GA 18 PTM Compressor Mannual (AIB GA 15-22 RD) PDF [PDF]

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GA 15, GA 18, GA 22

Instruction Book 1

OWNERSHIP DATA Unit type : ..................................................................... Motor type : ................................................................. Delivery date : .............................................................. Service Plan : ................................................................

Owner's machine No. : ................................................ Unit serial No. : ............................................................ Motor serial No. : ......................................................... First start-up date : ......................................................

Selected lubricants Compressor : ................................................................ Bearing grease type, electric motor ............................

Capacity : ......................................................................

Printed Matter Nos. Atlas Copco instruction book : .................................... Atlas Copco parts list : ................................................ Atlas Copco logbook : ..................................................

Motor instruction book : ............................................... Motor parts list : ..........................................................

Local Atlas Copco Representative Name : ............................................................................................................................................................................ Address : .......................................................................................................................................................................... Telephone : .......................................... Contact persons : Service : .................................................................. Telex : .................................................. Parts : ......................................................................

SAFETY PRECAUTIONS FOR STATIONARY COMPRESSORS AND EQUIPMENT To be read attentively and acted accordingly before installing, operating or repairing the unit. In addition to normal safety rules which should be observed with stationery air compressors and equipment, the following safety directions and precautions are of special importance. When operating this unit, the operator must employ safe working practices and observe all related local work safely requirements and ordinances.

lnstallation Apart from general engineering practice in conformity with the local safety regulations, the following directives are specially stressed:

The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation.

A compressor shall be lifted only with adequate equipment in conformity with local safety rules.

Installation, operation, maintenance and repair shall only be performed by authorized, trained, competent personnel.

Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden do dwell or stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within safe limits.

Normal ratings (pressures, temperatures, time settings etc.) shall be durably marked. Any modifications on the compressor shall only be performed in agreement with Atlas Copco and under supervision of authorized, competent personnel. If any statement in this book, especially with regard to safety, does not comply with local legislation, the stricter of the two shall apply. These precautions are general and cover several machine types and equipment; hence some statements may not apply to the unit(s) described in this book.

Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the pipes. Distribution pipes and connections shall be of correct size and suitable for the working pressure.

Atlas Copco Stationary Air Compressors GA 15, GA 18, GA 22

Instruction Book

•

Copyright Notice Any unauthorised use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. Use only authorised parts any damage or malfunction caused by the use of unauthorised parts is not covered by warranty or product liability.

www.atlascopco.com Marketing Handbook No. 9095 0503 04 2013-05

Atlas Copco Compressor Sales (A Division of Atlas copco (India) Ltd.) Industrial Air Division Pune - india

Instruction book

Table of Contents 1

Safety precautions........................................................................................................ 6

1.1

Precautions during installation................................................................................................................ 6

1.2

Safety precautions during operation ...................................................................................................... 8

1.3

Safety precautions during maintenance or repair ................................................................................. 9

1.4

Safety precautions during decommissioning ...................................................................................... 11

2

General description ....................................................................................................12

2.1

Introduction ............................................................................................................................................. 12

2.2

Air flow .................................................................................................................................................... 15

2.3

Oil system ............................................................................................................................................... 17

2.4

Cooling system ....................................................................................................................................... 18

2.5

Condensate system ................................................................................................................................ 19

2.6

Regulating system .................................................................................................................................. 20

2.7

Electrical system ..................................................................................................................................... 21

2.8

Electrical diagrams ................................................................................................................................. 22

2.9

Air dryer .................................................................................................................................................. 24

3

Controller ES99 ............................................................................................................25

3.1

General description ................................................................................................................................. 25

3.2

General features ..................................................................................................................................... 29

3.3

CONNECTIONS ..................................................................................................................................... 31

4

Installation ...................................................................................................................32

4.1

Dimension drawings ............................................................................................................................... 32

4.2

Installation proposal ................................................................................................................................ 36

4.3

Electrical connections ............................................................................................................................. 37

4.4

Pictographs ............................................................................................................................................. 38

