GA45 O&M Addendum
GA45 O&M Addendum
GA45 O&M Addendum
• This instruction book meets the requirements for instruction specified by the machin directive
98/37/EC and is valid for CE as well as non-CE labeled machines
2013 - 08
No. 2900 4018 85
www.atlascopco.com
Addendum to Instruction book No. 2920 7104 82
PREFACE
This is an addendum. This addendum describes how to handle and operate the subject machine, to ensure safe
operation, optimum working economy and long service life.
Please make this addendum available for the operator(s) and ensure that the machine is operated and maintained in
accordance with Atlas Copco instructions. Record all operating data, maintenance work ef fected, etc. in an operator's
logbook which is available from Atlas Copco. Follow all applicable safety precautions, as well as those mentioned in
this addendum.
It is highly recommended that repairs are performed by trained personnel fromAtlas Copco who can be contacted for
any further information.
This book only deals with the description and instructions applicable to the machine as it was shipped ex-factory. If
special devices or control systems are installed locally, complementary instructions must be added. If the machine is
used in a special process, the user should adapt the instructions, as required.
OWNERSHIP DATA
Selected lubricants
Compressor: ............................................................. Capacity: ............................................ .....................
Bearing grease type, electric motor: ............................
Dryer gearbox: .......................................................... Capacity: ............................................ .....................
Local Representative
Name: ......................................................................
Address: ..................................................................
Telephone: ............................ Contact persons: Service: ...................................................................
Telex: ................................... Parts: ......................................................................
E-mail: .....................................................................
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Addendum to Instruction book No. 2920 7104 82
Important notes :
Although any document that was delivered with the part is shipped with the machine, paper documents are often lost
or put aside.
Documentation of parts used in this machine fabricated by other manufacturers than Atlas Copco can best be found
on their internet website. (i.e. flow control products, motors, regulators …)
Most of them have a documentation sub-website where all information can be found.
If you have difficulties to find the information contact your Customer Centre.
B) Paint
Spare parts of these items will be delivered in st andard Atlas Copco grey for the canopy and standard black for the
frame. (Spare part numbers of standard parts are printed in the Spare parts list.)
If the unit is delivered with hydrostatic witnessed parts, spare part numbers of not witnessed standard parts are
printed in the Spare parts list.
To overcome long delays by ordering spare parts, partnumbers of hydrostatic witnessed parts will not be
supported.
D) Service Kits
In the Spare parts list only standard Service kits are printed. Service kits of special parts will not be supported.
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Addendum to Instruction book No. 2920 7104 82
A. SAFETY PRECAUTIONS
To be read attentively and acted accordingly before installing, operating or rep airing the unit.
All responsibility for damage or injury resulting from neglecting these precautions, or non-observance of
the normal caution and care required for inst allation, operation, maintenance and rep air, even if not
expressly stated, will be disclaimed by Atlas Copco.
General precautions
1. The operator must employ safe working practices and observe all related local work safety requirements
and regulations.
2. If any of the following statements does not comply with local legislation, the stricter of the two shall
apply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained,
specialised personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing
quality, the compressed air must be adequately purified according to local legislation and andards.
st
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor ,
press the emergency stop button, switch of f the voltage and depressurise the compressor. In addition,
the power isolating switch must be opened and locked.
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme
caution and wear eye protection.
1. The machine must only be lifted using suitable equipment in accordance with local 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.
Wear a safety helmet when working in the area of overhead or lifting equipment.
2. Place the machine where the ambient air is as cool and clean as possible. If necessary , install a suction
duct. Never obstruct the air inlet. Care must be taken to minimise the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can
lead to internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a clear sign stating:
DANGER: This machine is remotely controlled and may start without warning.
10. The machines must be installed in such a way that an adequate flow of cooling air is available and that
the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
11. The electrical connections must correspond to the local codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be
installed near the compressor.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the
instrument panel.
13. In multiple compressor systems, manual valves must be inst alled to isolate each compressor. Non-return
valves (check valves) must not be relied upon for isolating pressure systems.
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Addendum to Instruction book No. 2920 7104 82
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure-relieving device or devices as required.
15. Pipework or other parts with a temperature in excess of 80°C (176°F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high-temperature
pipework must be clearly marked.
16. If the ground is not level or can be subject to variable inclination, consult the Atlas Copco Customer Centre.
1. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely.A free end will whip and may cause injury. Make sure
that a hose is fully depressurized before disconnecting it.
2. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is
no one checking or working on the machine.To this end, a suitable notice shall be af fixed to the remote
start equipment.
3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or
particles.
4. Never operate the machine below or in excess of its limit ratings.
5. Keep all bodywork doors shut during operation.The doors may be opened for short periods only , e.g. to
carry out routine checks. Wear ear protectors when opening a door.
6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
7. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure-relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
8. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
9. Do not remove any of, or tamper with, the sound-damping material.
10. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall
be protected by a pressure-relieving device or devices as required.
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Addendum to Instruction book No. 2920 7104 82
11. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be openedbefore sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
12. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
13. Make sure that no tools, loose parts or rags are left in or on the machine.
14. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that
they function correctly. If removed, check that the coupling guard of the compressor drive shaf t has been
reinstalled.
15. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
16. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering
them, e.g. when steam-cleaning.
17. Make sure that all sound-damping material, e.g. on the bodywork and in the air inlet and outlet systems of
the compressor, is in good condition. If damaged, replace it by genuine Atlas Copco material to prevent the
sound pressure level from increasing.
18. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
19. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required,
use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin withwater. 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.
20. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
Note :
Some precautions are general and may not apply to your machine.
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Addendum to Instruction book No. 2920 7104 82
B. General
This addendum refers to the GA45 machine with serial numbers API S44534501, API S44534502, API S44534503
and API S44534504 only.
