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GA30-90C
2003-09
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Assembly instructions
Table of contents
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Assembly instructions
There are two different types of GA30-90C Workplace Full Feature units with ICD:
factory version and sales version. The factory version consists of a GA Workplace
unit and the associated ICD "pre-prepared", meaning that the piping and filters of the
compressor are fitted or replaced as appropriate and that in general the unit is as
complete and "installation ready" as possible. On the other hand the sales version
consists of a regular GA Workplace unit, plus an ICD with an installation kit comprising
all extra parts required. The installation of such a unit will require some more effort than
a factory version, as certain basic piping, filter and electrical modifications are needed
on the GA machine. The extra actions required for the sales version are described in
paragraph 1. Once these actions have been completed, the remaining assembly
instructions are the same as for the factory version, explained from paragraph 2 on.
This means that for the factory version one can skip the first paragraph and directly go
to paragraph 2.
WSD
1622 1694 00 1622 1698 00
1613 9561 01 Support Support
Pipe 1622 1695 00
1622 1696 00
WSD Pipe
Pipe
IPD filter
Figure 1: Replacing piping and installing appropriate components in GA55-90C Workplace units
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Assembly instructions
In order to connect the air outlet of the compressor to the air inlet of the dryer, some
piping of the regular GA Workplace unit need to be replaced. Furthermore, all GA30-
90C Workplace FF units with ICD should be equipped with a WSD and IPD filter with
differential pressure gauge.
This is illustrated by Figure 1 for the GA55-90C Workplace FF units with ICD. Two pipes
will be replaced by three pipes connecting the WSD and the IPD filter. The pipe
upstream the WSD is provided with a bracket for connection to the roof of the
compressor. The IPD filter should be connected to the roof by means of a support (1622
1694 00). A support for the differential pressure gauge (1622 1698 00) will be mounted
on the WSD by means of two bolts (M16).
1622 1700 00
1613 8374 00 Pipe end
Pipe
1622 1698 00
WSD 1622 1699 00 Support
Pipe
IPD WSD
filter
Figure 2: Replacing piping and installing appropriate components in GA30-55C Workplace units
Figure 2 shows how the piping of the regular Workplace unit should be replaced in case
of GA30-55C Workplace FF units with ICD. The outlet pipe of the regular unit is
replaced by two pipes connecting the WSD and the IPD filter. The original support on
the WSD will be re-used to mount WSD and IPD filter on the roof. A support for the
differential pressure gauge (1622 1698 00) will be mounted on the WSD by means of
two bolts (M8).
The set-up of the differential pressure gauge on the IPD filter is the same as used for
PD/DD filters. The wiring of the differential pressure gauge for the IPD filter should go to
the Elektronikon inputs (DIO's) by connecting the wiring to the terminal stroke 1X6. The
terminals reserved for the differential pressure gauge of the PD filter option can be used
for this application:
GA30-55C: terminal numbers 30 and 37
GA55-90C: terminal numbers 30 and 38
All electrical connections can also be found on the corresponding service diagrams of
the units (9820 3547 01 for GA30-55C with ICD and 9820 2958 41 for GA55-90C with
ICD).
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Assembly instructions
The connections for the manual and/ or automatic drain on the water separator (WSD)
and IPD filter remain the same. They are described in the corresponding piping
diagrams of the units (9820 3887 00 for GA30-55C with ICD and 9820 3893 00 for
GA55-90C with ICD), on which all mechanical connections from aftercooler to
compressor air outlet can be found for GA30-90C Workplace FF units with ICD.
Figure 3: Installation of DIN rail in compressor's cubicle for power supply ICD - GA30-55C with ICD
The position of the DIN rail in case of an ICD dryer is the same as for an IFD dryer. For
GA55-90C units with ICD the position of the DIN rail is indicated in Figure 4. The wires
L1 and L2 respectively coming from the fuses F90 and F91 on the ICD dryer rail have to
be connected to terminal 1X2 (L1, L2).
All electrical connections can be found on the corresponding service diagrams of the
compressor units (9820 3547 01 for GA30-55C with ICD and 9820 2958 41 for GA55-
90C with ICD) and the additional service diagram of the ICD (9820 2958 91). The
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Assembly instructions
assembly drawing of the DIN rail (9820 2958 90) also describes the wiring and
connections to the terminal stroke 1X2.
Figure 4: Installation of DIN rail in compressor's cubicle for power supply ICD - GA55-90C with ICD
The wiring for the power supply of the ICD coming from the cubicle inside the ICD
should be connected to the dryer rail once the ICD module is installed. This is described
in paragraph 4.1.
On the other hand, the plate in the "pre-lasered" hole in the compressor's front panel
has to be removed before installing the ICD module. Then, the two threaded pipes and
the lock nuts should be mounted on the front panel. This is shown in Figure 5.
