Technical Instruction

1. General Information

Pre Commissioning & Installation Guidelines

Document Number : CTS / 2019 / AII / PC / 004

Applicable to : GA 15 – 22
Date : December, 2019

2. Document Overview
This document describes the following:
1. General information ........................................................................................................................................................1
2. Document overview ........................................................................................................................................................1
3. Safety First .....................................................................................................................................................................2
4. Machine Inspection.........................................................................................................................................................3
5. Machine Dimension ........................................................................................................................................................4
6. Compressor Room .........................................................................................................................................................6
7. Layout.............................................................................................................................................................................7
8. Installation ......................................................................................................................................................................8
8.1 Electrical............................................................................................................................................................................8
8.2 Air Net ..............................................................................................................................................................................9
8.3 Ventilation Duct .................................................................................................................................................................9
8.4 Condensate Drain ...........................................................................................................................................................11
8.5 Air Receiver Tank ............................................................................................................................................................11
9. Technical Data..............................................................................................................................................................12
10. Recommendation .........................................................................................................................................................13

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3. Safety First

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4. Machine Inspection

Check packing thoroughly for any physical damage while receiving the machine. There should be no damage to wooden
packing.
Open wooden packing & inspect from inside. Check machine also thoroughly for any physical damage, if found any physical
damage to machine, mention the same on the LR copy & inform Atlas Copco immediately with snaps.
If wooden packing is intact but physical damage observed only on machine, then also mention the same on LR copy &
inform Atlas Copco immediately with snaps.
Place machine under shed with proper covering until Atlas Copco service engineer visits.

While moving the compressor take special care while lifing it. The compressor can be moved by a lift truck on the side of the
frame or by a suitable hoist.
Take care not to damage the bodywork during lifting or transport. Make sure that the forks support the frame sufficiently.

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5. Machine Dimension

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6. Compressor Room

Installing a compressor in a correct location is very critical for its performance. This must not to be compromised at any cost.
This is the most important activity in the entire commissioning process. Any compromises in finalising compressor room may
affect compressor performance adversely.
Wrong or faulty installation may increase overall maintenance costs & may also lead to pre mature failure of compressor
components.
Dust and Heat are the biggest contributor in compressor failure, so this must be kept in mind while choosing the compressor
location.
All stationary compressors are intended for indoor use, in frost free conditions.

Following points to be considered -

Room should have cross ventilation.
It should avoid direct sunlight & rainwater entry on machine.
There should be no recirculation of hot air.
Floor should be solid, levelled & should be able to bear weight of machine (No wooden planks) with maximum contact with
the compressor base frame.
There should not be any heat/dust/moisture source near the machine (Furnace, DG, Cooling tower etc).
There should be enough space all around machine for carrying out maintenance.
There should be enough space above machine for venting of hot air or installation of duct if required.
Provision for taking out condensate drain from cooler drains into proper channels.

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7. Layout

Install air dryer (stand alone) before or after recevier tank as per air demand. Install the bypass line and the on-off valves so
that the necessary maintenance may be carried out without interrupting the flow of compressed air. Check that the valve is
perfectly closed so that non-treated air does not pass through it during the operation.

A.) AIR TREATMENT WITH DRYER DOWNSTREAM FROM THE TANK :

This installation is suggested when the compressors run intermittently and the intermittent consumption, is equal to the flow
rate of the compressor. Under this condition the load of the dryer is particularly constant

B.) AIR TREATMENT WITH DRYER UPSTREAM FROM THE TANK :

This type of installation is suggested when the air demand is variable and the instant values of the air consumption are much
higher or lower than the flow rate of the compressors. The tank must be large enough to meet the max. requirement with the
stored dry air.

For Indian condition, type – A is more suitable.

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8. Installation

After installation of compressor in proper room as per above mentioned recommendation, electrical, piping, ducting,
condensate drain connections needs to be made.

8.1 Electrical
This machine can only be used in TT/TN networks and is intended for industrial environments where the electrical supply is
separated from the residential/commercial supply network. To use the machine in light industrial, commercial or residential
environments with a shared supply network, extra measures can be required: contact Atlas Copco.
To preserve the protection degree of the electric cubicle and to protect its components from dust from the environment, it is
mandatory to use a proper cable gland when connecting the supply cable to the compressor.
The voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is however highly
recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC
60204-1). If cables are grouped together with other power cables, it may be necessary to use cables of a larger size than
those calculated for the standard operating conditions.

Provide an isolating switch fuse unit nearby the compressor.

Connect the power supply cables at R, Y, B terminal. (For cable size refer Tech Data Section )
Connect the earth conductor to earth screw.
For cable entry use proper glands. Cables should be connected stress free to terminals.

Copper Cable is recommended. If Aluminium then use one size higher than recommended copper cable (though Aluminium
cable should be avoided). For incoming backup install only Fuses, MCB/MCCB is not recommended,.
Use proper cable only for earthing, no aluminium strips recommended. Earth cable size should be minimum half of the size
of main supply cable. For VSD compressors, dedicated earthing is must i.e earth cable connected to earth pit at one end &
the other end connected to earth screw at cubicle inside compressor.

