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Manuals and User Guides for Atlas Copco GA15. We have 6 Atlas Copco GA15 manuals available for free PDF download: Instruction Book, User Manual
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Atlas Copco
Oil-injected rotary screw compressors
GA 15, GA 18, GA 22
Instruction book
Related Manuals for Atlas Copco GA 15
Summary of Contents for Atlas Copco GA 15
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Page 1
Atlas Copco Oil-injected rotary screw compressors GA 15, GA 18, GA 22 Instruction book… -
Page 3
Atlas Copco Oil-injected rotary screw compressors GA 15, GA 18, GA 22 From following serial No. onwards: API 459 000 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited. -
Page 4: Table Of Contents
Instruction book Table of contents Safety precautions………………….7 ………………………7 AFETY ICONS ………………….7 AFETY PRECAUTIONS GENERAL ……………….7 AFETY PRECAUTIONS DURING INSTALLATION ………………..9 AFETY PRECAUTIONS DURING OPERATION ……………..10 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description………………….12 ……………………..12 NTRODUCTION ……………………….15 IR FLOW ……………………….17 IL SYSTEM ……………………..19 OOLING SYSTEM ……………………20…
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Page 5
Instruction book 3.10 ………………….39 ALLING UP RUNNING HOURS 3.11 …………………..40 ALLING UP MOTOR STARTS 3.12 …………………..41 ALLING UP MODULE HOURS 3.13 ………………….41 ALLING UP LOADING HOURS 3.14 ……………………41 ALLING UP LOAD RELAY 3.15 ………………42 ALLING UP RESETTING THE SERVICE TIMER 3.16 …………….43 ELECTION BETWEEN LOCAL… -
Page 6
Instruction book ……………………..76 ALLING UP MENUS ………………………77 NPUTS MENU ……………………..78 UTPUTS MENU ……………………….80 OUNTERS ……………………..81 ERVICE MENU 4.10 ……………………..85 ETPOINT MENU 4.11 ……………………87 VENT HISTORY MENU 4.12 ………………….88 ODIFYING GENERAL SETTINGS 4.13 ……………………….89 NFO MENU 4.14 ………………………90 EEK TIMER MENU 4.15 ………………………..99 EST MENU… -
Page 7
LECTRIC CABLE SIZE AND MAIN FUSES 10.3 ………………..148 ETTINGS FOR MOTOR OVERLOAD RELAY 10.4 ………………………148 RYER SWITCHES 10.5 ………………149 EFERENCE CONDITIONS AND LIMITATIONS 10.6 GA 15 GA 22………………149 OMPRESSOR DATA FOR UP TO 10.7 ® ………………154 ECHNICAL DATA LEKTRONIKON CONTROLLER Instructions for use………………..156 Guidelines for inspection……………….157… -
Page 8
Instruction book Declaration of conformity………………159 2920 7083 31… -
Page 9: Safety Precautions
Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions, general General precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
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Page 10
Instruction book Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits. -
Page 11: Safety Precautions During Operation
Instruction book Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
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Page 12: Safety Precautions During Maintenance Or Repair
Instruction book Safety precautions during maintenance or repair All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
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Page 13
Instruction book • 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. -
Page 14: General Description
Instruction book General description Introduction GA 15 up to GA 22 are single-stage, oil-injected screw compressors driven by an electric motor. The compressors are air-cooled. ® The compressors are controlled by an Elektronikon controller. GA Pack GA Pack are enclosed in a sound-insulated bodywork. The compressors are controlled by an Elektronikon®…
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Page 15
Front view, GA 15 up to GA 22 Tank-mounted Pack GA Full-Feature GA Full-Feature (FF) are controlled by an Atlas Copco Elektronikon® controller (standard version) or by an Elektronikon® Graphic controller (optional). They are provided with an air dryer, integrated in the sound- insulated bodywork. -
Page 16
Instruction book Front view, GA 15 up to GA 22 Tank-mounted Full-Feature Reference Name Air filter Air receiver Air outlet valve Air cooler Oil cooler Manual drain, air receiver Dryer Elektronikon® controller (standard) or Elektronikon® Graphic controller (optional) Motor Condensate trap (GA Pack) -
Page 17: Air Flow
Instruction book Air flow Flow diagrams Flow diagram, GA Pack 2920 7083 31…
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Page 18
Instruction book Flow diagram, GA Full-Feature Reference Description Intake air Air/oil mixture Wet compressed air Condensate Dried compressed air 2920 7083 31… -
Page 19: Oil System
Instruction book Description Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. Compressed air and oil flow into the oil tank (OT). The air is discharged through outlet valve (AV) via minimum pressure valve (Vp) and air cooler (Ca). During loaded operation, minimum pressure valve (Vp) keeps the pressure in the separator tank (OT) above a minimum value, required for lubrication.
