Instruction book kit: Rebuild instruction for GA75VSD 400V

1/20 9820 3135 20Ed 00

Atlas Copco Stationary Air Compressors





GA75VSD









Instruction book






Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium.
Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings.


This instruction book meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines.





For all AII compressors with an Mk3 & Mk4 Elektronikon controller
With serial number AII 493 000 until AII 496 999















No. 9820 3135 20



2006-02-22
Instruction book kit: Rebuild instruction for GA75VSD 400V
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This instruction book describes how to handle the machines to ensure safe operation, optimum
efficiency and long service life.

Read this book before changing the machine to ensure correct handling, operation and proper
maintenance from the beginning. The maintenance schedule comprises measures for keeping the
machine in good condition.

Keep this book available for the trained personnel from Atlas Copco and make sure that the machine
is operated. Record all operating data, maintenance performed, etc. in an operator's logbook
available from Atlas Copco. Follow all relevant safety precautions, including those mentioned in this
book.

Trained personnel from Atlas Copco who can be contacted for any further information must carry out
repairs.

In all correspondence always mention the type and the serial number, shown on the data plate and
the number of this instruction.

The company reserves the right to make changes without prior notice.


Instruction book kit: Rebuild instruction for GA75VSD 400V
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1 Table of content:

1 Table of content:................................................................................................................................. 3
2 Foreword and limitations:.................................................................................................................. 4
2.1 First some useful info:................................................................................................................................... 4
2.2 Unpacking the converter ACS 800: .............................................................................................................. 6
2.2.1 Unpacking the machine.......................................................................................................................... 6
3 Mounting of the VSD ACS800 in the converter cabinet: ................................................................ 7
3.1 Power connections of the converter:............................................................................................................. 7
3.2 Control wiring:............................................................................................................................................ 12
4 Parameterise the new VSD.............................................................................................................. 14
4.1 Before start-up............................................................................................................................................. 14
4.2 Start up...................................................................................................................................................... 14
4.3 Programming the new VSD........................................................................................................................ 14
4.3.1 Control panel........................................................................................................................................ 14
4.3.2 Changing parameters............................................................................................................................ 15
4.3.3 Programming the new VSD................................................................................................................. 15
5 Test .................................................................................................................................................... 20
5.1 Normal operation........................................................................................................................................ 20
5.2 Communication........................................................................................................................................... 20
5.3 Temperature test.......................................................................................................................................... 20
5.4 Converter test.............................................................................................................................................. 20
Instruction book kit: Rebuild instruction for GA75VSD 400V
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2 Foreword and limitations:


The replacement kit is designed for the replacement of the integrated converter of ABB ACS 600
series to the ABB converter ACS 800 series

2.1 First some useful info:

Before starting rebuilding the compressor disconnect the power of the Compressor and wait for 5
minutes.
For the Compressor with MkIII controller use the SD 9820 3135 18






Instruction book kit: Rebuild instruction for GA75VSD 400V
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For the Compressor with Mk IV controller use the SD 9820 3135 17


Instruction book kit: Rebuild instruction for GA75VSD 400V
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2.2 Unpacking the converter ACS 800:

2.2.1 Unpacking the machine



To rebuilt the converter use this instruction starting at the last point to the first instruction.

Instruction book kit: Rebuild instruction for GA75VSD 400V
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3 Mounting of the VSD ACS800 in the converter cabinet:

3.1 Power connections of the converter:

1
st
step
Take out the previous (broken) converter ACS 600.
Remove the ducting plate.





Disconnect the filter and remove it from the cubicle.
Remove the short treated rods from the cubicle back plate.

2
nd
install the 4 threaded rods (L =65 mm) in the backplate of the converter cubicle.

2 threaded rods at the top
2 threaded rods at the bottom +2 nuts M8 ( as on the picture)


Instruction book kit: Rebuild instruction for GA75VSD 400V
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Install the L support on the 2 top rods and screw them with a washer and nut.





Instruction book kit: Rebuild instruction for GA75VSD 400V
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3
rd
step

Unpack the new converter and change install/screw the new converter (ACS800) on then new
backplate:
Remark the converter needs to be installed on the left side of the mounting plate.







Instruction book kit: Rebuild instruction for GA75VSD 400V
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4
th
step
The 4
th
step is mounting the converter +back plate in the converter cubicle.
Mount the Duct on top of the converter.



