May 2000

May 2000
 OBJECTIVES
• INTRODUCTION TO ATLAS COPCO
• INTRODUCTION TO AII PRODUCTS
• MAJOR COMPONENTS OF GA’S
• FLOW CHARTS OF GA’S
• BASIC ELECTRICS/ ELECTRIC DRAWINGS
• INTRODUCTION TO MIII ELEKRONIKON
• VSD PRODUCTS
• ES PRODUCTS
May 2000
 Atlas Copco Worldwide

• 21,000 employees

• The Atlas Copco Group Manufactures

Products at 57 plants in 15 countries

• The Atlas Copco Products are marketed

and sold through Sales companies and
Distributors in 150 countries

May 2000
 ATLAS COPCO Factory in Antwerp , Belgium

60 SALES COMPANIES - 160 SERVICE CENTERS WORLDWIDE

May 2000
Industrial Model
Designations

GMODEL principles books.PPT

 Industrial Air Products
• FD = refrigerated dryer
• ID= integrated (full feature) refrigerated dryer

• G = oil injected, rotary screw

• GA = single stage, air or water cooled
• GR = two stage, air or water cooled

• L = small reciprocating pump

• LE = lubricated, single stage, air cooled
• LF = oil-free, single stage, air cooled
• LT = lubricated, two stage, air cooled

May 2000 • SF = oil-free, single stage, air cooled, scroll

 What does it mean?

refrigerated dryer dryer capacity, liters/sec

FD160
ID120
(liters / second) x (2.119) = cubic feet / minute (CFM)

May 2000
 What does it mean?

oil flooded, rotary screw motor power, kW

GA45-175
single stage nominal working pressure

May 2000
 What does it mean?

reciprocating pump motor power, kW x 10

LE22
single stage

May 2000
 What does it mean?

single stage, air cooled, scroll motor power, kW

SF2
oil-free

May 2000
 The “G” History

Old Model Horsepower Current Model

7.5 GA5

10 GA7

GA111, GA10, GAU15 15 GA11

GA/GAU 207/209, 20 GA15

GA115, GAU20

GA118, GAU25 25 GA18

GA/GAU 307/309, 30 GA22

GA122, GAU30

GA/GAU 407/409 40 GA30

GA230, GAU40
May 2000
The “G” History (continued)

Old Model Horsepower Current Model

GA/GAU 507/509, 50 GA37
GA237, GAU50

GA/GAU 607/609, 60 GA45

GA345

GA/GAU 707/709, 75 GA55

GA355

GA/GAU 807/809, 100 GA75

GAU100, GA375

GAU 907/909 125 GA90

GA/GAU 1107/1109, 150 GA110

GA1207 (Non USA),
May 2000
GAU150
 The “G” History (continued)

Old Model Horsepower Current Model

GA/GAU 1407/1409, 200 GA160
GAU200

250 GA200

300 GA250

350 GA315

GR1120/1520 150 GR110

250 GR200

May 2000
 Kilowatt to Horsepower Conversion
Kilowatts Horsepower
5 7.5
7 10
10 15

11 15
15 20
18 25
22 30

30 40
37 50
45 60
May 2000
 Kilowatt to Horsepower Conversion (continued)

Kilowatts Horsepower
55 75
75 100

90 125
110 150
160 200

200 250
250 300
315 350

(kilowatt) x (1.34) = approximate horsepower (HP)

May 2000
 Principles of Air
Compression
Atlas Copco Service Training
May 2000
 Types of Compressors

May 2000
 GA Compressors
The GA product lines is of the Positive displacement Type and
uses oil injection principle. The oil is used for four things:
Remove the heat of compression.
Lubricate the gears and bearings.
Seal the rotors.
prevent rotor to rotor contact.

May 2000
 Rotary Screw
• As the rotors revolve, the
air inlet is sealed off
• The rotary motion
produces a smooth
compression, until each
section reaches the
beginning of the outlet
port
• The compressed air then
flows smoothly out of the
element
May 2000
 Compressor Element
• The Compressor Element or Air End is the
casing that includes the male and female rotor
and associated bearings.
• The male rotor is driven by the drive motor and
the female rotor is driven by the male rotor.
• No timing gears are used.
• The oil is used to prevent contact of the male
and female rotor .

May 2000
 Regulation

• In the GA line the standard regulation is

Full load - No load (Loaded - Unloaded).
• Which means the compressor puts out
100% of its capacity or 0%.
• The regulation system monitors the
compressor discharge pressure to maintain
the system pressure between preset upper
and lower limits.
May 2000
 Regulation

• Unloading is accomplished by closing the

unloading valve which blocks the inlet of
the compressor element (does allow a small
amount of air in) at the same time the blow-
off valve is opened to blow-off air pressure
from the separator vessel back to the
compressor inlet (between the air filter and
unloading valve) through a orifice.
May 2000
 Regulation

• The separator vessel is dropped to about 10

- 14 psi.
• The compressor remains in this state until
the loading pressure is reached.
• The unloading valve will then open fully
and the blow-off valve will close
completely.