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Page 20
Instruction book References Description Compressed air flow towards the condensate trap (Pack units). Compressed air flow to the air dryer (compressors with integrated dryer) Intake air Air/oil mixture Wet compressed air Description In oil tank (OT) most of the oil is removed from the air/oil mixture by centrifugal action. The rest is removed by oil separator (OS). -
Page 21: Cooling System
Instruction book Cooling system Flow diagram Cooling system References Description Intake air Air/oil mixture Wet compressed air Description The cooling system comprises air cooler (Ca) and oil cooler (Co). On air-cooled compressors, the cooling air flow is generated by fan (FN). 2920 7083 31…
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Page 22: Condensate System
Instruction book Condensate system Condensate drains Condensate drains, Pack units Condensate drain, Full-Feature units Pack units have a condensate trap (MT) downstream the air cooler. The condensate trap is provided with a manual drain outlet (Dm) and an automatic drain outlet (Da). On Full-Feature units, the dryer is equipped with an electronic drain (1).
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Page 23: Regulating System
Instruction book Regulating system Flow diagram Regulating system (loaded condition) Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results: • The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank pressure (1) via the solenoid valve.
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Page 24: Electrical System
Electrical system General Also consult sections Electrical diagrams Electrical connections. Electrical components The electrical system comprises following components: Electric cubicle on GA 15 up to GA 22, typical example Reference Designation F1/2/3 Fuses F4/5/6 Fuses F7/8 Fuses for dryer (only on Full-Feature compressors)
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Page 25: Electrical Diagrams
Instruction book Reference Designation Earth terminal Electrical diagrams Text on drawing Reference Designation Customer’s installation Option All other voltages except 440-460 V — 60 Hz Remote start/stop Motor protection Emergency stop 2920 7083 31…
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Page 26
Instruction book Reference Designation Remote emergency stop Supply of dryer All other voltages Designations used Typical references used in the electric diagram of the compressor: Reference Compressor Dryer Compressor motor PT20 Pressure sensor, air delivery TT11 Temperature sensor, element outlet TT90 Temperature sensor, LAT dryer (GA Full-Feature only) Solenoid valve… -
Page 27: Air Dryer
Instruction book Reference Compressor control module Stop Reference Optional equipment Electronic water drain Timer drain Phase sequence relay Main switch Anti-condensation heaters Air dryer Description Air dryer Air circuit Compressed air enters heat exchanger (10) and is cooled by the outgoing, cold, dried air. Water in the incoming air starts to condense.
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Page 28: Elektronikon® Controller
Instruction book Elektronikon® controller ® Elektronikon 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) Automatic control of the compressor The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor.
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Page 29: Control Panel
The regulator has a built-in function to automatically restart the compressor when the voltage is restored after voltage failure. This function is deactivated in compressors leaving the factory. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. If activated, and if the regulator was in the automatic operation mode, the compressor will…
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Page 30: Icons Used On The Display
Instruction book Reference Designation Function LED, Service Is lit when service is needed. Start button This button starts the compressor. Automatic operation LED (3) lights up. The Elektronikon is operative. Stop button This button is used to stop the compressor. Automatic operation LED (3) goes out.
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Page 31
Instruction book Function Icon Description Units Pressure unit (Mega Pascal) Pressure unit (pounds per square inch) Pressure unit (bar) Temperature unit Temperature unit Hours (always shown together with seconds) Percent The value shown must be multiplied by 10 to get the actual value The value shown must be multiplied by 100 to get the actual value… -
Page 32: Main Screen
The Main screen shows: • The compressor status by means of pictographs • The air outlet pressure Always consult Atlas Copco if the pressure on the display is preceded by a «t». Shut-down warning Description A shut-down warning will appear in the event of: •…
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Page 33: Dewpoint Temperature
Instruction book • Press Scroll down button (12). The screen shows the temperature at the compressor element outlet: The screen shows that the temperature at the element outlet is 122 °C It remains possible to scroll through other screens, using the Scroll buttons up and down (12) to check the actual status of other parameters.
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Page 34: Shut-Down
Instruction book Warning screen, dewpoint temperature The screen shows that the dewpoint temperature is 9˚C. • It remains possible to scroll through other screens (using Scroll buttons 12) to check the actual status of other parameters. • Press button (11) to stop the compressor and wait until the compressor has stopped. •…
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Page 35: Service Warning
Instruction book • Press Scroll buttons (12) until the actual compressor element temperature appears. Shut-down screen, element outlet temperature The screen shows that the temperature at the outlet of the compressor element is 122 ˚C. • Switch off the voltage and remedy the trouble. •…
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Page 36
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-Inject Fluid, the service timer has to be decreased. See section Preventive maintenance schedule. 2920 7083 31… -
Page 37: Scrolling Through All Screens
Instruction book • After servicing, reset the service timer. See section Calling up/resetting the service timer Scrolling through all screens Control panel Control panel Scroll buttons (12) can be used to scroll through all screens. The screens are divided into register screens, measured data screens, digital input screens (numbered as <d.in>, <d.1>, …), parameter screens (numbered as <P.01>, <P.02>, …), protections screens (numbered as <Pr.01>,…) and test screens (numbered as <t.01>,…).