Before After
The power cables and the data cable should be guided through the holes in the front
panel when the ICD module is mounted to the compressor. These actions are described
in paragraph 4.1.
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Assembly instructions
2.1 Compressor
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Assembly instructions
Screws
Drain tubes
Tap
Door panels to
be removed
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Assembly instructions
Detaching
clips of cover
Outer beams to
be removed
Bolts (M8)
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Assembly instructions
Pipe coupling to
be removed
Gasket of pipe
coupling
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Assembly instructions
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Assembly instructions
Alignment plate
Notch
Frame ICD
Bolts in frame
GA (M8)
Compressor frame
Alignment plate
Bolts in frame
ICD (M8)
Frame ICD
Figure 15: Result of alignment procedure
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Assembly instructions
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Assembly instructions
So, put the plug of the sensor cable in the pressure transducer at the outlet pipe of the
ICD, as illustrated in Figure 17.
Coming from
compressor cubicle
Pressure transducer
at outlet of ICD
Transformer
Figure 18: Cubicle of ICD Setting the primary voltage for the power supply of the ICD
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Assembly instructions
Hole in frame
for drain
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Assembly instructions
4.2.4 Mount outer beams on left and right side of the canopy.
Before installing the outer beams on the unit, some bolts/screws need to be removed:
- Unscrew at the bottom on both sides of the compressor the 2 bolts (M8) that fix the
compressors front panel to the frame.
- Unscrew the corner attachments near the roof on both sides of the compressor. For
the left side it is necessary to remove partially the cubicle door. Open the cubicle
door, remove the plug in the upper hinge, so you can turn over the door and unscrew
the screw in the corner of the roof. This is illustrated in Figure 23.
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Assembly instructions
Upper hinge
Corner screw
Lower hinge
Figure 23: Turning over cubicle door and unscrewing corner attachment
Important note: In order to perform these actions two persons are required: one person
can hold the cubicle door, whilst the other is assembling the outer beam. In case there
is ONLY 1 PERSON to do the installation, it is not possible to hold the cubicle door as
shown in Figure 23 and to assemble the outer beam at the same time.
Therefore, in case there is ONLY 1 PERSON for the installation, it is necessary to
unplug all connectors at the back of the Elektronikon module and to undo the earth wire
from the cubicle door (see Figure 24). Once the outer beams have been installed, one
can plug the connectors in the Elektronikon again.
The outer beam at the front side (side of compressor cubicle) should be installed now
as follows (see Figure 25):
- Take the outer beam equipped with a gap in the left lip for the lower hinge of the
cubicle door. Place that beam against the compressor with the pin on top, so that the
most left lip of the beam falls behind the cubicle door.
- Fix the outer beam at the bottom to the compressor frame by means of the
unscrewed bolt (M8) below and at the top to the compressors roof by means of the
screw in the upper corner.
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Assembly instructions
- Fix the outer beam on the inner beam of the ICD by means of 3 bolts (M8).
3 Bolts (M8)
in inner
Pin on top
beam ICD
for cover
Position of screw
in upper corner
The outer beam at the back of the compressor package should be installed now as
follows (see Figure 26):
- Take the remaining outer beam with the pin on top and place it against the
compressor so that the most right lip of the beam will fall behind the door panel of the
compressor.
- Fix the outer beam at the bottom to the compressor frame by means of the
unscrewed bolt (M8) below and at the top to the compressor roof by means of the
screw in the upper corner.
- Fix the outer beam on the inner beam of the ICD by means of 3 bolts (M8).
Pin on top
for cover
3 Bolts (M8)
Bolt (M8) at the bottom in inner
(in compressor frame) beam ICD
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Assembly instructions
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Assembly instructions
Notes:
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O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................
SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.
In addition to normal safety rules which should be observed with stationary If necessary, install a suction duct. Never obstruct the air inlet. Care
air compressors and equipment, the following safety directions and shall be taken to minimize the entry of moisture with the inlet air.
precautions are of special importance.
4. The aspirated air shall be free from flammable fumes or vapours,
When operating this unit, the operator must employ safe working practices e.g. paint solvents, that can lead to internal fire or explosion.
and observe all related local work safety requirements and ordinances.
5. Air-cooled units shall be installed in such a way that an adequate
The owner is responsible for maintaining the unit in a safe operating flow of cooling air is available and that the exhausted air does not
condition. Parts and accessories shall be replaced if unsuitable for safe recirculate to the inlet.
operation.
6. Arrange the air intake so that loose clothing of people cannot be
Installation, operation, maintenance and repair shall only be performed sucked in.
by authorized, trained, competent personnel.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
Normal ratings (pressures, temperatures, time settings, etc.) shall be air dryer or air net is free to expand under heat and that it is not in
durably marked. contact with or close to flammable material.