5

Operating instructions ...............................................................................................39

5.1

Before initial start-up .............................................................................................................................. 39

5.2

Initial start-up .......................................................................................................................................... 39

5.3

Before starting......................................................................................................................................... 43

5.4

Starting .................................................................................................................................................... 43

5.5

During operation ..................................................................................................................................... 43

5.6

Stopping .................................................................................................................................................. 44

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Instruction book

6

Maintenance ................................................................................................................45

6.1

Preventive maintenance schedule ......................................................................................................... 45

6.2

Drive motor ............................................................................................................................................. 47

6.3

Oil specifications .................................................................................................................................... 47

6.4

Oil and oil filter change ........................................................................................................................... 48

6.5

Oil separator change .............................................................................................................................. 49

6.6

Storage after installation ........................................................................................................................ 50

6.7

Service kits.............................................................................................................................................. 51

7

Adjustments and servicing procedures ....................................................................52

7.1

Air filter ................................................................................................................................................... 52

7.2

Coolers ................................................................................................................................................... 53

7.3

Safety valves........................................................................................................................................... 53

8 8.1

9

Problem solving ..........................................................................................................55 Problem solving ...................................................................................................................................... 55

Technical data .............................................................................................................58

9.1

Electric cable size .................................................................................................................................. 58

9.2

Settings for overload relay and fuses ..................................................................................................... 58

9.3

Dryer switches (IFD) ............................................................................................................................... 58

9.4

Reference conditions and limitations ...................................................................................................... 59

9.5

Compressor data for GA 15 up to GA 22 ............................................................................................... 60

10 Instructions for use of air receiver .............................................................................61 10.1

5

Instructions for use .............................................................................................................................. 61

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1

Safety precautions To be read attentively and acted accordingly before installing, operating, repairing or decommissioning 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 air compressors and equipment, the following safety directions and precautions are of special importance. When operating this unit, the operator must employ safe working practices and observe all related local work safety requirements and ordinances. The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation. Authorized, trained, competent personnel only shall perform installation, operation, maintenance or repair. Normal ratings (pressures, temperatures, time settings, etc.) shall be durably marked. Any modification on the compressor shall only be performed in agreement with Atlas Copco and under supervision of authorized, competent personnel. If any statement in this book, especially with regard to safety, does not comply with local legislation, the stricter of the two shall apply. These precautions are general and cover several machine types and equipment; hence some statements may not apply to the unit(s) described in this book.

1.1 Precautions during installation Apart from general engineering practice in conformity with the local safety regulations, the following directives are specially stressed: 1. A compressor shall be lifted only with adequate equipment in conformity with local safety rules. Please consult Atlas Copco to check if a dedicated lifting device is designed for this purpose. Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment. 2. Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the pipes. Any device for protection during transport shall be removed. Distribution pipes and connections shall be of correct size and suitable for the working pressure. Undersized pipe or poor routing of pipe will degrade the performance of the compressor.