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Page 38
Instruction book Digital input Designation Related topic screens <d.4> Loading hours (hrs or x1000 hrs) See section Calling up loading hours <d.5> Load relay (x1 or x 1000) See section Calling up Calling up load relay <d.6> Service timer reading (hrs or x 1000 hrs) See section Calling up/resetting the service timer… -
Page 39
Instruction book Test screens Designation Related topic <t.01> Display test See sections Test screens <t.02> Safety valve test See sections Test screens <t.03> Production test See sections Test screens Menu flow Simplified menu flow 2920 7083 31… -
Page 40: Calling Up Outlet And Dewpoint Temperatures
Instruction book Ref. Description Ref. Description Compressor outlet pressure (16) Pressure band setting Compressor outlet temperature (17) Service timer settings Dewpoint temperature (18) Temperature unit Digital input status (19) Unit pressure Running hours (20) Auto restart Motor starts (21) Selection Y-D/DOL Module hours (22) Load delay time…
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Page 41: Calling Up Running Hours
Instruction book The screen shows that the outlet temperature is 82 ˚C. • For Full-Feature compressors: Press Scroll button (12). The dewpoint temperature will be shown: The screen shows that the dewpoint temperature is 3 ˚C. • Press Scroll button (12) to scroll downwards or upwards through the screens. 3.10 Calling up running hours Control panel Starting from the Main screen:…
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Page 42: Calling Up Motor Starts
Instruction book The screen shows the unit used (x1000 hrs) and the value (11.25): the running hours of the compressor are 11250 hours. 3.11 Calling up motor starts Control panel Starting from the Main screen: • Press Scroll button (12) until <d.2> is shown and then press Enter button (13): This screen shows the number of motor starts (x 1 or — if <x1000>…
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Page 43: Calling Up Module Hours
Instruction book 3.12 Calling up module hours Control panel Starting from the Main screen: • Press Scroll button (12) until <d.3> is shown and then press Enter button (13): In the example shown, the screen shows the unit used (hrs) and the value (5000): the regulator module has been in service during 5000 hours.
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Page 44: Calling Up/Resetting The Service Timer
Instruction book • Press Scroll button (12) until <d.5> is shown and then press Enter button (13): This screen shows the number of unload to load actions (x 1 or — if <x1000> lights up — x 1000). In the above example, the number of unload to load actions is 10100.
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Page 45: Selection Between Local, Remote Or Lan Control
Instruction book This screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1191>. In the example shown, the compressor has run 1191 hours since the previous service. Resetting the service timer After servicing, see section Service warning, the timer has to be reset: •…
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Page 46
Instruction book If necessary enter the password. The next screen shows that the function is “ON or OFF” Press the Enter button (13) to change this mode Use the Scroll buttons (12) to select ON or OFF. When this function is ON, use the Scroll buttons up or down (12) to see the node ID. If desired the user can change this ID. -
Page 47: Calling Up/Modifying Ip, Gateway And Subnetmask
Instruction book Press the Enter button (13) to modify the setting. The utmost left value will blink. Change this value by using the Scroll buttons (12). Press the Enter button (13) to confirm. Change the other values in the same way, as required.
