air compressor system

Document Type:

SYSTEM DESCRIPTION

Procedure/Work Plan Title:

Air Compressor System Document Number:

LP-SD-002

ENGRO ENERGY LIMITED of 32

Revision: 0 Date: July 15,2008

Change: Date:

Revision Description Date By Approved

A Initial Draft 15-July-2008 SMAi

0 Issued for Unrestricted Use

AIR COMPRESSOR SYSTEM

SYSTEM DESCRIPTION

ENGRO ENERGY LIMITED

1 226.52 MW Combined Cycle Power Plant

Qadirpur, District Ghotki Sindh, Pakistan

AIR COMPRESSOR

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:

EEL Raw Rater System

General Description….....................................................................................................

Introduction.....................................................................................................................

Air Flow..........................................................................................................................

Oil System.......................................................................................................................

Cooling System...............................................................................................................

Condensate System.........................................................................................................

Regulating System...........................................................................................................

Electrical System.............................................................................................................

Electrical Diagrams.........................................................................................................

Air Dryer.........................................................................................................................

Elektronikon II Regulator................................................................................................

Operating Instructions.....................................................................................................

Before Initial Startup.......................................................................................................

Initial Startup...................................................................................................................

Before Starting................................................................................................................

Starting............................................................................................................................

During Operation............................................................................................................

Checking the Display......................................................................................................

Stopping..........................................................................................................................

Taking Out of Drive Motor............................................................................................

Oil Specifications............................................................................................................

Oil and Oil Filter Change................................................................................................

Operation........................................................................................................................

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


1.0 PURPOSE AND SCOPE

The purpose of this document is to present an over view of the Air Compressor system including

Instrument Air System. Canal and ground water sources. The scope of this document will be limited

to the description of systems including Air Compressor and Instrument Air system supply, and key

components involved.

1.0 PURPOSE AND SCOPE

The purpose of this document is to present an over view of the Air Compressor system System including Instrument Air System. The scope of this document will be limited to the description of systems including Air Compressor and Instrument Air system supply, and key components involved.

Description:

Two ATLAS GA 55+ up to GA 90 are single-stage, oil-injected screw compressors driven by an electric motor. Air drawn by the Compressor passing Pre-Filter (Buyers Vendor) and goes to Air Dryer system (Buyers Vendor) and inlet outlet pressure gauges are installed and one DP switch is also installed at the filters to know chock age of the filters. Two sets of Electronic control dryers are installed to purify the compressed air to Instrument air. Remove all the moisture through silica gel process. One air dryer will be in service other will be on stand by or on purging process. After Air passing through dryer goes to after filter to remove any moisture left from dryer. Two After Filter are installed one in service other on S/B mode at the outlet of the dryers . Also inlet outlet pressure gauges are installed and one DP switch is also installed for the the indication of chock age of the filters. After Air passes these filters and goes to One Air Receiver tank. The tank capacity is -8 Mpa. One safety valve is installed at the top of the tank to avoid any kind of over pressurizing in tank and pressure safety valve setting is 1 MPA. Also one condensate trap is provided at the bottom of tank to remove condensate or water from the bottom of the tank. Two connections are taken from the tank one goes to Control of the instruments system and one is use for as service air for the plant users. There are eight connections are given to supply instrument control system and eight connections are provided for service air system. The Compressors are available in air-cooled and water-cooled version. GA Workplace is enclosed in sound-insulated bodywork. The compressors are controlled by the Atlas Copco Elektronikon® II regulator. The electronic control module is fitted to the door on the right side. An electric cabinet comprising the motor starter is located behind this panel. A condensate trap with Electronic Water Drain (EWD) is provided.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


2.2 AIR FLOW

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Reference Description

A Intake air

B Air/oil mixture

C Oil

D Wet compressed air

F Condensate

G Dry compressed air

Note: The cooling fan is not provided on water-cooled compressors.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


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 (AR) via check valve (CV). The air is

discharged through outlet valve (AV) via minimum pressure valve (Vp) and air cooler (Ca).

The air cooler is provided with a moisture trap (MT).

On Full-Feature compressors, the air flows through air dryer (DR) before it is discharged through

outlet valve (AV). Also see section Air dryer. Instruction book 16 2920 1633 02

Check valve (CV) prevents blow-back of compressed air when the compressor is stopped. Minimum

pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure.

2.3 OIL SYSTEM OIL FLOW DIAGRAM

Oil system

References Description

1. For Workplace units, compressed air flow to the air outlet valve

For Full-Feature units, compressed air flow to the air dryer

1. Intake air

2. Air/oil mixture

3. Oil

D4. Wet compressed air

F Condensate

Note: The cooling fan is not provided on water-cooled compressors.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Description

In air receiver/oil separator (AR), most of the oil is removed from the air/oil mixture centrifugally.

The rest is removed by oil separator (OS). The oil collects in the lower part of air receiver/oil

separator (AR), which Serves as an oil tank.