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Instruction book 3. Place the unit where the air is as cool and clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care shall be taken to minimize the entry of moisture with the inlet air. Stationary compressors are not designed for outdoor operation. 4. The aspired air shall be free from corrosive chemicals (e.g. sulfur) and flammable fumes or vapors (e.g. paint solvents that can lead to internal fire or explosion). 5. Air-cooled units shall 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 inlet. 6. Arrange the air intake so that loose clothing of people cannot be sucked in. 7. Ensure that the discharge pipe from the compressor to the after-cooler or air net is free to expand under heat and that it is not in contact with or close to flammable material. 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 unit shall bear an obvious sign reading: “DANGER: This machine is remotely controlled and may start without warning.” As a further safeguard, persons switching on remotely controlled units shall take adequate precautions to ensure that there is no one checking on or working on the machine. To this end, a suitable notice shall be affixed to the start equipment. 10. On units with automatic start-stop system, a sign stating “This machine may start without warning.” Shall be attached near the instrument panel. 11. Manual valves shall be installed to isolate each compressor from other compressors or from the system air pressure. Non-return valves (check valves) shall not be relied upon for safely isolating pressure systems A check valve in the air piping from the compressor can interfere with the proper operation of the compressor controls. 12. Never remove or tamper with the safety devices, guards or insulations fitted on the unit. Every pressure vessel or auxiliary installed outside the unit to contain air above atmospheric pressure shall be protected by a pressure-relieving device or devices as required. 13. Pipework or other parts with a temperature in excess of 70°C and which personnel in normal operation may accidentally touch, shall be guarded or insulated. Other high-temperature pipework shall be clearly marked. 14. If the ground is not level or can be subject to variable inclination, consult Atlas Copco. 15. Never drill holes in an electrical cabinet. Small metallic burrs can cause short-circuits in electrical components. 16. Make sure to avoid condensation on electrical components (e.g. cubicle, Elektronikon and frequency converter). 17. To preserve the protection of the electric cabinet and to protect its components from dust from the environment and the entry of moisture in the electrical cabinet, it is absolutely necessary to use a proper cable gland when connecting the power supply cable to the compressor. Use of an improper cable gland can result in damage to or failure of the equipment. This could also result in fire and fatalities. 18. For shipboard applications where variable inclination is expected, consult Atlas Copco’s line of dedicated Marine equipment. 19. Avoid contact with sharp edges or hot surfaces to prevent damage to cable insulation. 20. The unit shall be protected against short circuits by fuses or adequate circuit breakers. 21. The customer shall provide a main disconnecting device in the compressor room.

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Instruction book 22. Before initial start-up and after service interventions, make sure the following final inspection checks are made: a. Inspect all electrical connections to verify there are no loose connections and all are tightened correctly. b. Check for strain relief on the (main) power cables. c. Verify that the power requirement for the unit has been provided for by referencing to the unit power label on the inside of the electrical cabinet door of the unit. d. The branch circuit protection and supply cable size for the compressor must be sized to meet the power requirement per local electrical codes. e. Verify that the unit is correctly grounded using the proper size of wire connected to a tested earth ground. An improper electrical installation can result in damage to or failure of the equipment. This could also result in fire and fatalities. 23. Before initial start-up and after service interventions, make sure the following final mechanical inspection checks are made: a. Inspect all connections to make sure they are tight, sealed and secured. b. Visually inspect metal or nylon tubing located in the compressor. Tubes can come loose or get damaged in shipping. Verify the flexibility of the nylon tubes while inspecting for damage. Verify that all tubes are secure in their fittings to insure that none might leak or come loose when the compressor is in operation. Damaged or loose tubes can result in lubricant being sprayed on hot surfaces when the compressor is in operation and result in damage to the compressor or fire. After inspection, the power can be put to the installed compressor. With the proper power applied, the rotation of the compressor and the cooling fan can be verified.

1.2

Safety precautions during operation 1. Air hoses shall be of correct size and suitable for the working pressure. Never use frayed, damaged or deteriorated hoses. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or airline, 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. Never play with compressed air. Do not apply it to your skin or direct an air stream at people. Never use it to clean dirt from clothes. When using it to clean equipment, do so with extreme caution and use eye protection. 3. The compressor is not considered as capable of producing air for breathing quality. For breathing air quality, the compressed air must be adequately purified according to local legislation and standards. 4. Never operate the unit when there is a possibility of taking in flammable or toxic fumes. 5. Never operate the unit at pressures below or in excess of its limit ratings as indicated on the Principal Data sheet. 6. Keep all bodywork doors shut during operation. The door may be opened for short periods only, e.g. to carry out checks. Wear ear protection when opening a door.

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Instruction book 7. People staying in environments or rooms where sound pressure level reaches or exceeds 90dB (A) shall wear ear protection. 8. Periodically check that: a. All guards are in place and securely fastened. b. All hoses, tubes and / or pipes inside the unit are in good condition, secure and not rubbing. c.

There are no leaks.

d. All fasteners are tight. e. All electrical cables are secure and in good order. f.