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Page 48
Instruction book Modification Press the Enter button (13) and if necessary enter the password. The first digits are blinking. Use the Scroll buttons Up or Down (12) to modify the settings and press Enter (13) to confirm. Modify the next digits the same way. -
Page 49: Calling Up/Modifying Pressure Band Settings
Instruction book 3.19 Calling up/modifying pressure band settings Calling up the settings Starting from the Main screen: • Press Scroll button (12) until <P.04> is shown and then press Enter button (13). Pressure band 1 (<Pb.1>) is shown on the display. Button (12) can be used to scroll to pressure band 2 (<Pb.2>). •…
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Page 50: Modifying The Pressure Band Selection
Instruction book Loading pressure Unloading pressure • Press Enter button (13) to modify the load level (value starts blinking). A password may be required. Use Scroll buttons (12) to change the loading pressure. • Press Enter button (13) to program the new values or press the Escape button (14) to cancel. 3.20 Modifying the pressure band selection Control panel 2920 7083 31…
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Page 51: Calling Up/Modifying Service Timer Settings
Instruction book Starting from the Main screen: • Press Scroll button (12) until <P.05> is shown and then press Enter button (13). The active pressure band 1 (<Pb.1>) is shown on the display. • Press Enter button (13) to modify the pressure band selection (a password may be required). The active pressure band <Pb.1>…
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Page 52: Calling Up/Modifying Unit Of Pressure
3.24 Activating automatic restart after voltage failure Description This parameter, accessible in screen <P.09>, can only be modified after entering a code. Consult Atlas Copco if this function is to be activated. 3.25 Selection between Y-D or DOL starting…
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Page 53: Calling Up Modifying Load Delay Time
Instruction book • This parameter can only be modified after entering a code. Consult Atlas Copco if the parameter is to be changed. 3.26 Calling up modifying load delay time Control panel Starting from the Main screen: • Press Scroll button (12) until <P.11> and the compressor load pictograph is shown and press the Enter button (13): •…
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Page 54: Activating Password Protection
Instruction book • Press the Scroll button (12) until <P.12> and the motor pictograph is shown and press the Enter button (13): • This screen shows the minimum stop time (20) and the unit <s> (seconds). • To modify this value press the Enter button (13). The value starts blinking and Scroll buttons (12) can be used to modify this value.
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Page 55: Calling Up/Modifying Protection Settings
Instruction book • Press the Enter button (13). • The function of this screen is to activate the remote load/unload relay. To be able to activate this remote Load/Unload functionality, a physical digital input with function Load/Unload is required. Once this parameter is activated, the physical digital input can be used to switch the compressor between Load and Unload.
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Page 56
Instruction book • A low warning level, shown on the display as <AL-L>. • A high warning level, shown on the display as <AL-H>. • A low shut-down level, shown on the display as <Sd-L>. • A high shut-down level, shown on the display as <Sd-H>. •… -
Page 57: Test Screens
Safety valve test In the test screen <t.02> a safety valve test is provided. The safety valves can only be tested after entering a code. Consult Atlas Copco if the safety valves are to be tested. Production test Test screen <t.03> is only intended for production test. If the Main screen shows following screen, the…
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Page 58: Web Server
Instruction book 3.32 Web server 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). This allows to consult certain data and settings via a PC instead of via the display of the controller.
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Page 59
Instruction book • 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). 2920 7083 31… -
Page 60
Instruction book • Use the checkbox Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, de-select other properties if they are selected. After selecting TCP/IP, click on the Properties button (2) to change the settings. • Use the following settings: •… -
Page 61
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). 2920 7083 31… -
Page 62
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). Now you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture). -
Page 63
Instruction book Navigation and options • The banner shows the compressor type and the language selector. In this example, three languages are installed on the controller. • On the left side of the interface you can find the navigation menu (see picture below). If a license for ESi is foreseen, the menu contains 3 buttons. -
Page 64
Instruction book Compressor settings All compressor settings can be hidden or shown. Put a mark for each setting. Only the machine status is fixed and can not be removed from the main screen. Analog inputs (The units of measure can be changed in the preference button from the navigation menu). Counters Counters give an overview of all actual counters from controller and compressor. -
Page 65
Instruction book Digital outputs Shows a list of all digital outputs and their status. Special protections Give an overview of all special protections of the compressor. Service plan Shows all levels of the service plan and status. This screen only shows the running hours. It is also possible to show the actual status of the service interval. -
Page 66: Programmable Settings
Instruction book A possible ESi screen 3.33 Programmable settings Parameters: unloading/loading pressures for compressors without built-in refrigeration dryer Minimum Factory Maximum setting setting setting Unloading pressures Unloading pressure (7.5 bar compressors) bar(e) Unloading pressure (7.5 bar compressors) psig 59.5 101.5 108.8 Unloading pressure (8.5 bar compressors) bar(e)
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Page 67
Instruction book Minimum Factory Maximum setting setting setting Loading pressure (13 bar compressors) psig 172.6 187.1 Loading pressure (100 psi compressors) bar(e) Loading pressure (100 psi compressors) psig 91.4 105.9 Loading pressure (125 psi compressors) bar(e) Loading pressure (125 psi compressors) psig 130.5 Loading pressure (150 psi compressors) -
Page 68
Also see section Preventive maintenance schedule. Consult Atlas Copco if a timer setting has to be changed. See section Calling up/modifying service timer settings. The intervals must not exceed the nominal intervals and must coincide logically. 2920 7083 31… -
Page 69
Minimum stop Once the compressor has automatically stopped, it will remain stopped for the minimum time stop time, whatever happens with the net air pressure. Consult Atlas Copco if a setting lower than 20 seconds is required. Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is Loading pressure programmed at 7.0 bar(e) (101 psi(g)), the maximum limit for the loading pressure changes… -
Page 70: Elektronikon® Graphic Controller
Instruction book Elektronikon® Graphic controller ® Elektronikon Graphic controller Control panel ® Display of the Elektronikon Graphic controller Introduction The Elektronikon controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) Automatic control of the compressor operation The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor.