The oil system is provided with a thermostatic by-pass valve (BV). When the oil temperature is

below its set point, by-pass valve (BV) shuts off the supply to oil cooler (Co) and the oil cooler is

bypassed. See section Compressor data for the set point of valve (BV).

Air pressure forces the oil from air receiver/oil separator (AR) through oil filter (OF) and oil stop

valve (Vs) to compressor element (E) and its lubrication points.

By-pass Valve (BV) starts opening the supply from cooler (Co) when the oil temperature has

increased to the set point. At approx. 15 ˚C (27 ˚F) above the set point, all the oil flows through the

oil cooler.

Oil Stop Valve (Vs) prevents the compressor element from flooding with oil when the compressor is

stopped. The valve is opened by element outlet pressure when the compressor is started.

2.4 COOLING SYSTEM

Flow diagram

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Cooling system, air-cooled compressors

Cooling system, water-cooled compressors

References Description

1. A Intake air

2. B Air/oil mixture

3. C Oil

4. D Wet compressed air

5. E Condensate

6. F Water flow

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).

Water-cooled compressors have a cooling water system. The water flows through the inlet pipe, the

coolers and the outlet pipe.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


2.5 CONDENSATE SYSTEM

ELECTRONIC WATER DRAINS

GA Workplace and Workplace Full-Feature compressors have an electronic water drain (EWD).

The condensate from the air cooler accumulates in a collector. When the condensate reaches a

certain level, it is discharged through drain outlet (Da).

On GA Workplace Full-Feature compressors, an additional electronic water drain (EWD1) is

provided. The Condensate trap of the heat exchanger is drained by EWD1 and discharged through

drain (Da1).

Also see section Air flow. Testing the electronic water drain can be done by briefly pressing the test

button (1) on top of the drain.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


2.6 REGULATING SYSTEM

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


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 plunger of

the valve returns:

Solenoid valve (Y1) de-activates unloading valve/blow-off valve (UV).

Unloading valve/blow-off valve (UV) connects the air receiver pressure (1) with chamber (2)

and blow off opening (3).

The pressure in chamber (2) causes the loading plunger (LP) to move upwards.

The pressure is stabilized at low value. A small amount of air is kept drawn in and is blown to

the unloaded.

LOADING

When the net pressure decreases to the loading pressure, solenoid valve (Y1) is energised. The

plunger of solenoid (Y1) moves upwards:

Solenoid valve (Y1) controls the unloading valve/blow-off valve (UV).

Unloading valve/blow-off valve (UV) closes the air blow-off opening (3) and shuts off the

supply to Chamber (2).

This causes loading plunger (LP) to move downwards and inlet valve (IV) to open fully.

Air delivery is resumed (100%), the compressor runs loaded.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


2.7 ELECTRICAL SYSTEM

General

Also consult sections Electrical diagrams and Electrical connections.

Electrical components

The electrical system comprises following components:

Electric cubicle on GA 55+ up to GA 90, typical example

Reference Designation

F1/2/3 Fuses

F3 is only provided in case of a phase sequence relay

F4/5/6 Fuses

F7/F8/F9 Fuses (only on Full-Feature)

F10/11/12 Fuses

F21 Overload relay, compressor motor

Q15 Circuit breaker, fan motor (on air-cooled compressors)

K5 Auxiliary relay

K11 Auxiliary contactor for dryer (only on Full-Feature)

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


K21 Line contactor

Instruction book

2920 1633 02 21


K22 Star contactor

K23 Delta contactor

T1 Transformer

1X0 Terminal strip (voltage supply)

X103/X108 Connectors

(1) Emergency stop

(2) Remote start/stop

(3) Remote load/unload

(4) Remote pressure sensing

(5) Motor protections

Instruction book

22 2920 1633 02


(6) Overload, fan motor

(7) Fault, EWD

(8) Dp, DD filter

(9) Dp, PD filter

(10) Remote pressure set selection

(11) Option ES 100

(12) Remote emergeny stop

(13) Auxiliary contacts

(14) Manual/automatic operation

(15) General warning

(16) General shut-down

Designations for Elektronikon II

Reference Sensors / solenoid valves / electronic water drain

A1 Dryer (Full-Feature)

B1 Electronic water drain (EWD)

PDT01 Pressure sensor, pressure difference across oil separator

PT20 Pressure sensor, air outlet

TT01 Temperature sensor, ambient air

TT11 Temperature sensor, element outlet

TT51 Temperature sensor, cooling water inlet (water-cooled compressors)

TT52 Temperature sensor, cooling water outlet (water-cooled compressors)

TT53/54 Temperature sensor, energy recovery water inlet/outlet (water-cooled compressors)

TT90 Temperature sensor, dew-point (Full-Feature)

Y1 Loading solenoid valve

Reference Motors

M1 Drive motor

M2 Fan motor (on air-cooled compressors)