Safety valves and other pressure-relief devices are not obstructed by dirt or paint.

g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse. h. There is no excess of dust in the electrical cabinet. 9. If warm cooling air from compressors is used in heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air. 10. Do not remove any of or tamper with the sound-damping material.

1.3

Safety precautions during maintenance or repair Maintenance and repair work shall only be carried out under supervision of someone qualified for the job. To maintain warranty and to insure the compressor operates correctly and safely, genuine parts must be used. Use of non-genuine parts, failure to correctly install equipment or perform recommended scheduled maintenance will void warranty and result in damage to or failure of the equipment. This could also result in fire and fatalities. Before performing any maintenance, stop the compressor, close the shut-off valve at the unit discharge, remove all electrical power from the equipment, verify the receiver tank on the unit is at zero pressure and let the machine cool down. Take positive precautions to ensure that the unit cannot be started inadvertently by following a lock-out tag-out procedure. In addition, a warning sign bearing a legend such as “work in progress; do not start” shall be attached to the starting equipment. 1. Before removing any pressurized component, effectively isolate the unit from all sources of pressure and relieve the entire system of pressure and electrical power. Take positive precautions to ensure that the unit cannot be started inadvertently. In addition, a warning sign bearing a legend such as “work in progress; do not start” shall be attached to the starting equipment. 2. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil. 3. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapors of cleaning liquids. Never use caustic solvents, which can damage materials of the air net, e.g. polycarbonate bowls. 4. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed openings with clean cloth, paper or tape. Make sure that no tools, loose parts or rags are left in or on the unit.

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Instruction book 5. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels. 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 opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc. 6. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them, e.g. when steam-cleaning or due to condensation of humid ambient air. 7. If the branch circuit is provided using a fused disconnect to supply power to the compressor, then verify that all the fuses are of the same type and properly sized. If a circuit breaker is used to supply power, verify that it is properly sized. 8. Visually inspect and verify that the connections at the branch circuit protection device are tight and the wire insulation is not degraded. 9. Visually inspect the wire from the branch circuit protection device to the compressor starter to verify that it is sized correctly and in good order. 10. Verify that the power wire and ground connections at the compressor starter are tight and in good order. 11. Verify that the wire connections from the compressor starter to the compressor motor are tight and in good order. 12. Replace filters in the electrical cabinet when they are saturated with dust. 13. Check if the sealing of the electrical cabinet is in perfect condition. If not, replace it. 14. Inspect all tubing in the compressor for possible leaks or normal aging and replace with genuine parts if needed. 15. Verify if all tube fittings are tight and tubes are securely held in the fittings. 16. Also check all nylon tubes for chaffing, cracks and flexibility and replace with genuine parts to insure safe operation. 17. Drain any condensate that may have collected in the receiver tank. 18. Take oil samples for evaluation and be sure to mark with customer name, compressor model, compressor serial number and running hours of the compressor. Respect oil service intervals. Oxidized oil will result in higher compressor temperatures that could result in fire. 19. Replace oil with genuine compressor oil of the same type when needed. Low oil will result in oil foaming, oil carry over and higher compressor temperatures that could result in fire. 20. Replace all consumables at recommended service intervals or sooner if operating conditions warrant or replace every 12 months. 21. 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 material to prevent the sound pressure level from increasing. 22. 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.

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Instruction book 23. Before clearing the unit for use after maintenance or overhaul, check that operating pressures, temperatures and time settings are correct and that the control and shutdown devices function correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled. 24. The following safety precautions are stressed when handling refrigerant: a. Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if required, use breathing protection. b. Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear of or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid. c. Always wear safety glasses. Poor maintenance or use of non-genuine parts will cause equipment failure and possibly result in fire.

