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Assembly instructions

Atlas Copco Stationary Air Compressors

GA30-90C

Field Assembly Instruction for ICD

No. 2920 1515 00

Registration code: APC G30-55/98 / 38 / 981


APC G55-90C/2000 / 38 / 986

2003-09

2920 1515 00 1
Assembly instructions

Table of contents

1. PREPARING COMPRESSOR FOR INSTALLATION OF ICD (SALES VERSION ONLY)....................3


1.1 INSTALLING APPROPRIATE PIPING AND FILTER AT OUTLET OF COMPRESSOR................................................3
1.2 INSTALLING DIN-RAIL FOR POWER SUPPLY ICD .........................................................................................5
1.3 REPLACING PRESSURE TRANSDUCER CABLE ................................................................................................7
2. PREPARATION FOR ASSEMBLY ................................................................................................................7
2.1 COMPRESSOR ..............................................................................................................................................7
2.1.1 Remove all door panels (see Figure 6). .................................................................................................7
2.1.2 Disassemble inlet baffle of compressor. ................................................................................................7
2.1.3 Disconnect cover plate for manual and automatic drain.......................................................................8
2.2 DRYER MODULE ..........................................................................................................................................8
2.2.1 Remove both door panels (see Figure 8). ..............................................................................................8
2.2.2 Remove cover from ICD module............................................................................................................9
2.2.3 Remove outer beams of ICD module......................................................................................................9
2.2.4 Remove pipe coupling on T-part..........................................................................................................10
2.3 IMPORTANT NOTE ......................................................................................................................................10
3. POSITIONING OF ICD MODULE IN RELATION TO THE COMPRESSOR UNIT ALIGNMENT
OF BOTH MODULES..............................................................................................................................................11
3.1 POSITIONING OF COMPRESSOR ...................................................................................................................11
3.2 POSITIONING OF THE DRYER UNIT TOWARDS THE COMPRESSOR ................................................................11
3.3 MOUNTING ALIGNMENT PLATE..................................................................................................................11
3.3.1 Connect alignment plate to frame of compressor. ...............................................................................11
3.3.2 Check alignment of both units..............................................................................................................12
3.3.3 Connect alignment plate to frame of ICD and tighten all bolts. ..........................................................12
3.3.4 Important note: use of shims in case of alignment problems...............................................................12
4. CONNECTING ICD MODULE TO COMPRESSOR INSTALLING INTERFACE PARTS ..............13
4.1 ELECTRICAL CONNECTIONS .......................................................................................................................13
4.1.1 Power supply of dryer..........................................................................................................................13
4.1.2 Data cable of cubicle of ICD ...............................................................................................................13
4.1.3 Connecting sensor cable of Elektronikon to pressure transducer at outlet of ICD .............................13
4.1.4 Setting multi-voltage transformer in ICD cubicle (selection of right voltage) ....................................14
4.1.5 Main power supply of compressor package.........................................................................................14
4.2 MECHANICAL CONNECTIONS .....................................................................................................................15
4.2.1 Connect piping of compressor and ICD. .............................................................................................15
4.2.2 Install cover for manual and automatic drain on front panel of ICD module. ....................................15
4.2.3 Install inlet baffle in front panel of ICD. .............................................................................................16
4.2.4 Mount outer beams on left and right side of the canopy......................................................................16
4.2.5 Mount the cover on the roof of the ICD. ..............................................................................................19
4.2.6 Install the 2 ball valves at the outlet of the ICD. .................................................................................19
4.2.7 Place back all door panels and lock them (see Figure 28). .................................................................19

2920 1515 00 2
Assembly instructions

Field Assembly Instruction for ICD100-280


The instructions below describe how both modules, compressor and ICD dryer, should
be joined together. Before explaining the installation instructions one should pay
attention to the following points:
Make sure that both compressor and ICD module are installed on a smooth base
in order to ensure a proper assembly and alignment.
Install compressor with ICD on a solid floor suitable for taking the weight.
NEVER lift both modules together.
Unwrap both compressor and ICD module completely before starting the assembly.

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.

1. Preparing compressor for installation of ICD (sales version only)

1.1 Installing appropriate piping and filter at outlet of compressor

Regular GA55-90C 1622 1697 00 GA55-90C Workplace FF with ICD


1613 9560 01
Workplace unit Pipe end
Pipe

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).