Reference Electric cabinet

F1/9 Fuses

F21 Overload relay, drive motor

K21 Line contactor

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


K22 Star contactor

K23 Delta contactor

Q15 Circuit breaker, fan motor

T1 Transformers

1X0 -1X7 Terminal strips

X101-117 Connectors

Instruction book

2920 1633 02 23

Reference Control module

I Start button

K01 Blocking relay

K02 Auxiliary relay, star contactor

K03 Auxiliary relay, delta contactor

K04 Auxiliary relay, loading/unloading

K05 Auxiliary relay, air pressure high/low

K06 Auxiliary relay, dryer

K07 Auxiliary relay, manual/automatic operation

K08 Auxiliary relay, warning

K09 Auxiliary relay, shut-down

O Stop button

S3 Emergency stop button

Reference Optional equipment

AIE1/2 Expansion modules, analogue input

B2 Electronic water drain (EWD) (Full-Feature)

DPT11/12 Dual pressure transmitters

K04’ Auxiliary relay, load/unload for ES100

K21 Auxiliary contact, compressor running for ES100

K25 Phase sequence relay

PDS11 Delta p switch for integrated DD filter

PDS12 Delta p switch for integrated PD filter

R1, K34 Drive motor thermistor protection, shut-down

R2, K35 Drive motor thermistor protection, warning

R3/R4/R7 Heaters, freeze protection

R96/97 Anti-condensation heaters

S10 Main power isolating switch

TSLL91 Thermostat, freeze protection

Y2 Solenoid valve

Y51 Water shut-off valve (water-cooled compressors)

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


2.9 AIR DRYER

A Refrigerant gas

B Refrigerant liquid

C Condensate

AI Air inlet

AO Air outlet

1 Air/air heat exchanger

2 Air/refrigerant heat exchanger/evaporator

3 Condensate separator

4 Condensate outlet

5 Refrigerant compressor

6 Refrigerant condenser

7 Liquid refrigerant dryer/filter

8 Thermostatic expansion valve

9 Hot gas by-pass valve

10 Condenser cooling fan

11 Pressure switch, fan control

Compressed Air Circuit

Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the

incoming air starts to condense. The air then flows through heat exchanger/evaporator (2) where the

refrigerant evaporates causing the air to be cooled further to close to the evaporating temperature of

the refrigerant. More water in the air condenses. The cold air then flows through separator (3) where

all the condensate is separated from the air. The condensate is automatically drained through outlet

(4).

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


The cold, dried air flows through heat exchanger (1) where it is warmed up by the incoming air.

Refrigerant Circuit Compressor (5) delivers hot, high-pressure refrigerant gas which flows through

condenser (6) where most of the refrigerant condenses.

The liquid flows through liquid refrigerant dryer/filter (7) to thermostatic expansion valve (8). The

refrigerant leaves the thermostatic expansion valve 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.

General

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 compressor operation

The regulator maintains the net pressure between programmable limits by automatically loading and

unloading the compressor. A number of programmable settings, e.g. the unloading and loading

pressures, the minimum stop time and the maximum number of motor starts are taken into account.

The regulator stops the compressor whenever possible to reduce the power consumption and restarts

it automatically when the net pressure decreases. If the expected unloading period is too short, the

compressor is kept running to prevent too-short standstill periods. A number of time-based automatic start/stop commands may be programmed. Take into account that a start

command will be executed (if programmed and activated), even after manually stopping the compressor.

Protecting the compressor

Shut-down

If the compressor element outlet temperature exceeds the programmed shut-down level, the

compressor will be stopped. This will be indicated on display (1) and general alarm LED (2) will

flash.

The compressor will also be stopped in the event of overload of:

• The drive motor

• The fan motor

Remedy the trouble and reset the message. See also the Status data menu. Before remedying, consult the Safety precautions.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Shut-down warning

A shut-down warning level is a programmable level below the shut-down level.

If the compressor element outlet temperature exceeds the programmed shut-down warning level, a

message will appear on display (1) and general alarm LED (2) will light up, to warn the operator that

the shut-down warning level is exceeded.

The message disappears as soon as the warning condition disappears.

Service warning

A number of service operations are grouped (called Service plans A, B, C,). Each Service plan has a

programmed time interval. If a time interval is exceeded, a message will appear on display (1) to

warn the operator to carry out the service actions belonging to that plan.

Warning

A warning message also appears if:

• On water-cooled compressors the cooling water temperature exceeds the warning level.

• On Full-Feature compressors, the dew-point temperature is too high in relation to the

ambient temperature.

Automatic restart after voltage failure

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 compressor slaving the factory. 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 within a programmed time period.

The power recovery time (the period within which the voltage must be restored to have an Automatic restart)

can be set between 10 and 3600 seconds or to ‘Infinite’. If the power recovery time is set to ‘Infinite’, the

compressor will always restart after a voltage failure, no matter how long it takes to restore the voltage. A

restart delay can also be programmed, allowing e.g. two compressors to be restarted one after the other.