1.4 Safety precautions during decommissioning Before decommissioning, stop the compressor, close the shut-off valve at the unit discharge, remove all electrical power from the equipment, verify the receiver tank on the unit is at zero pressure and let the machine cool down. Take positive precautions to ensure that the unit cannot be started inadvertently. In addition, a warning sign bearing a legend such as “work in progress; do not start” shall be attached to the starting equipment. 1. Before performing other work on the compressor, remove the power cable from the power supply. 2. Before removing any pressurized component, effectively isolate the unit from all sources of pressure and relieve the entire system of pressure. 3. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil. 4. Drain any condensate that may have collected in the receiver tank. 5. The following safety precautions are stressed when handling refrigerant: a. Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if required, use breathing protection. b. Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear of or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid. c.

Always wear safety glasses.

6. Dispose of the compressor according to local waste handling regulations.

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2

General description

2.1 Introduction lntroduction GA 15 up to GA 22 are single-stage, oil-injected screw compressors driven by an electric motor. The compressors are air-cooled. GA Pack GA Pack are enclosed in sound-insulated bodywork. The compressors are controlled by the Atlas Copco ES99 I regulator. The electronic control module is fitted to the door on the front side. An electric cabinet comprising the motor starter is located behind this panel.

Front view, GA 15 up to GA 22 Floor-mounted Pack

Floor-mounted compressors are directly installed on the floor.

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Instruction book

Front 1iew, GA 15 up to GA 22 Tank-mounted Pack GA 15 up to GA 22 Tank-mounted are mounted on a large air receiver (AR) of 500 l (125 gal, 4.5 cu.ft)

13

Reference

Name

AF

Air filter

AR

Air receiver

AV

Air outlet valve

Ca

Air cooler

Co

Oil cooler

Dm1

Manual drain, air receiver

E1

Control panel

M1

Drive motor

MT

Condensate trap

OF

Oil filter

OS

Oil separator

OT

Oil tank

S3

Emergency stop button

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GA Full-Feature GA Full-Feature (FF) are controlled by the Atlas Copco ES99. They are provided with an air dryer integrated in the sound-insulated bodywork. The dryer removes condensate from the compressed air by cooling the air to near freezing point and automatically draining the condensate

Front view, GA 15 up to GA 22 Floor-mounted Full-Feature Floor-mounted compressors are directly installed on the floor.

Front 1iew, GA 15 up to GA 22 Tank-mounted Full-Feature GA 15 up to GA 22 Tank-mounted are mounted on a large air receiver (AR) of 500 l (125 gal, 4.5 cu.ft)

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Instruction book

Reference

Name

AF

Air filter

AR

Air receiver

AV

Air outlet valve

Ca

Air cooler

Co

Oil cooler

Reference

Name

Dm1

Manual drain, air receiver

DR

Dryer

ER1

Elektronikon I regulator

M1

Drive motor

OF

Oil filter

OS

Oil separator

OT

Oil tank

S3

Emergency stop button

2.2 Air flow

Flow diagram, GA Pack

15

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Instruction book

Flow diagram, GA Full-Feature Reference

Description

A

Intake air

B

Air/oil mixture

C

Oil

D

Wet compressed air

F

Condensate

G

Dry compressed air

Description Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. Compressed air and oil flow into the oil tank (OT). The air is discharged through outlet valve (AV) via minimum pressure valve (Vp) and air cooler (Ca). Pack units are provided with a condensate trap (MT).

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Instruction book On Full-Feature compressors, the air flows through air dryer (DR) before it is discharged through outlet valve (AV). Also see section Air dryer IFD.

2.3 Oil system Flow diagram

Oil system References

Description

1

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

A

Air intake

B

Air/oil mixture

C

Oil

D

Wet compressed air

F

Condensate

Description In oil tank (OT) most of the oil is removed from the air/oil mixture centrifugally. The rest is removed by oil separator (OS). The oil collects in the lower part of oil tank (OT). Air pressure forces the oil from oil tank (OT) through oil cooler (Co) and filter (OF) to compressor element (E) and the lubrication points. Thermostatic by-pass valve (BV) starts opening the supply from cooler (Co) when the oil temperature has increased to the set point. At approx. 15 ·C (27 ·F) above the set point, all the oil flows through the oil cooler.