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Page 71: Protecting The Compressor
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.
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Page 72: Control Panel
Instruction book Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Display Shows the compressor operating condition and a number of icons to navigate through the menu. Pictograph Automatic operation Pictograph General alarm General alarm LED Flashes if a shut-down warning condition exists. Pictograph Service Service LED…
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Page 73: Icons Used
Instruction book Icons used Status icons Name Icon Description Stopped / Running When the compressor is stopped, the icon stands 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…
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Page 74
Instruction book Input icons Icon Description Pressure temperature Digital input Special protection System icons Icon Description Compressor element (LP, HP, …) Dryer Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm 2920 7083 31… -
Page 75
Instruction book Menu icons Icon Description Inputs Outputs Alarms (Warnings, shutdowns) Counters Test Settings Service Event history (saved data) Access key / User password Network Setpoint Info Navigation arrows Icon Description Down 2920 7083 31… -
Page 76: Main Screen
Instruction book Main screen Control panel Scroll keys Enter key Escape key Function The Main screen shows the status of the compressor operation and is the gateway to all functions implemented in the controller. The Main screen 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.
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Page 77
Instruction book Text on figures Compressor Outlet Element Outlet (fixed speed compressors) Flow in % (compressors with frequency converter) Load (text varies upon the compressors actual condition) Menu Unload (text varies upon the compressors actual condition) • Section A shows information regarding the compressor operation (e.g. the outlet pressure (1), the temperature at the compressor outlet (2)). -
Page 78: Calling Up Menus
Instruction book Calling up menus Control panel Control panel Scroll keys Enter key Escape key Description When the voltage is switched on, the main screen is shown automatically (see section Main screen): • To go to the Menu screen, highlight the Menu button (3), using the Scroll keys. •…
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Page 79: Inputs Menu
Instruction book • Press the Escape key to return to the Main screen. Inputs menu Control panel Scroll keys Enter key Escape key Menu icon, Inputs Function To call up information regarding the actually measured data and the status of some inputs such as the emergency stop switch.
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Page 80: Outputs Menu
Instruction book 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: Text on figure Inputs Compressor outlet Element outlet Ambient air Emergency stop…
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Page 81
Instruction book Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the condition of the Fan overload contact (on air cooled compressors), the Emergency stop contact, etc. Procedure Starting from the Main screen (see Main screen), •… -
Page 82: Counters
Instruction book Counters Control panel Scroll keys Enter key Escape key Menu icon, Counters Function To call up: • The running hours • The loaded hours • The number of motor starts • The number of hours that the regulator has been powered •…
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Page 83: Service Menu
Instruction book 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 Running hours Motor starts Load relay VSD 1-20 % rpm in % (the percentage of the time during which the motor speed was between 1 and 20 %) (compressors with frequency converter) The screen shows a list of all counters with their actual readings.
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Page 84
Instruction book Menu icon, Service Function • 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 85
Instruction book Overview Text on figure Overview Running Hours (green) Real Time hours (blue) Reset Example for service level (A): The figures at the left are the programmed service intervals. For Service interval A, the programmed number of running hours is 4000 hours (upper row, green) and the programmed number of real time hours is 8760 hours, which corresponds to one year (second row, blue). -
Page 86
Instruction book Service plan Level Running hours Real time hours Modify Modifying a service plan 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. A screen similar to the one below appears: Press the Enter key. -
Page 87: Setpoint Menu
Instruction book 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. History 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.
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Page 88
Instruction book Text on figure Menu Regulation • Move the cursor to the Setpoint icon (see above, section menu icon) using the Scroll keys. • Press the Enter key. Following screen appears: Text on figure Regulation Unloading pressure 1 Loading pressure 1 Unloading pressure 2 Loading pressure 2 Modify… -
Page 89: Event History Menu
Instruction book • The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the ↑ or ↓ key of the Scroll keys to modify the settings as required and press the Enter key to accept. If necessary, change the other settings as required in the same way as described above.