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8.2 Air Net

Recommended Del pipe size can be calculated by following formula considering the pressure drop as 0.1bar (1.5 psi),
DP = (L * 450 * QC^1.85)/ (D^5*P), Where DP-recommended pressure drop
L- Length of Del pipe in m
D - Dia of delivery pipe in mm
P - Absolute pressure at the compressor outlet
QC - Free air delivery of compressor in L/S
Minimum pipe size should be more /equal to outlet valve connection already provided in compressor.
It is recommended, for overhead header, that connection of the compressor air outlet pipe is made on the top of the main air
net pipe (Goose Neck type) in order to minimise carryover of possible condensate residue. There should be no NRV
installed in between compressor & Main receiver tank.

NOT OK OK
Downward conn ections Go ose neck C onnectio n
may allo w back flow of
condensat e into the
compressor .

Compressor

8.3 Ventilation Duct

The inlet grids & ventilation fan should be installed in such way that any recirculation of cooling air should be avoided. The
air velocity to the grid must be limited to 5 m/s. The max allowable pressure drop over the cooling air ducts is 30 Pa.If it is
greater than this value then fan is needed at the outlet of cooling ducts .Pl consult Atlas copco.
For full feature machines i.e. with integrated dryers, there will be two outlet for exhaust air at the top of canopy. Duct to be
installed on main cooling fan outlet.

For normal conditions, Alternative 1 is suitable. For duct length above 3 meters, Alt. 2 is suitable. For Alt 2, fan capacity
should match the compressor fan capacity at a pressure head equal to the pressure drop across the cooling ducts. Give
proper support to duct, its weight must not fall onto compressor bodywork.

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In general, the cross sectional area of duct should remain the same throughout its length avoiding any sharp bend.

NOT OK NOT OK

Cross section al a rea reduced, this will Too many bends, t his will restrict air f low.
re strict air flo w.

NOT OK NOT OK

Dryer duct merg ed i nto main c ooling fa n Duct o utle t kept to wards ope ning for s uction
duct, this wil l aff ect dryer dew poin t. air, this will cause hot air recir cula tion .

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8.4 Condensate Drain
The drain pipes to the drain collector must not dip into the water of the drain collector. The condensate drain
should be visible so that any abnormalities can be identified at initial stage itself.

Compressor
Condensate drain

Open drain receptacle

To drain

8.5 Air Receiver Tank

The air receiver (Optional) should be installed in a frost – free room on a solid level floor. For normal air consumption the
volume of airnet (receiver & piping) can be calculated as follows:
V = (0.25*Qc*P1*T0)/ (fmax*dp*T1)
V=Volume of airnet in Lt
Qc = Free air delivery of compressor in l/s, P1 = compressor air inlet pressure in bar absolute
Fmax = cycle frequency =1 cycle/30s, Dp = Punload-Pload in bar
T1 = compressor air inlet temp in K, T0 = air receiver temp in k

Following thumb rule can be considered :-

Air flow Capacity Recommended Receiver Volume

cfm m3/h cu ft gal m3
100 170 13 100 0.4
200 340 27 200 0.8
300 510 40 300 1.1
400 680 54 400 1.5
500 850 67 500 1.9
750 1275 101 750 2.9
1,000 1700 134 1,000 3.8
1,500 2550 201 1,500 5.7
2,000 3400 268 2,000 7.6
3,000 5100 402 3,000 11.4
4,000 6800 536 4,000 15.2
5,000 8500 670 5,000 19.0
7,500 12750 1005 7,500 28.5
10,000 17000 1340 10,000 38.0

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9. Technical Data

Cable Size :-

Compressor Model Cable Size (Sq mm _ Copper_ 3.5 core)

At Ambeint 45 dC* At Ambeint 3 0 dC
GA 15 16 10
GA 18 25 16
GA 22 35 25

* Cable size selected based on Ambient temp (i.e Max. 45 deg) if the temp increases more
than 45 deg then cable size also need to be Checked as per local requirement and
upgraded to higher size.

Back up Fuse :-

Compressor Model Fuse (Amp)

gL/gG
GA 15 40
GA 18 50
GA 22 63

Setting for overload relay (F-21) :-

Model GA 15 GA 18 GA 22
Setting 20.55 23.8 28.1

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10. Recommendation

After completing all the above activates call Atlas Copco for commissioning of your compressor. Commissioning of
compressor is specialised job hence it is highly recommended that compressor should start first in presence of Atlas Copco
engineer only. Do not try to start the machine in absence of Atlas Copco engineer.

Wrong installation or wrong maintenance practices are the biggest contributor in compressor failure. Do not over due the
maintenance. Air filter is the most critical part in compressor, don't over due air filter replacement under any circumstances.
Air filter replacement frequency will solely depends upon the dust in environment. For Indian condition it needs to be
inspected at every 15 days & should be cleaned accordinging to its condition. At thrid cleaning this needs to be replaced wit h
new one.

Any failure due to wrong installation or wrong maintenance practice will not qualify for warranty replacement.

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