Parts and functions

Reference Designation Function

1 Start button Button to start the compressor. LED (8) lights up indicating that the Elektronikon

regulator is operative.

2 Display Shows messages about the compressor operating condition, a service need or a fault.

3 Scroll keys Keys to scroll upwards or downwards through the display.

4 Tabulator key to select the parameter indicated by the horizontal arrow. Only the parameters

followed by an arrow pointing to the right can be modified.

5 Function keys Keys to control and program the compressor.

6 Voltage on LED Indicates that the voltage is switched on.

7 General alarm LED Is lit if a warning, service warning or shut-down warning condition exists.

8 General alarm LED Flashes if a shut-down condition exists, if an important sensor is out of order or

after an emergency stop.

9 Automatic operations LED Indicates that the regulator is automatically controlling the compressor.

10 Stop Button to stop the compressor. LED (8) goes out. The compressor will stop after running in

unloaded condition for about 30 seconds. S3 Emergency stop button Push button to stop the

compressor immediately in the event of an emergency. After remedying the trouble, unlock the button

by pulling it out.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Function keys

The keys (1) are used:

• To manually load/unload the compressor

• To call up or to program settings

• To reset a motor overload, shut-down or service message, or an emergency stop

• To access all data collected by the regulator

The functions of the keys vary depending on the displayed menu. The actual function is indicated

just above the relevant key. The most common functions are listed below:

Designation Function

‘Add’ To add compressor start/stop commands (day/hour)

‘Back’ To return to a previously shown option or menu

‘Canc’ To cancel a programmed setting when programming parameters

‘Del.’ To delete compressor start/stop commands

‘Help’ To find the Atlas Copco Internet address

‘Lim.’ To show limits for a programmable setting

‘Load’ To load the compressor manually

‘Main’ To return from a menu to the main screen

‘Menu’ Starting from the main screen, to have access to the submenus

‘Menu’ Starting from a submenu, to return to a previous menu

‘Mod.’ To modify programmable settings

‘Prog’ To program modified settings

‘Rset’ To reset a timer or message

‘Rtrn’ To return to a previously shown option or menu

‘Unld’ To unload the compressor manually

‘Xtra’ To find the module configuration of the regulator

3.5 EMERGENCY STOP BUTTON

In the event of an emergency, press button (S3) to stop the compressor immediately. Before starting any maintenance or repairs, wait until the compressor has stopped. Close the air outlet valve.

Unlock the button by pulling it out. Press the test button on top of the electronic water drain(s) until the air

system between the air receiver and outlet valve is fully depressurized. Open the isolating switch (customer's

installation) to switch off the voltage to the compressor. Depressurize the air system. See section Problem

solving.

Apply all relevant Safety precautions

The Status data submenu gives information regarding the status of the compressor protection

functions (shutdown,

shut-down warning, service warning and warning) and allows resetting of a shut-down, motor over

load and service condition.

Procedure

Starting from the Main screen (see Main screen menu):

• Press the key ‘Menu’ (F1): the option ‘Status data’ will be followed by a horizontal arrow.

• Press the tabulator key (2).

No message exists

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


• General alarm LED (1) is out and the message on the display will indicate that all conditions

are normal: ‘All Conditions are OK’

A shut-down message exists

• If the compressor is shut down, LED (1) will flash.

• In the event of a shut-down due to too high a temperature at the outlet of the compressor

element: ‘Element Outlet’˚C 122‘Shd’ ‘Max.’ 120‘Menu**’ ‘**Rset’F1 F2 F3

• The indicators (**) are flashing. The screen shows the actual reading (122˚C), that the

compressor is shut down (‘Shd’), and the shut-down setting (120˚C).

• It remains possible to scroll through other menus, e.g. to check the values of other

parameters.

When returning to the ‘Status data’ menu, the option ‘Shutdowns’ will flash. This option can

be selected by pressing the tabulator key (2) to return to the above shut-down screen.

Shut-down reset

• Switch off the voltage and remedy the trouble. After remedying and when the shut-down

condition has disappeared, switch on the voltage and press the key ‘Rset’ (F3).

• Press the keys ‘Menu’ and ‘Main’ to return to the Main screen and restart the compressor by

means of start button (3).

Motor overload reset

• Switch off the voltage and remedy the trouble. The overload relay (F21) and fan circuit

breaker (Q15) must be reset manually. Switch on the voltage and press the key ‘Rset’ (F3).

• Press the keys ‘Menu’ and ‘Main’ to return to the Main screen and restart the compressor by

means of start button (3).

A shut-down warning message exists

A shut-down warning level is a programmable level below the shut-down level.

• If a shut-down warning exists, LED (1) is lit. The Main screen will change into a screen

similar to the onebelow: ‘Compr. Outlet’bar 7.0 ‘*Shutd’ ‘Warn*’ ‘Menu**’ ‘**Unld’F1 F2 F3

• The indicators (**) are flashing. The message ‘*Shutd’ ‘Warn*’ appears alternately with the

messages indicating whether the compressor runs unloaded or loaded.