Regular GA30-55C GA30-55C Workplace FF with ICD


Workplace unit

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.

Note about the manual and automatic drain:


Connect the plastic drain tubes on the WSD and IPD filter, but wait to fasten the
couplings of both tubes on the cover in the front panel till the dryer module has
been installed properly, as the cover for manual and automatic drain should be
mounted on the front panel of the ICD module. This is explained in section 4.2.2.

1.2 Installing DIN-rail for power supply ICD


The power supply of the ICD dryer is derived from the main voltage supply of the
compressor: one phase of the main supply is used to feed the dryer. Therefore, one has
to use terminal stroke 1X2, especially reserved for dryer connections. As for an IFD
dryer, a DIN rail (9820 2958 90) should be installed in the compressor's cubicle. For
GA30-55C units with ICD, this is illustrated in Figure 3.

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

Hole in front panel for


main power cables

Hole for data cable and


Pre-lasered hole power cable of dryer
Figure 5: Removing plate in "pre-lasered" hole in compressor front panel and mounting threaded
pipes with lock nuts

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

1.3 Replacing pressure transducer cable


As the outlet pressure of the GA Workplace units with ICD is measured at the outlet of
the ICD, the pressure transducer (PT20) should be installed on the outlet pipe of the
dryer. Therefore the pressure transducer cable in the wire harness of the compressor
has to be replaced by a new one (1622 1755 00) which is somewhat longer.
So, cut through all necessary cable ties and loosen the cable gland of the wire harness
to remove the pressure transducer cable that has already been provided. Put the new
pressure transducer cable (1622 1755 00) in the existing wire harness, fasten the cable
gland, fix the cable to the push mounts by means of cable ties and make the required
connections in the compressor's cubicle. The pressure transducer cable has to be
connected to the pressure sensor on the outlet pipe of the ICD once the ICD module
has been installed. This is explained in section 4.1.3.

2. Preparation for assembly

2.1 Compressor

2.1.1 Remove all door panels (see Figure 6).

2.1.2 Disassemble inlet baffle of compressor.


Remove the inlet baffle of the compressor carefully by unscrewing 4 bolts (M8). Keep
the inlet baffle apart, as it should be mounted into the front panel of the ICD module
(see Figure 6).

Figure 6: Compressor inlet baffle and door panels removed

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Assembly instructions

2.1.3 Disconnect cover plate for manual and automatic drain.


Remove the cover with tap for manual and automatic drain from the front panel (two
screws, see Figure 7). Detach the plastic drain tubes from the cover plate by loosening
the coupling elements on the cover plate. Leave the part of those couplings on the drain
tubes untouched. Keep cover and tap apart, as it should be mounted on the front panel
of the ICD module.

Screws

Drain tubes
Tap

Cover plate Couplings

Figure 7: Removing cover for manual and automatic drain

2.2 Dryer module

2.2.1 Remove both door panels (see Figure 8).

Door panels to
be removed

Figure 8: Removing door panels

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Assembly instructions

2.2.2 Remove cover from ICD module.


Remove the cover on the roof of the ICD module by detaching the two clips aside, as
illustrated by Figure 9. Handle with care, even if the clips are tightened quite hard and
will not loosen up easily.

Detaching
clips of cover

Figure 9: Removal of cover

2.2.3 Remove outer beams of ICD module.


Disassemble the outer beams on both sides of the ICD module by unfastening the
required bolts (3 x M8 on each side). See Figure 10.

Outer beams to
be removed

Bolts (M8)

Figure 10: Disassembling outer beams

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Assembly instructions

2.2.4 Remove pipe coupling on T-part.


Remove the pipe coupling on the T-part at the dryer inlet (compressors side). Once
compressor and dryer module have been mounted together, this coupling will be used
to connect the outlet pipe of the compressor to the inlet of the ICD. See Figure 11.

Pipe coupling to
be removed

Figure 11: Pipe coupling on the T-part at the dryer inlet

2.3 Important note


Put the GASKET of the pipe coupling described in section 2.2.4 on the outlet pipe of the
compressor BEFORE starting to position the ICD module towards the compressor (see
Figure 12). Do not skip this step, as aforementioned action cannot be performed once
the ICD and compressor have been mounted together!