May 2000
 Capacity Control Regulation

• There is also a capacity control regulation

system available.
• A reverse regulator is installed to control
the opening amount of the unloading valve
based on the discharge pressure.
• So that when the discharge pressure
increases the unloading valve closes and
vise versa.
May 2000
 Air Flow - Loaded
• Air flows into the compressor via the air filter
then through the unloading valve. It then
travels into the compressor element where oil
is injected in with the air. The air/oil mixture
then travels into the separator vessel where
must of the oil is removed from the air. The air
then exits the separator via the check valve and
minimum pressure valve. Then through the
aftercooler.

May 2000
 Air Flow - Loaded

• If the unit is a full feature it then enters the

ID refrigerant dryer air to air heat
exchanger. Then through the air to
refrigerant heat exchanger and onto the
WSD moisture trap. After the moisture trap
it exits the compressor via the air to air heat
exchanger.

May 2000
 Air Flow - Loaded

• If compressor is not a full feature the air

just goes through the WSD moisture trap
and exits the unit.

May 2000
 Air flow - Unloaded

• Air flows in through the bypass orifice

around the unloading valve plunger. The air
then enters the element. Where oil is
injected with it. Then through the separator
vessel where it is cycled back into the inlet
before the unloading valve plunger via the
orifice and blow-off valve.

May 2000
 Oil Separation

• Once the air is

compressed the oil
then most be removed
from the discharge air.
• Accomplished with 3
stage separation.
• Cyclone, direction
change and filter.

May 2000
 Oil System

• The Scavenge line is used to remove the oil

that is built up in the bottom of the separator
element.
• The Scavenge line is feed back into the Inlet
end of the Compressor Element (Air End).
• If the Scavenge line becomes blocked the
compressor will have excessive oil carry-over.

May 2000
 Oil System
• Oil pressure comes from air pressure in the
separator vessel pressing down on the oil in
the bottom of the vessel.
• The minimum pressure valve is used to
maintain 45 psi pressure in the separator
vessel.
• The discharge check valve is incorporated
with the minimum pressure valve to prevent
the back flow of system pressure into the
unit while unloaded.
May 2000
 Oil System

• The oil pressure forces the oil through the

thermostatic bypass valve which determines
if the oil cooler will be bypassed based on
the oil temperature.
• The oil then passes through the oil filter and
on to the element bearings, gears and
Element inlet (injection oil).

May 2000
 Oil System
• The oil temperature (Element outlet temp) is
critical to the compressors performance and
longevity.
• If the oil temperature is to low then condensation
from the inlet air can not be removed from the
oil.
• If the oil temperature is to high above 212ºF it
will decrease the oil lifetime. If the oil is not
changed it will cause varnishing.

May 2000
 Oil System

• The Element outlet temp is controlled in

part by the oil thermostatic bypass valve
setting and by the inlet air temp.
• The correct Element outlet temp is
determined by the inlet air temp and
humidity. (See Graph)

May 2000
 Element
Outlet Temp

May 2000
 MAJOR COMPONENTS

May 2000
 GA 30 - 90 C
Compressor Element and Drive System
(Star Delta Starter)

May 2000
 GA90-315 UNLOADER
Plug used to precharge the Element
Air pressure here to load

Inlet

Outlet
Spring loaded in the unload position
Loader Piston
Bolts to LP Element (Moves to the right to load)

May 2000
 GA 30-45 BUILD-UP

Loader Piston

Blow-off Valve

Filter Indicator

Plate

May 2000
 INLET/UNLOADER VALVE

May 2000
 INLET VALVE
DISASSEMBLED

May 2000
 OIL STOP VALVE
Low Point Drain

Oil In

Spring
Oil Out
May 2000
 OIL STOP VALVE

May 2000
 OIL STOP VAVLE
DISASSEMBLED

May 2000
 CHECK VALVE

May 2000
 Oil separator element

May 2000
 Oil separator element

May 2000
 Oil separator element

May 2000
 Oil separator element

May 2000
 Exchange of thermostat

May 2000
 Unloader

May 2000
 Unloader

May 2000
 Unloader

May 2000
 Unloader

May 2000
 Unloader

May 2000
 Unloader

May 2000
 Minimum pressure valve

May 2000
 Minimum pressure valve

May 2000
 Oil stop valve

May 2000
 Oil stop valve

May 2000
 Flow Diagrams Review

May 2000
 GA with ID dryer

May 2000
May 2000