• Press the key ‘Menu’ (F1) and the tabulator key (2) to select the ‘Status data’ menu; the

option ‘Protection’ is flashing.

• Scroll to this option and select it by pressing the tabulator key (2). A screen similar to the

one below appears: Element outlet ˚C ‘Shdw’ ‘Max.’ 116 ‘Menu**’ 110 F1 F2 F3

• The screen indicates that the temperature at the outlet of the compressor element exceeds the

programmed shut-down warning level.

• If necessary, stop the compressor by means of stop button (4) and wait until it has stopped.

• Switch off the voltage, inspect and remedy.

• The warning message will disappear automatically as soon as the warning condition

disappears.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


A service warning exists

• LED (1) is lit. The Main screen will change into a screen similar to the one below: ‘Comp. Outlet’ bar

‘*Serv.Requir.*’

‘Menu**’ ‘**Unld’

F1 F2 F3

• The indicators (**) are flashing and the service warning message appears alternately with the

messages indicating whether the compressor runs unloaded or loaded.

• Press the key ‘Menu’ (F1) and the tabulator key (2) to select the ‘Status data’ menu: the

option ‘Service’ is flashing.

• Scroll to this option and select it by pressing the tabulator key (2); two options may flash:

• ‘Inputs’: if the programmed service level of a component is exceeded (e.g. the maximum

pressure drop of the oil separator).

• ‘Plans’: if a service plan interval is exceeded.

• Stop the compressor and switch off the voltage.

• If the service message was referring to ‘Inputs’ (oil separator): replace the separator, switch

on the voltage, scroll in the ‘Status data’ menu to ‘Inputs’ and press the ‘Reset’ key to reset

the service message.

• If the service message was referring to ‘Plans’: carry out the service actions related to the

indicated plans.

Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See

section Service menu.

A warning message exists

• LED (1) is lit and a warning message will appear on the screen.

• The indicators (**) are flashing and the warning message appears alternately with the

messages indicating whether the compressor runs unloaded or loaded. This warning

indicates that:

• On water-cooled compressors the cooling water temperature exceeds the programmed

warning level.

• On Full-Feature compressors with IFD dryer the dew-point temperature is too high in

relation to the ambient temperature.

• Stop the compressor and switch off the voltage. Inspect the compressor and remedy.

Modifying the loading and unloading pressures

If desired, the operator can program two pressure bands (band 1 and band 2) with different loading

and Unloading pressures. The settings for band 1 are indicated as ‘Loading Press.’ and ‘Unloading

Press.’, the Settings for band 2 are indicated as ‘Loading Press.2’ and ‘Unloading Press.2’).

Example:

For pressure band 1:

• Loading pressure: 6.4 bar

• Unloading pressure: 7.0 bar

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


For pressure band 2

• Loading pressure: 4.0 bar

• Unloading pressure: 6.0 bar

Procedure

• Consult the section Procedure above to select ‘Loading Press’. ‘Loading Press.’ bar 6.0 ‘Menu’ ‘Mod.’ F1 F2 F3

• The screen shows that the current setting is 6.0 bar (e). To modify this setting, press the key

‘Mod.’ (F2); the setting will flash.

• The key ‘Lim.’ (F2) can be used to find out the limitations for the parameter.

• Use the scroll keys (1) to change the setting.

• Press the key ‘Prog’ (F1) to program the new value or the key ‘Canc’ (F3) to cancel the

modification operation.

• The procedure to modify the unloading pressure is similar.

• If required, repeat the procedure for pressure band 2.

• The procedure to modify other parameters is similar. The regulator will not accept new values beyond the limits. Press the key ‘Lim.’ to check the

Limitations for the parameter. Consult section Programmable settings for the most important

SETTINGS

OPERATING INSTRUCTIONS

7.1 BEFORE INITIAL START-UP

Safety

The operator must apply all relevant safety precautions, including those mentioned in this book.

Outdoor/altitude operation

If the compressor is installed outdoors or if the air inlet 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.

Moving/lifting

The compressor can be moved by a lift truck using the slots in the frame. Take care not to damage

the bodywork during lifting or transport. Before lifting, reinstall the transport securing bolts. Make

sure that the forks protrude from the other side of the frame. The compressor can also be lifted after

inserting beams in the slots.

Make sure that the beams cannot slide and that they protrude from the frame equally. The chains

must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. The

lifting equipment must be placed in such a way that the compressor is lifted perpendicularly. Lift

gently and avoid twisting. In case of units equipped with the Lifting Device Option, it is not allowed to lift the compressor if the canopy

parts or lifting supports are not completely installed. When the compressor is being lifted, it is also forbidden

to come under the load or to perform maintenance activities to it.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Regulator

Have the modifications checked by Atlas Copco.