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Page 90: Modifying General Settings
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. •…
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Page 91: Info Menu
Instruction book • Using the Scroll keys, move the cursor to the Settings icon (see above, section menu icon). • Press the Enter key. Following screen appears: Text on figure General Language used Time Date Date format Modify • To modify, select the Modify button using the Scroll keys and press the Enter key. •…
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Page 92: Week Timer Menu
• 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. 4.14 Week timer menu…
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Page 93
Instruction book Scroll keys Enter key Escape key Menu icon, Week timer Function • 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. •… -
Page 94
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. Programming week schemes •… -
Page 95
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. When ready press the Enter key to confirm. -
Page 96
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 ↑ or ↓ key of Scroll keys to modify the values of the hours. Use the ← or →… -
Page 97
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. Press the Enter key to confirm. -
Page 98
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. Programming the week cycle 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 99
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 100
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 101: Test Menu
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. Week Timer Week action schemes Remaining Running Time…
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Page 102: User Password Menu
Instruction book Procedure 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: • Using the scroll keys (1), move the cursor to the test icon (see above, section Menu icon) •…
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Page 103: Web Server
Instruction book Menu icon, Password Function If the password option is activated, it is impossible for not authorized persons to modify any setting. Procedure Starting from the Main screen (see Main screen), • Move the cursor to the action button Menu and press the Enter key. Following screen appears: •…
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Page 104
Instruction book Configuration of the network card • Go to My Network places (1). • Click on View Network connections (1). • Select the Local Area connection (1), which is connected to the controller. 2920 7083 31… -
Page 105
Instruction book • Click with the right button and select properties (1). • Use the checkbox Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, de-select other properties if they are selected. After selecting TCP/IP, click on the Properties button (2) to change the settings. •… -
Page 106
Instruction book • When using Internet Explorer: Open Internet Explorer and click on Tools — Internet options (2). • 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). 2920 7083 31… -
Page 107
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). Now you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture). -
Page 108
Instruction book Navigation and options • The banner shows the compressor type and the language selector. In this example, three languages are installed on the controller. • On the left side of the interface you can find the navigation menu (see picture below). If a license for ESi is foreseen, the menu contains 3 buttons. -
Page 109
Instruction book Compressor settings All compressor settings can be hidden or shown. Put a mark for each setting. Only the machine status is fixed and can not be removed from the main screen. Analog inputs (The units of measure can be changed in the preference button from the navigation menu). Counters Counters give an overview of all actual counters from controller and compressor. -
Page 110
Instruction book Digital outputs Shows a list of all digital outputs and their status. Special protections Give an overview of all special protections of the compressor. Service plan Shows all levels of the service plan and status. This screen only shows the running hours. It is also possible to show the actual status of the service interval. -
Page 111: Programmable Settings
Instruction book A possible ESi screen 4.18 Programmable settings Parameters: unloading/loading pressures for compressors without built-in refrigeration dryer Minimum Factory Maximum setting setting setting Unloading pressures Unloading pressure (7.5 bar compressors) bar(e) Unloading pressure (7.5 bar compressors) psig 59.5 101.5 108.8 Unloading pressure (8.5 bar compressors) bar(e)
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Page 112
Instruction book Minimum Factory Maximum setting setting setting Loading pressure (13 bar compressors) psig 172.6 187.1 Loading pressure (100 psi compressors) bar(e) Loading pressure (100 psi compressors) psig 91.4 105.9 Loading pressure (125 psi compressors) bar(e) Loading pressure (125 psi compressors) psig 130.5 Loading pressure (150 psi compressors) -
Page 113
Also see section Preventive maintenance schedule. Consult Atlas Copco if a timer setting has to be changed. The intervals must not exceed the nominal intervals and must coincide logically. See section Modifying general settings. 2920 7083 31… -
Page 114
Minimum stop Once the compressor has automatically stopped, it will remain stopped for the minimum time stop time, whatever happens with the net air pressure. Consult Atlas Copco if a setting lower than 20 seconds is required. Unloading/ The regulator does not accept inconsistent settings, e.g. if the unloading pressure is Loading pressure programmed at 7.0 bar(e) (101 psi(g)), the maximum limit for the loading pressure changes… -
Page 115: Installation
Instruction book Installation Dimension drawings GA 15 up to GA 22 Pack, Floor-mounted 2920 7083 31…
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Page 116
Instruction book GA 15 up to GA 22 Full-Feature, Floor-mounted 2920 7083 31… -
Page 117
Instruction book GA 15 up to GA 22 Tank-mounted Pack 2920 7083 31… -
Page 118
Instruction book GA 15 up to GA 22 Tank-mounted Full-Feature Type GA 15 GA 18 GA 22 GA 15 Full- GA 18 Full- GA 22 Full- Pack Pack Pack Feature Feature Feature Weight of Floor- mounted version (kg) Weight of Tank-… -
Page 119: Installation Proposal
Instruction book Ref. Name Compressor air inlet Motor and cooling air inlet Compressed air outlet Motor and compressor cooling air outlet Electrical cable entry Dryer cooling air inlet Dryer cooling air outlet Automatic drain Manual drain Installation proposal Compressor room example 2920 7083 31…
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Page 120
If frost might occur, the appropriate measures should be taken to avoid damage to the machine and its ancillary equipment. In this case, and also if operating above 1000 m (3300 ft), consult Atlas Copco. Moving/lifting Floor-mounted unit: the compressor can be moved by a lift truck. -
Page 121: Electrical Connections
5. Connect neutral conductor to connector (N). 6. Connect earth conductor bolt (PE). On GA 15 up to GA 22 Full-Feature: • The voltage supply to the dryer must be 230 V single-phase. The voltage to the dryer is supplied over the contacts of relay (K11), which close when the compressor is started.