Gasket of pipe
coupling

Figure 12: Gasket on outlet pipe of compressor

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Assembly instructions

3. Positioning of ICD module in relation to the compressor unit


Alignment of both modules

3.1 Positioning of compressor


Use a fork-lift truck for lifting the compressor and placing it on the right spot.

3.2 Positioning of the dryer unit towards the compressor


- Use a fork-lift truck to lift the dryer unit and place it against the compressor. Take
care when positioning the dryer towards the compressor to prevent damage to the
canopy.
- Take some time to align the ICD to the compressor accurately, as this facilitates the
mounting of the interface parts. This is also very important in order to create a
smooth look for the package.
The result of aforementioned actions is illustrated by Figure 13.

Figure 13: ICD module positioned towards compressor

3.3 Mounting alignment plate

3.3.1 Connect alignment plate to frame of compressor.


Fix the black alignment plate to the compressors frame by tightening the two bolts (M8)
only partially into the frame.
Note: The bolts should only be pulled tight once the alignment has been checked (see
section 3.3.2 !!) and the plate has been mounted to the dryers frame. Be aware that the
tolerance field is quite small.

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Assembly instructions

3.3.2 Check alignment of both units.


Alignment can be checked by verifying if the notch in the alignment plate corresponds
with the centre of the hole ( 5 mm) in the frame of the ICD. If this is not the case, the
position of the ICD module in relation to the compressor should be adjusted till the
alignment is perfect. It is recommended to aim at a tolerance of 1 mm at sight. See
Figure 14.
3.3.3 Connect alignment plate to frame of ICD and tighten all bolts.
The mounting of the alignment plate should be completed by fixing the plate to the
frame of the ICD by means of two bolts (M8) and by completely screwing down the two
bolts (M8) in the compressors frame.

Alignment plate

Notch

Frame ICD

Figure 14: Alignment plate


After completing the alignment procedure and fixing the alignment plate the result
should be as shown in Figure 15.

Bolts in frame
GA (M8)

Compressor frame

Alignment plate

Bolts in frame
ICD (M8)
Frame ICD
Figure 15: Result of alignment procedure

3.3.4 Important note: use of shims in case of alignment problems


As mentioned before, it is strongly advised to install the compressor with ICD on a
smooth base in order to ensure a proper assembly and alignment. Nevertheless, small
roughness of the base causing misalignment of the dryer module with regard to the
compressor can be dealt with by using the shims delivered with the ICD. After all, every
ICD is supplied with a package comprising a number of shims of different thickness.

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Assembly instructions

4. Connecting ICD module to compressor Installing interface parts

4.1 Electrical connections

4.1.1 Power supply of dryer


The power supply of the dryer is derived from the main voltage supply of the
compressor: one phase of the main supply is thus used to feed the dryer.
The power supply cable coming from the cubicle inside the ICD should be guided
through the lowest hole in the compressor front panel (see Figure 19) and connected to
the fuse holders on the dryer DIN rail in the compressor cubicle. The earth wire should
be connected to the PE terminal on the same rail. This is illustrated by Figure 16.

Power cable from ICD cubicle: to


be connected to DIN rail dryer
Data cable from ICD cubicle: to
be plugged into Elektronikon

Figure 16: Connection to cubicle of compressor

4.1.2 Data cable of cubicle of ICD


The data cable coming from the Emix expansion module in the ICD cubicle should be
connected to the compressors Elektronikon by plugging the plug into the I/O port at the
back of the Elektronikon (see Figure 16). Use also the lowest hole in the compressor
front panel (see Figure 19) to bring the data cable inside the compressor cubicle.

4.1.3 Connecting sensor cable of Elektronikon to pressure transducer at outlet of ICD


As the working pressure for the Elektronikon is measured at the outlet of the complete
package (after the dryer), the pressure sensor cable coming from the compressor
cubicle should be connected to the pressure transducer at the outlet pipe of the dryer.

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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.