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Instruction book

2.4 Cooling system Flow diagram

Cooling system References

Description

A

Intake air

B

Air/oil mixture

C

Oil

D

Wet compressed air

E

Condensate

Description The cooling system comprises air cooler (Ca) and oil cooler (Co). The cooling air is generated by the drive motor fan (FN).

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Instruction book

2.5 Condensate system Condensate drains

Condensate drains pack units

Condensate drain Full-Feature units

Pack units have a condensate trap (MT). The condensate trap is provided with a manual drain (Dm) and an automatic drain (Da). Full-Feature units have an electronic drain (1). The electronic drain is provided with an automatic drain (Da). Tank-mounted units are provided with an additional manual drain on the air receiver.

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2.6 Regulating system Flow diagram

Regulating system of GA 15 up to GA 22 Unloading If the air consumption is less than the air output of the compressor, the net pressure increases. When the net pressure reaches the unloading pressure, solenoid valve (Y1) is de-energised. The plunger of the valve returns: • Solenoid valve (Y1) de-activates unloading valve/blow-off valve (UV). • Unloading valve/blow-off valve (UV) connects the air receiver pressure (1) with chamber (2) and to the blow-off opening (3). • The pressure in chamber (2) causes the loading plunger (LP) to move upwards. • The pressure is stabilised at low value. A small amount of air is kept drawn in and is blown to the unloader. Loading When the net pressure decreases to the loading pressure, solenoid valve (Y1) is energised. The plunger of solenoid (Y1) moves upwards: • Solenoid valve (Y1) controls the unloading valve/blow-off valve (UV). • Unloading valve/blow-off valve (UV) closes the air blow-off opening (3) and shuts off the supply to chamber (2). This causes loading plunger (LP) to move downwards and inlet valve (IV) to open fully. Air delivery is resumed (100%), the compressor runs loaded.

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Instruction book

2.7 Electrical system General Also consult sections Electrical diagrams and Electrical connections. Electrical components The electrical system comprises following components:

Electric cubicle on GA 15 up to GA 22, typical example

21

Reference

Designation

F1/2/3

Fuses

F4/5/6

Fuses

F7/8

Fuses for dryer (only on Full-Feature compressors)

F21

Overload relay, compressor motor

K11

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

K21

Line contactor

K22

Star contactor

K23

Delta contactor

Reference

Designation

T1/T3

Transformers

1X0

Terminal strip (voltage supply)

1X1

Terminal strip (motor)

X103/X108

Connectors

PE

Earth terminal

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2.8 Electrical diagrams Service diagram

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Diagram for Control Panel

23

Reference

Compressor

T1

Transformer

K25

Phase sequence relay

K22

Start contactor

K23

Start contactor

K21

Line contactor

F1

Fuse

F2

Fuse

F3

Fuse

F21

Overload relay, compressor motor

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2.9 Air dryer Description

Air dryer Compressed air enters heat exchanger (10) and is cooled by the outgoing, cold, dried air. Water in the incoming air starts to condense. The air then flows through heat exchanger/evaporator (4) where the refrigerant evaporates causing the air to be cooled further to close to the evaporating temperature of the refrigerant. More water in the air condenses. The cold air then flows through separator (5) where all the condensate is separated from the air. The condensate is automatically drained. The cold, dried air flows through heat exchanger (10) where it is warmed up by the incoming air.

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Instruction book

3

Controller ES99

3.1 General description ES99 is a control box for small and medium capacity compressors. The board enables to manage all the operations concerning starting and stopping of the compressor. The same board checks the status of the machine and informs about defaults.

3.1.1 Input devices The board has 7 digital inputs optoinsulated and equipotential. The chart below shows the use of the inputs and how the contacts should be in normal conditions. Description

Contact

1

Overload el. motor

Normally closed

2

Wrong rotation

Normally closed

3

Oil over temperature

Normally closed

4

Emergency push button

Normally closed

5

Pressure switch

Open : P>Pmax Closed : P105 GAR Applications