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Page 122: Pictographs
• Remote starting and stopping (switch S1′) • Remote loading/unloading (external pressure switch S4′) • Remote pressure sensing (switch S’): • LAN control: The compressor is controlled via a local network. Consult Atlas Copco. See section Electrical system to locate the connectors.
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Page 123
Instruction book Reference Designation Warning: disconnect electrical supply before opening 2920 7083 31… -
Page 124: Operating Instructions
Instruction book Operating instructions Initial start-up Safety The operator must apply all relevant Safety precautions. Procedure For the location of the air outlet valve and the drain connections, see sections Introduction Condensate system. Motor and gear casing transport fixtures 2920 7083 31…
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Page 125
Instruction book Position of oil level sight-glass Electric cubicle 2920 7083 31… -
Page 126
Check the oil level. See section Oil and oil filter change. Provide labels, warning the operator that: • The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco). • The compressor is automatically controlled and may be restarted automatically. -
Page 127: Before Starting
Instruction book Before starting Procedure Check the oil level, top up if necessary. See section Initial start-up. Starting Procedure For the position of the air outlet valve and the drain connections, see sections Introduction Condensate system Control panel Elektronikon® Control panel Elektronikon® Graphic Step Action Switch on the voltage.
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Page 128: During Operation
Instruction book During operation Warnings The operator must apply all relevant Safety precautions. Also consult section Problem solving. Removing the front panel (service panel) during operation will lead to an automatic shutdown of the unit after a certain time depending of the compressor version. When the motors are stopped and LED (8) (automatic operation) is alight, the motors may start automatically.
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Page 129
Remove the plug and top up oil, until the sight-glass is full. Fit and tighten the plug (FC). Position of oil level sight-glass on GA 15 up to GA 22 On compressors with an Elektronikon® controller, unlock the emergency stop button (10) and press the ‘Rset’ key (5) before restarting. -
Page 130: Checking The Display
Instruction book Checking the display Procedure Control panel of the Elektronikon® controller Control panel of the Elektronikon® Graphic controller Compressors with Elektronikon® controller: Check the display (2) regularly for readings and messages. The display normally shows the compressor outlet pressure, while the status of the compressor is indicated by pictographs. Remedy the trouble if alarm LED (7) is lit or flashes, see section Shutdown warning Shutdown…
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Page 131: Stopping
Instruction book Stopping Elektronikon regulator Control panel Elektronikon® Control panel Elektronikon® Graphic 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).
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Page 132: Taking Out Of Operation
Instruction book Taking out of operation Warning The operator must apply all relevant Safety precautions. Procedure Step Action Stop the compressor and close the air outlet valve. Open the manual condensate drain (if provided). Consult section Condensate system locate the drain valve. Switch off the voltage and disconnect the compressor from the mains.
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Page 133: Maintenance
Instruction book Maintenance Preventive maintenance schedule Control panel Control panel Elektronikon® Control panel Elektronikon® Graphic Warning Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Press the emergency stop button. • Switch off the voltage. •…
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Page 134
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. -
Page 135: Oil Specifications
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 Preventive maintenance schedule for replacement intervals and section Service Kits for part number information.
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Page 136: Storage After Installation
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.
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Page 137: Disposal Of Used Material
Instruction book Disposal of used material 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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Page 138: Adjustments And Servicing Procedures
The motor bearings are greased for life. Air filter Location of air filter Air filter, GA 15 up to GA 22 Recommendations 1. Never remove the element while the compressor is running. 2. For minimum downtime, replace the dirty element by a new one.
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Page 139: Oil And Oil Filter Change
Procedure Oil system components of GA 15 up to GA 22 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 (AR) tank by unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape.
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Page 140: Oil Separator Change
Procedure Oil system components of GA 15 up to GA 22 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.
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Page 141: Coolers
• 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. Safety valves…
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Page 142: Dryer Maintenance Instructions
Instruction book Safety valve air receiver on Tank-mounted units Operating Operate the safety valve by unscrewing the cap one or two turns and retighten it. Testing 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.
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Page 143
Instruction book 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. -
Page 144: Problem Solving
Instruction book Problem solving Warning Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped (approx. 30 seconds), press the emergency stop button and switch off the voltage. Close the air outlet valve, open manual drain (Dm) on Pack units and also open the manual condensate drain (Dm1) on Tank-mounted units.