Sensor cable with plug to be


plugged into pressure transducer

Coming from
compressor cubicle

Pressure transducer
at outlet of ICD

Figure 17: Connecting sensor cable to pressure transducer

4.1.4 Setting multi-voltage transformer in ICD cubicle (selection of right voltage)


As a multi-voltage transformer has been installed in the ICD cubicle, the primary voltage
should be set with regard to the supply voltage of the compressor (1 phase).
Verify the supply voltage of the compressor, open the cubicle of the ICD and connect
the wiring for the power supply of the ICD dryer to the right screw terminal of the
transformer (see Figure 18).
Connection of
wires to set
primary voltage

Transformer
Figure 18: Cubicle of ICD Setting the primary voltage for the power supply of the ICD

4.1.5 Main power supply of compressor package


The main voltage supply for the compressor coming from the customers installation
should be connected to the correct terminal in the compressor cubicle (see service
diagram compressor). The power cables for this main voltage supply go through the
ICD part before entering the compressor cubicle. In the ICD module a cable channel
has been provided on the roof, in which the power cables should be laid (see Figure
19). The main power cables have to be guided through the second highest hole in the
compressors front panel (see Figure 19).

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Assembly instructions

Hole in front panel for


main power cables

Cable channel in ICD Hole in front panel


for main power cables for data cable and
power cable of dryer
Figure 19: Main power supply

4.2 Mechanical connections

4.2.1 Connect piping of compressor and ICD.


Connect the outlet pipe of the compressor to the inlet pipe (T-part) of the dryer module
by means of the previously removed pipe coupling for grooved pipes (see section 2.2.4,
Figure 11).
4.2.2 Install cover for manual and automatic drain on front panel of ICD module.
Take the tubes for manual and automatic drain (coming from the WSD and PD filter
inside the compressor) and lay them down on the frame of the ICD.
Then, put the tubes through the drain holes manufactured into the frame. Fasten the
couplings of both tubes on the cover as assembled before, and mount the cover on the
front panel by means of 2 screws. Put tap for manual drain on the cover.

Hole in frame
for drain

Hole in frame and


panel for drain

Figure 20: Installation of cover for manual and automatic drain

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Assembly instructions

4.2.3 Install inlet baffle in front panel of ICD.


Put the inlet baffle previously removed from the compressor see section 2.1.2 in
the front panel of the ICD and fix it in the same way by using the 4 bolts (M8).

Mounting inlet baffle


in front panel of ICD
module

Figure 21: Inlet baffle in ICD module

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.

Figure 22: Unscrewing bolts at the bottom of the compressor

- 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.

Figure 24: Unplugging the connectors at the back of the Elektronikon

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

Gap in beam for Bolt (M8) at the bottom (in


cubicle door hinge frame of compressor)

Figure 25: Mounting outer beam at front side of compressor package

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

Figure 26: Mounting outer beam at back of compressor package

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Assembly instructions

4.2.5 Mount the cover on the roof of the ICD.


The cover should be mounted on the roof of the ICD (see Figure 27):
- By clicking the clips on both sides of the cover on the pins of the outer beams.
- By means of tapping screws on top (5 x ST3,9; article no. 0226 3343 93). Some
small holes ( 5 mm) have been drilled in the cover just to indicate the position of the
screws. Holes of diameter 3 mm should be drilled in the roof of the ICD on the same
position, as no holes have been provided in the roof itself. Then one can fix the cover
by means of the tapping screws.

Clicking clips on pin Tapping screws

Figure 27: Mounting of cover on roof of ICD

4.2.6 Install the 2 ball valves at the outlet of the ICD.


Install the ball valves delivered with the unit on the outlet pipe of the ICD and on the
dryer bypass pipe (see Figure 28).
4.2.7 Place back all door panels and lock them (see Figure 28).
After completion of all actions described above, the field assembly procedure of
compressor and ICD is finished and the result should be as shown in Figure 28

Figure 28: Final result of field installation procedure

2920 1515 00 19
Assembly instructions

Notes:

2920 1515 00 20
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.

2920 1377 03 1/2 (continued on inside of cover)


SAFETY PRECA UTIONS (continued)
14. If the ground is not level or can be subject to variable inclination, 5. Never use flammable solvents or carbon tetrachloride for cleaning
consult Atlas Copco. parts. Take safety precautions against toxic vapours of cleaning
liquids.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses. 6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
Operation clean cloth, paper or tape.

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.

2920 1377 03 2/2

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