Stop the compressor and switch off the voltage before connecting external equipment. Only voltage-free

contacts are allowed.

Consult section Programming compressor control modes if it is desired to switch to another control

mode.

The following control modes can be selected:

• Local control: The compressor will react to commands entered by the buttons on the control

panel.

Compressor start/stop commands via Clock function are active, if programmed.

• Remote control: The compressor will react to commands from external switches. Emergency

stop remains active. Compressor start/stop commands via Clock function are still possible.

For remote starting and stopping:

• Connect a start/programmed stop button between terminals 1 and 2 of connector (X108). See

section. Electrical system to locate the connector.

• Bridge terminals 1 and 3 of connector (X108): In this mode, the outlet pressure is still sensed

by pressure transducer (PT20), resulting in loading and unloading of the compressor at the

pressures programmed in the electronic regulator. If terminals 1 and 3 of connector (X108)

are not bridged, the compressor is switched out of automatic load/unload operation and

remains running unloaded. Electrical system to locate the connector.

For remote loading/unloading (via external pressure switch):

• Bridge terminals 5 and 6 of connector (X108) and connect a load/unload switch between

terminals 1and 3 of connector strip (X108). This results in loading and unloading of the

compressor at the closing and opening pressures of the external pressure switch respectively.

• LAN control: The compressor is controlled via a local network. Consult Atlas Copco.

7.2 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 and Condensate

system.

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.

- 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.

On air-cooled compressors, check the setting of circuit breaker (Q15). Also check that the switch on the

circuit breaker is in position I.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Fit air outlet valve (AV); see section Introduction for the location of the valve.

Close the valve.

Connect the air net to the valve.

On compressors equipped with a dryer by-pass, fit the air outlet valve to the dryer by-pass pipe.

Connect the condensate drain outlet(s) to a drain collector.

See section Condensate system.

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. For draining of pure condensate water,

Install an oil/water separator which is available from Atlas Copco as an option. See section OSD unit.

For compressors with a DD or a DD and PD filter connect the automatic drain of the filters to a suitable

drain collector.

On water-cooled compressors, drain valves, shut-off valves and a regulating valve should be fitted by the

customer in the cooling water piping.

- 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. On water-cooled compressors, close the cooling water drain valves. Open the cooling water inlet valve and

the regulation valve.

Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of drive

motor (M1) while the motor is coasting to a stop. The correct rotation direction of the drive motor is

indicated by an arrow shown on the motor fan cowl.

On air-cooled compressors, check also the rotation direction of the fan motor. Rotation arrows, visible

through the grating in the roof, are provided on the plate below the fan to indicate the correct rotation

direction of the fan motor.

If the rotation direction of the drive motor is incorrect, open the isolating switch and reverse two incoming

electric lines.

If the rotation direction of the fan motor is incorrect, open the isolating switch and reverse two incoming

electric connections at the terminals of circuit breaker (Q15).

Incorrect rotation direction of the drive motor may cause damage to the compressor.

On compressors equipped with an Elektronikon II regulator; check the programmed settings. Consult

section Programmable settings.

Start and run the compressor for a few minutes. Check that the compressor operates normally.

7.3 BEFORE STARTING

Remarks

• If the compressor has not run for the past 6 months, it is strongly recommended to improve

the lubrication of the compressor element at starting. Disconnect the inlet hose, remove the

unloader (UA) and pour 0.75 l (0.20 US gal, 0.17 Imp gal) of oil into the compressor

element. Reinstall the unloader and reconnect the inlet hose. Make sure that all connections

are tight.

• On Full-Feature compressors, switch on the voltage 4 hours before starting to Energies the

crankcase heater of the refrigerant compressor of the dryer.

See section Initial start-up for location of the oil system components.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Check oil level (Gl), top up if necessary. The pointer should be in the upper field of the green range

or in the orange range. If the pointer registers in the LOW range, depressurize the oil system (see

section Problem solving). Wait until the compressor has depressurized. Unscrew oil filler plug (FC)

only one turn to permit any pressure in the system to escape. Remove the filler cap and add oil until

the level reaches the filler neck. Tighten the plug. - If necessary, empty the dust trap of the filter, see section Air filter.

- If the red part of the air filter service indicator shows full out, replace the air filter element. Reset the

service indicator (VI) by pushing the knob in the extremity of the body and reset the service warning.

On compressors equipped with an Elektronikon II regulator, see section Service menu.

- On water-cooled compressors, also:

• Check that the cooling water drain valves in the inlet and outlet pipes are closed.

• Open the cooling water inlet valve.

• Open the water flow regulating valve. This step can be skipped if, after previous operation,

the setting of this valve has not been changed.

7.4 STARTING

Procedure

For the position of the air outlet valve and the drain connections, see sections Introduction and

Condensate system

Step Action

- Switch on the voltage. Check that voltage on LED (6) lights up.

- Open the air outlet valve.

