugs
after draining.
4. Remove the oil filter (OF). Clean the seat on the manifold. Oil the gasket of the new filter and screw
it into place. Tighten firmly by hand.
5. Remove filler plug (FC).
Fill the air receiver/oil tank (OT) with oil until the level reaches the middle of sight-glass (Gl).
Take care that no dirt drops into the system. Refit and tighten filler plug (FC).
6. Run the compressor loaded for a few minutes. Stop the compressor and wait a few minutes to allow
the oil to settle.
7. Depressurise the system by unscrewing filler plug (FC) just one turn to permit any pressure in the
system to escape. Remove the plug.
Add oil until the sight-glass (Gl) is 3/4 full.
Take care that no dirt enters the system. Tighten the filler plug.
8. Reset the service warning after carrying out all service actions in the relevant Service Plan:
For compressors equipped with an Elektronikon I regulator, see section Calling up resetting service
timer
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Warning
Procedure
1. Run the compressor until warm. Stop the compressor, 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.
2. Wait 5 minutes and remove the oil separator (OS). Clean the seat on the manifold. Oil the gasket of
the new separator and screw it into place. Tighten firmly by hand.
3. Reset the service timer:
For compressors equipped with an Elektronikon I regulator, see section Calling up resetting service
timer
7.5 Coolers
General
Keep the coolers clean to maintain their efficiency.
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Testing
Before removing the valve, depressurize the compressor. See also section Problem solving.
The safety 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.
Warning
No adjustments are allowed. Never run the compressor without safety valve.
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Safety precautions
Refrigeration dryers of ID type contain refrigerant HFC.
When handling refrigerant, all applicable safety precautions must be observed. Please be specifically
aware of the following points:
Contact of refrigerant with the skin will cause freezing. Special gloves must be worn. If contacted
with the skin, the skin should be rinsed with water. On no account may clothing be removed.
Fluid refrigerant will also cause freezing of the eyes; always wear safety glasses.
Refrigerant is harmful. Do not inhale refrigerant vapours. Check that the working area is adequately
ventilated.
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.
Local legislation
Local legislation may stipulate that:
Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function
must be undertaken by an authorised control body.
The installation should be checked once a year by an authorised control body.
General
For all references see section Introduction.
The following remarks should be kept in mind:
Keep the dryer clean.
Brush or blow off the finned surface of condenser monthly.
Inspect and clean the electronic condensate drain monthly.
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8 Problem solving
Warning
Before carrying out any maintenance, repair work or adjustment, press the stop button,
wait until the compressor has stopped, press the emergency stop button and switch off
the voltage. Close the air outlet valve and lock it if necessary.
If provided, open the manual condensate drain valves. Depressurise the compressor by
opening the oil filler plug one turn.
For location of components, see sections:Introduction, Condensate system and
Initial start-up.
Open and lock the isolating switch.
The operator must apply all relevant Safety precautions.
Compressor
On compressors equipped with an Elektronikon I regulator, if the alarm LED is lit or flashes, consult
section Shut down warning.
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9 Technical data
Elektronikon
Elektronikon I regulator
Important
The readings mentioned below are valid under the reference conditions (see section
Reference conditions and limitations).
Reference Reading
Air outlet pressure Modulates between programmed unloading and loading pressures.
Compressor element Approx. 60 C (108 F) above cooling air temperature.
outlet temperature
Dew point See section Compressor data
Important warning
To preserve the protection degree of the electric cubicle and to protect its components
from dust from the environment, it is mandatory to use a proper cable gland when
connecting the supply cable to the compressor.
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The voltage on the compressor terminals must not deviate more than 10% of the
nominal voltage.
It is however highly recommended to keep the voltage drop over the supply cables
at nominal current below 5% of the nominal voltage (IEC 60204-1). If cables are
grouped together with other power cables, it may be necessary to use cables of a
larger size than those calculated for the standard operating conditions.
Use the original cable entry. See section Dimension drawings.
Local regulations remain applicable if they are stricter than the values proposed
below.
Attention
Local regulations remain applicable if they are stricter than the values proposed below.
The voltage drop must not exceed 5% of the nominal voltage. It may be necessary to
use cables of a larger size than those stated to comply with this requirement.
GA7
Frequency Voltage Cable size
Hz (V)
IEC Star-delta mm2
50 400 4
GA7 GA7
Frequenc Voltage Overload Main fuses,
y (Hz) (V) relay F21 compresso
(A) r supply (A)
IEC Star-delta gL/gG
50 400 10 25
General
The regulating and safety devices are factory-adjusted to give optimum performance of the dryer.
Do not alter the setting of any of the devices.
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Reference conditions
Limits
Reference conditions
All data specified below are valid at reference conditions, see section Reference
conditions and limitations.
GA7
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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 tank 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.
The pressure and temperature of this vessel must be clearly indicated.
The safety valve must correspond with pressure surges of 1.1 times the maximum allowable operating
pressure. It should guarantee that the pressure will not permanently exceed the maximum allowable
operating pressure of the vessel.
Use only oil as specified by the manufacturer.
In case of misuse of the units (very low oil temperature or long interval of shut down), a certain amount of
condensate can gather in the oil separator vessel which must be properly drained. To do so, disconnect the
unit from the power line, wait until it is cooled down and depressurized and drain the water via the oil drain
valve, positioned at the bottom of the oil separator vessel.
Local legislation may require an periodic inspection.
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Guidelines
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this compressor.
Local legal requirements and/or use outside the limits and/or conditions as specified by the manufacturer
may require other inspection periods as mentioned below.
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Overall rating
The compressors conform to PED smaller than category I.
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13 Declaration of conformity
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On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this device.
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services that help to increase your business efficiency and
profitability.
Atlas Copco's pursuit of innovation never ceases, driven by our
need for reliability and efficiency. Always working with you, we
are committed to providing you the customized quality air
solution that is the driving force behind your business.
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