Any modification on the compressor or air dryer shall only be performed
8. No external force may be exerted on the air outlet valve; the connected
in agreement with Atlas Copco and under supervision of authorized,
pipe must be free of strain.
competent personnel.
If any statement in this book, especially with regard to safety, does not 9. If remote control is installed, the unit shall bear an obvious sign
comply with local legislation, the stricter of the two shall apply. reading:
These precautions are general and cover several machine types and DANGER: This machine is remotely controlled and may start
equipment; hence some statements may not apply to the unit(s) described without warning.
in this book.
As a further safeguard, persons switching on remotely controlled
units shall take adequate precautions to ensure that there is no one
Installation checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed: 10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
1. A compressor or air dryer shall be lifted only with adequate equipment instrument panel.
in conformity with local safety rules.
11. In multiple compressor systems manual valves shall be installed to
Loose or pivoting parts shall be securely fastened before lifting. It is isolate each compressor. Non-return valves (check valves) shall not
strictly forbidden to dwell or stay in the risk zone under a lifted load. be relied upon for isolating pressure systems.
Lifting acceleration and retardation shall be kept within safe limits.
12. Never remove or tamper with the safety devices, guards or insulations
W ear a safety helmet when working in the area of overhead or lifting
fitted on the unit. Every pressure vessel or auxiliary installed outside
equipment.
the unit to contain air above atmospheric pressure shall be protected
2. Any blanking flanges, plugs, caps and desiccant bags shall be by a pressure-relieving device or devices as required.
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working 13. Pipework or other parts with a temperature in excess of 80 degrees
pressure. celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
3. Place the unit where the ambient air is as cool and clean as possible. pipework shall be clearly marked.
1. Air hoses shall be of correct size and suitable for the working pressure. 7. Never weld or perform any operation involving heat near the oil
Never use frayed, damaged or deteriorated hoses. Use only the correct system. Oil tanks must be completely purged, e.g. by steam-cleaning,
type and size of hose end fittings and connections. When blowing before carrying out such operations.
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 Never weld on, or in any way modify, pressure vessels.
fully depressurized before disconnecting it.
Whenever there is an indication or any suspicion that an internal
Never play with compressed air. Do not apply it to your skin or part of a machine is overheated, the machine shall be stopped but no
direct an air stream at people. Never use it to clean dirt from your inspection covers shall be opened before sufficient cooling time
clothes. When using it to clean equipment, do so with extreme caution has elapsed; this to avoid the risk of spontaneous ignition of the oil
and use eye protection. vapour when air is admitted.
2. The compressor is not considered as capable of producing air of Never use a light source with open flame for inspecting the interior
breathing quality. For breathing air quality, the compressed air must of a machine, pressure vessel, etc.
be adequately purified according to local legislation and standards.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes. 9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
4. Never operate the units at pressures below or in excess of their limit and that the control and shut-down devices function correctly. If
ratings as indicated on the Principal Data sheet. removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear 10. Every time the separator element is renewed, examine the discharge
protectors when opening a door. pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors. 11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
7. Periodically check that:
a. All guards are in place and securely fastened 12. Make sure that all sound-damping material, e.g. on the bodywork
b. All hoses and/or pipes inside the unit are in good condition, secure and in the air inlet and outlet systems of the compressor, is in good
and not rubbing condition. If damaged, replace it by genuine Atlas Copco material
c. There are no leaks to prevent the sound pressure level from increasing.
d. All fasteners are tight
e. All electrical leads are secure and in good order 13. Never use caustic solvents which can damage materials of the air
.
f Safety valves and other pressure-relief devices are not obstructed net, e.g. polycarbonate bowls.
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, 14. The following safety precautions are stressed when handling
valves, hoses, etc. are in good repair, free of wear or abuse refrigerant:
8. If warm cooling air from compressors is used in air heating systems, a. Never inhale refrigerant vapours. Check that the working area
e.g. to warm up a workroom, take precautions against air pollution is adequately ventilated; if required, use breathing protection.
and possible contamination of the breathing air.
b. Always wear special gloves. In case of refrigerant contact with
9. Do not remove any of, or tamper with, the sound-damping material. 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
Maintenance refrigerant is flushed away; then seek medical first aid.
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job. c. Always wear safety glasses.
1. Use only the correct tools for maintenance and repair work. 15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be Note: W ith stationary machine units driven by an internal combustion
undertaken when the unit is stopped, the main power supply is engine, allowance has to be made for extra safety precautions, e.g. spark
switched off and the machine has cooled down. Take positive arrestors, fuelling care, etc. Consult Atlas Copco.
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in All responsibility for any damage or injuryresulting from neglecting
progress; do not start" shall be attached to the starting equipment. these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
4. Before removing any pressurized component, effectively isolate the not expressly mentioned in this book, will be disclaimed by Atlas
unit from all sources of pressure and relieve the entire system of Copco.
pressure.