- Press start button (1) on the control panel. The compressor starts running and the automatic

operation LED (8) lights up. Ten seconds after starting, the drive motor switches over from

star to delta and t he compressor starts running loaded.

- On water-cooled compressors, regulate the cooling water flow during loaded running to

obtain the most suitable temperature at the outlet of the compressor element, i.e. between 2

and 7 ˚C (4 and 13 ˚F) above the relevant temperature in the figure below. For optimum

operation, the cooling water outlet temperature must never exceed the value specified in

section Compressor data. Consult Atlas Copco if condensate should form during frequent

unloading periods.

Minimum compressor element temperature for water-cooled units

(A): Air inlet temperature

(B): Condensation temperature

(C): Working pressure

(D): Relative air humidity

Example:

If operating at a pressure of 10 bar (e) (145 psig) in an ambient temperature of 20 ˚C (68 ˚F) and at a

relative air humidity of 100%, the minimum temperature to prevent condensate from forming is 68

˚C (154 ˚F). Regulate the cooling water flow during loaded operation to obtain a temperature

between 70 and approx. 75 ˚C (158 and approx. 167 ˚F) at the outlet of the compressor element.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


7.5 DURING OPERATION

Procedure

The operator must apply all relevant Safety precautions. Also consult section Problem solving. Keep

the doors closed during operation; they may be opened for short periods only to carryout checks.

When the motors are stopped and LED (8) is a light, the motors may start automatically.

If not, press stop button (9). Close the air outlet valve and press the test button on top of the

electronic water drain (two water drains are provided on Full-Feature compressors) until the air

system between the air receiver and outlet valve is fully depressurized. See section Introduction and

section Condensate system for location of the outlet valve and water drain. Press the emergency stop

button (10).

Wait until the compressor has depressurized. Unscrew oil filler plug (FC) one turn to permit any

pressure in the system to escape. Wait a few minutes. Remove the plug and add oil until the level

reaches the filler opening. Fit and tighten the plug (FC).

If the colored part of service indicator (VI) shows full out, replace the air filter element. Reset the

service indicator by pushing the knob in the extremity of the body.

When automatic operation LED (8) is lit, the regulator is automatically controlling the compressor,

i.e. loading, unloading, stopping of the motors and restarting.

Regularly check that condensate is discharged during operation. See section Condensate system and

in case of an OSD, also check the level in the oil collector; see section OSD Maintenance and

operating Instruction. The amount of condensate depends on environmental and working conditions.

7.7 STOPPING

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 II: after remedying the fault, unlock the button by pulling

it out and press ‘Rset’ key (5) before restarting.

- Close air outlet valve (AV), see section Introduction.

- Press the test button on top of the electronic water drain(s) until the air system between air

receiver and outlet valve is fully depressurized. See section Condensate system.

Switch off the voltage.

- On water-cooled compressors:

• Close the cooling water inlet valve.

• If freezing temperatures can be expected, drain the cooling system completely.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


7.8 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.

Step Action

Press the test button on top of the electronic water drain(s) until the air system between

air receiver and outlet valve is fully depressurized. Consult section Condensate system

to locate the drain valve.

Switch off the voltage and disconnect the compressor from the mains.

Unscrew the oil filler plug only one turn to permit any pressure in the system to escape.

Consult section Oil and oil filter change to locate the filler plug.

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.

- On water-cooled compressors:

• Isolate and disconnect the water system from the cooling water net.

• Drain the water circuit.

• Drain the oil.

• Drain the condensate circuit and disconnect the condensate piping from the

condensate.

11.6 REFERENCE CONDITIONS AND LIMITATIONS

Reference conditions

Air inlet pressure (absolute) bar 1

Air inlet pressure (absolute) psi 14.5

Air inlet temperature ˚C 20

Air inlet temperature ˚F 68

Relative humidity % 0

Working pressure for GA 55+ up to GA 90 See section Compressor data

On water-cooled units also:

Cooling water inlet temperature ˚C 20

Cooling water inlet temperature ˚F 68

Limits

Maximum working pressure for GA 55+ up to GA 90 See section Compressor data

Minimum working pressure bar(e) 4

Minimum working pressure psig 58

Maximum air inlet temperature ˚C 46

Maximum air inlet temperature ˚F 115

Minimum air inlet temperature ˚C 0

Minimum air inlet temperature ˚F 32

On water-cooled units also:

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Maximum cooling water outlet temperature ˚C 50

Maximum cooling water outlet temperature ˚F 122

Maximum cooling water inlet pressure bar(e) 5

Maximum cooling water inlet pressure psig 72.52

11.7 COMPRESSOR DATA

Reference conditions

All data specified below apply under reference conditions, see section Reference

Conditions and limitations.

GA 55+

Units 7.5 bar 8 bar 10 bar 100 psi 125 psi 150 psi

Frequency Hz 50/ 50/ 50/ 60/ 60/ 60.