In the first section of this document, reference will be made to the constructional adaptations.
1.1 Additional
The compressor fulfills specific demands of the customer to perform its aimed tasks.
The following modifications have been made to the GA45 machine version:
COMPRESSOR
MECHANICAL
ELECTRICAL
SUPPLY DATA
SETTING
1.2 Attachments
The following drawings are an integral part of this addendum and must always accompany this publication:
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Addendum to Instruction book No. 2920 7104 82
C. Modifications
As explained in the introduction theGA45 machine supplied for this contract has been modified.The following modifications
to the standard instruction book are cross referenced by section, sub-section and paragraph.
1 General Description
1.1 Introduction
2 Installation
For specifications about the connections, refer the service drawing no.9820 7984 82.
10 2900 4018 85
COMPRESSOR
COOLING AIR
OUTLET
274 150 246 593±25 1764 68 175
Mainswitch
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A-meter
130
Local/LAN switch
150
369
187
Compressed
air outlet
824
COMPRESSOR
1523
COOLING AIR
1392
INLET
1325
1285
1284
730
Dimension drawing no. 9820 7320 00.
750
A
165
Addendum to Instruction book No. 2920 7104 82
74(2x)
15(2x)
1755
CUBICLE
CAN-cable connection 370 112 COOLING AIR
INLET
CUBICLE
COOLING AIR
OUTLET
571
79 150
245
811
150
Ø 42
523
50
520
283
50
78
70 370
660 295 125 295
1124
1102
Compressor mounting
54 481 972,5 holes Ø13mm (4x)
25
150
75
125
920
904,5
11
12
INSTALLED OPTIONAL COMPONENTS
S10 : Main disconnecting switch
MAIN POWER SUPPLY
VOLTAGE : 460V
FREQ : 60Hz 3 PH
125 A
Service drawing no. 9820 7984 82-01
SETTING
F21 56,1 A
TN/TT Q15 3,5 A
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Addendum to Instruction book No. 2920 7104 82
POWER CIRCUIT MAIN MOTOR
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Service drawing no. 9820 7984 82-02
Addendum to Instruction book No. 2920 7104 82
13
POWER CIRCUIT FAN
14
Service drawing no. 9820 7984 82-03
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Addendum to Instruction book No. 2920 7104 82
SUPPLY CONTROL CIRCUIT
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Service drawing no. 9820 7984 82-04
Addendum to Instruction book No. 2920 7104 82
15
CONTROL CIRCUIT
16
Service drawing no. 9820 7984 82-05
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Addendum to Instruction book No. 2920 7104 82
REGULATOR MK5
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Service drawing no. 9820 7984 82-06
Addendum to Instruction book No. 2920 7104 82
17
SMARTBOX
18
Service drawing no. 9820 7984 82-07
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Addendum to Instruction book No. 2920 7104 82
INPUT CONNECTIONS 2X27
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GND
T01
GND
T02
GND
T03
GND
P01
V+
DI-SUPPLY
DI02
MOTOR PROTECTIONS
DI01
EMERGENCY STOP
DI04
FAULT ELECTRONIC DRAIN
DI03
REMOTE START/PR. STOP
SUPPLY
24VAC
SUPPLY
24VAC
Service drawing no. 9820 7984 82-08
Addendum to Instruction book No. 2920 7104 82
19
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ACD
GND
PSI
Drawing owner
Name
T04
GND
T05
DIAGRAM SERVICE
GA45P A 175 APB 460 60 MED
GND
P02
V+
DI-SUPPLY
SPECIAL 445345/GBN
DI06
REMOTE LOAD/UNLOAD
(CLOSED=LOAD)
DI05
REMOTE PRESS. SENSING
(LINK=REMOTE)
Approved
STATUS
DI08
LOCAL LAN SWITCH
Ed.
00
Date
DI07
2013-07-02
PRESSURE SWITCH PS11
Drawn by
Prev. Page
DI10
08
REMOTE PRESS.SET SELECTION
(OPEN = PRESSURE SET 1)
AIR15417
(CLOSED = PRESSURE SET 2)
DI09
Date
Next Page 10
2013-07-02
A3
Designation
Sheet
9820 7984 82
09
( 14)
INPUT CONNECTIONS 2X28
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Service drawing no. 9820 7984 82-10
Addendum to Instruction book No. 2920 7104 82
21
22
Service drawing no. 9820 7984 82-11
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Addendum to Instruction book No. 2920 7104 82
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Service drawing no. 9820 7984 82-12
Addendum to Instruction book No. 2920 7104 82
23
24
Service drawing no. 9820 7984 82-13
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Addendum to Instruction book No. 2920 7104 82
NOTES :
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[A] Maximum fuses with regard to short circuit protection Pressure transducer pin configuration
of compressor. 1 : Supply V+
2 : Ground
[B] Power supply to be connected for : 3: Signal
1. CLOCKwise rotation of fanmotor 4 : Sealed with dummy
2. COUNTER CLOCKwise rotation of comp. motor
Rotation to be observed while facing the drive end
shaft of the motors.
Pressure difference transducer
[C] Check rotation of dryer fan motor (suction). 1 : Supply V+
2 : Ground
[E] Tightening torque of bolts:
3 : Signal
For contactors
metric thread size M6 7Nm (5lbft)
metric thread size M8 12Nm (9lbft)
metric thread size M10 20Nm (15lbft)
Service drawing no. 9820 7984 82-14
46 45 15 12 2 5 2 1 13 2
43 42
Coding key
X105-Supply
X105
25
Addendum to Instruction book No. 2920 7104 82
Notes:
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Addendum to Instruction book No. 2920 7104 82
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Addendum to Instruction book No. 2920 7104 82
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28 2900 4018 85
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