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Page 145
Oil cooler clogged Clean cooler Bypass valve malfunctioning Have valve tested Air cooler clogged Clean cooler Compressor element out of order Consult Atlas Copco Customer Centre Faults and remedies, dryer For all references hereafter, consult section dryer. Condition Fault Remedy… -
Page 146
Instruction book Condition Fault Remedy Evaporator pressure too high See below Condenser pressure too high See below Condenser pressure too high Fan control switch out of order Replace or too low Fan blades or fan motor out of Check fan/fan motor order Ambient temperature too high Check and correct;… -
Page 147: Technical Data
Air outlet pressure Modulates between programmed unloading and loading pressures. Compressor element 55-65 ˚C (99-117 ˚F) above cooling air temperature. outlet temperature Dewpoint temperature For GA 15 up to GA 22 with built-in dryer: see section Compressor data. 2920 7083 31…
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Page 148: Electric Cable Size And Main Fuses
Instruction book 10.2 Electric cable size and main fuses Important • 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).
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Page 149
Approval Recommended wire Recommended wire Main section (2) section (3) fuses (A) (4) GA 15 4 x 25 mm 4 x 35 mm GA 15 4 x 10 mm 4 x 16 mm GA 15 4 x 10 mm 4 x 16 mm… -
Page 150: Settings For Motor Overload Relay
Fuse specifications IEC: gL/gG Fuse specifications UL/cUL: HRC Form II — UL: Class 5 10.3 Settings for motor overload relay Overload relay settings GA 15 GA 18 GA 22 Frequency (Hz) Voltage (V) Overload relay F21 (A) Overload relay F21 (A) Overload relay F21 (A)
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Page 151: Reference Conditions And Limitations
Maximum air inlet temperature ˚F Minimum ambient temperature ˚C Minimum ambient temperature ˚F 10.6 Compressor data for GA 15 up to GA 22 Reference conditions All data specified below apply under reference conditions, see section Reference conditions and limitations. GA 15 7.5 bar 8.5 bar 10 bar…
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Page 152
Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Maximum (unloading) psig pressure, Full-Feature units Nominal working bar(e) 12.5 10.3 pressure Nominal working psig pressure Pressure drop over dryer, bar(e) 0.25 0.25 0.25 0.25… -
Page 153
Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Refrigerant quantity, Full- 0.84 0.84 0.84 0.84 0.84 0.84 0.84 0.84 Feature units Oil capacity 6.75 6.75 6.75 6.75 6.75 6.75 6.75 6.75 Oil capacity US gal… -
Page 154
Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Temperature of air ˚C leaving outlet valve (approx.), Full-Feature units Temperature of air ˚F leaving outlet valve (approx.), Full-Feature units Pressure dew-point, Full- ˚C Feature units Pressure dew-point, Full-… -
Page 155
Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Maximum (unloading) bar(e) 7.25 8.25 9.75 12.75 7.15 8.85 10.55 12.25 pressure, Full-Feature units Maximum (unloading) psig pressure, Full-Feature units Nominal working bar(e) 12.5 10.3… -
Page 156: Technical Data Elektronikon® Controller
Instruction book 7.5 bar 8.5 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi Refrigerant type, Full- R404A R404A R404A R404A R404A R404A R404A R404A Feature units Refrigerant quantity, Full- Feature units Refrigerant quantity, Full- Feature units Oil capacity 7.75 7.75…
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Page 157: Analog Inputs
Instruction book Digital inputs Parameter Value Number of inputs 4 (Elektronikon® controller — p.n. 1900 5200 00 …. 1900 5200 09) 10 (Elektronikon® Graphic controller — p.n. 1900 5200 10 …. 1900 5200 19) Supply by controller 24 V DC Supply protection Short circuit protected to ground Input protection…
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Page 158: Instructions For Use
Instruction book Instructions for use Oil separator vessel This vessel can contain pressurised 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.
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Page 159: Guidelines For Inspection
Instruction book Guidelines for inspection 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.
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Page 160: Pressure Equipment Directives
Instruction book Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive Compressor type Part number Description PED class GA 15 up to GA 22 0832 1000 77 Safety valve 0830 1009 87 0832 1000 78 Safety valve 0832 1002 23…
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Page 161: Declaration Of Conformity
Instruction book Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium 2920 7083 31…
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Page 164
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.
Atlas Copco GA15: List of Available Documents
Note for Owners:
Guidesimo.com webproject is not a service center of Atlas Copco trademark and does not carries out works for diagnosis and repair of faulty Atlas Copco GA15 equipment. For quality services, please contact an official service center of Atlas Copco company. On our website you can read and download documentation for your Atlas Copco GA15 device for free and familiarize yourself with the technical specifications of device.
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