Maximum (unloading) pressure bar (e) 7.5/ 8/ 10 /7.4 /9.1 /10.8.

Maximum (unloading) pressure psig 109 /116 /145 /107 /132 /156.

INSTRUCTIONS FOR USE OF AIR RECEIVER

12.1 INSTRUCTIONS FOR USE

Instructions

1 This vessel can contain pressurized air; this can be potentially dangerous if the equipment is

misused.

2 This vessel must only be used as a compressed air/oil separator and must be operated within

the limits specified on the data plate.

3 No alterations must be made to this vessel by welding, drilling or other mechanical methods

without the written permission of the manufacturer.

4 The pressure and temperature of this vessel must be clearly indicated.

5 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.

6 Use only oil as specified by the manufacturer.

7 Original bolts have to be used after opening for inspection. The maximum torque has to be

taken into consideration: for M12 bolts 73 Nm (53.87 lbf.ft) (+/- 18), for M16 bolts 185 Nm

(136.53 lbf.ft) (+/- 45).

13.1 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.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


Local legal requirements and/or use outside the limits and/or conditions as specified by Atlas Copco

may require other inspection periods as mentioned below.

Instruction book

2920 1633 02 119

14 PED

14.1 PRESSURE EQUIPMENT DIRECTIVES

Components subject to 97/23/EC Pressure Equipment Directive

The following table contains the necessary information for the inspection of all pressure equipment

of category II and higher according to the Pressure Equipment Directive 97/23/EC and all pressure

equipment according to the Simple Pressure Vessel Directive 87/404/EEC.

Compressor type Component Description Volume Design Pressure Minimum and Maximum

design temperature PED Class

GA 55+ up to GA 90 1622 3658 99 Vessel 63 l 15 bar(e) -10 ˚C/ 120 ˚C II

1202 5401 00 Safety valve - - - IV

1202 5749 00 Safety valve - - - IV

1202 5452 00 Safety valve - - - IV

1613 7810 00 Safety valve - - - IV

Compressor type Component Description Number of cycles (1) Minimum wall thickness Visual

inspection requirements

(2) Hydrostatic inspection requirement s (2)

GA 55+ up to GA 90 1622 3658 99 Vessel 2 x 106 8 mm 10 years 10 years

1202 5401 00 Safety valve - - - -

1202 5749 00 Safety valve - - - -

1202 5452 00 Safety valve - - - -

1613 7810 00 Safety valve - - - -

(1) The number of cycles refers to the number of cycles from 0 bar(e) to maximum pressure.

(2) Other inspection techniques such as ultrasonic or X-ray are equivalent to hydrostatic testing

for this equipment.

The compressors conform to PED smaller than category II. What sets Atlas Copco apart as a

company is our conviction that we can only excel in what we do if we provide the best possible

know-how and technology to really help our customers produce, grow and succeed.

There is a unique way of achieving that - we simply call it the Atlas Copco way. It builds on

interaction, on long-term relationships and involvement in the customers’ process, needs and

objectives. It means having the flexibility to adapt to the diverse demands of the people we cater for.

It’s the commitment to our customers’ business that drives our effort towards their productivity

through better solutions. It starts with fully supporting existing products and continuously doing

things better, but it goes much further, creating advances in technology through innovation. Not for

the sake of technology, but for the sake of our customer’s bottom line and peace-of-mind.

That is how Atlas Copco will strive to remain the first choice, to succeed in attracting new business

and to maintain our position as the industry leader.

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


15.0 INSTRUMENTS AND THEIR FUNCTION

15.1 PG001/002………..Pressure gauge on two pressure gauges are installed to measure the inlet and outlet pressure of pre-filters.

15.2 RLC01A/RL01B …….Relays installed for starting of compressor.

15.3 RAC01A/RAC01B……Relays for Malfunctioning of compressor alarm.

15.4 HSC01A/HSC01B…… Stop Switch relay is installed for stop the

Compressors.

15.5 PG006/PG007………… Pressure gauges are installed to measure the discharge pressure of the Compressors.

15.6 RLN01A/RL01B…………Relays are installed on dryers to show running state.

15.7 RAN01A/RAN01B…………Relays for Malfunctioning alarm of dryers.

15.8 AA001…………..Dew point switch is installed for dew point.

15.9 PG003/PG004……… Two pressure gauges are installed at the inlet and outlet of the After Filters to measure the pressure.

15.10 PG005……………. Pressure gauge is installed to measure the pressure of the Air Compressor tank.

15.11 PT001……………. Pressure transmitter is installed to control discharge pressure through service air motorized valve.

15.12 PT002…………. Pressure transmitter is installed on the service air header to measure the service header pressure.

9.0 REFERENCES

TO7BO9-240PS07-001 PID – Air Compressor System

Prepared By Muhammad Suleman Malik

Reviewed By

Approved By

Document Type:

SYSTEM DESCRIPTION



LP-SD-002



Change: Date:


air compressor system

Documents