Remark:
The chimney duct needs to fit in the converter. Pay attention to the sticker UP



Place the horizontal duct on the chimney duct and fix it with 5 bolds.


Connect the horizontal duct to the L profile support.
Instruction book kit: Rebuild instruction for GA75VSD 400V
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5
th
step
Connect the supply & motor cables.




Connect power cable in the correct way



Connect the Earth wire
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Please note that it is important to mount all protective covers.


3.2 Control wiring:
1
st
step


Communication module (RMBA module) Digital IO connections (X21 & X22)
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Connect the control wires as on the service diagram






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4 Parameterise the new VSD
4.1 Before start-up

Check all connections according the service diagram

Check that there are no tools left in the electrical cubicle.
Check all earth connections

4.2 Start up
Put power on the converter
And wait for 1 minute

4.3 Programming the new VSD
4.3.1 Control panel




Instruction book kit: Rebuild instruction for GA75VSD 400V
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4.3.2 Changing parameters


4.3.3 Programming the new VSD
Enable the option modbus

Push the Emergency stop button and wait for 5 minutes.
Pull the emergency stop button

Program the parameters in parameter group 99:


Push the Emergency stop button and wait for 5 minutes.
Pull the emergency stop button

Do the ID magnetisation and wait for 1 minute.
Do not start the quick commissioning and press the PAR button.
Program the other parameters
Instruction book kit: Rebuild instruction for GA75VSD 400V
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Check the cubicle number

GA 75VSD 1900 2021 51 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 53 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 52 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 54 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 56 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 57 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 58 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 59 GA 75 VSD 9824 0733 11
GA 75VSD 1900 2021 86 GA 75VSD 9824 0733 11
GA 75VSD 1900 2021 92 GA 75VSD 9824 0733 12
GA 75VSD 1900 2021 93 GA 75VSD 9824 0733 12

Program the other parameters

Compressor GA75VSD GA75VSD
Voltage range 380-500V 380-500V
Parameter set 9824 0733 11 9824 0733 12
Edition 0 0
Par. NAME VALUE VALUE
01 ACTUAL SIGNALS
02 ACTUAL SIGNALS
03 ACTUAL SIGNALS
09 ACTUAL SIGNALS
10 START/STOP/DIR
10,01 EXT1 STRT/STP/DIR COMM.CW COMM.CW
10,02 EXT2 STRT/STP/DIR KEYPAD KEYPAD
10,03 DIRECTION FORWARD FORWARD
10,04 EXT 1 STRT PTR 0X0 0X0
10,05 EXT 2 STRT PTR 0X0 0X0
10,06 J OG SPEED SELECT NOT SEL NOT SEL
11 REFERENCE SELECT
11,01 KEYPAD REF SEL REF1 (rpm) REF1 (rpm)
11,02 EXT1/EXT2 SELECT DI2 DI2
11,03 EXT REF1 SELECT COMM. REF COMM. REF
11,04 EXT REF1 MINIMUM [rpm] 0 0
11,05 EXT REF1 MAXIMUM [rpm] 2700 2850
11,06 EXT REF2 SELECT KEYPAD KEYPAD
11,07 EXT REF2 MINIMUM [%] 0 0
11,08 EXT REF2 MAXIMUM [%] 100 100
11,09 EXT 1/2 SEL PTR 0X0 0X0
11.10 EXT 1 REF PTR 0X0 0X0
11,11 EXT 2 REF PTR 0X0 0X0











Instruction book kit: Rebuild instruction for GA75VSD 400V
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12 CONSTANT SPEEDS
12,01 CONST SPEED SEL DI2(SPEED2) DI2(SPEED2)
12,02 CONST SPEED 1 [rpm] 0 0
12,03 CONST SPEED 2 [rpm] 600 600
12,04 CONST SPEED 3 [rpm] 0 0
12,05 CONST SPEED 4 [rpm] 0 0
12,06 CONST SPEED 5 [rpm] 0 0
12,07 CONST SPEED 6 [rpm] 0 0
12,08 CONST SPEED 7 [rpm] 0 0
12,09 CONST SPEED 8 [rpm] 0 0
12.10 CONST SPEED 9 [rpm] 0 0
12,11 CONST SPEED 10 [rpm] 0 0
12,12 CONST SPEED 11 [rpm] 0 0
12,13 CONST SPEED 12 [rpm] 0 0
12,14 CONST SPEED 13 [rpm] 0 0
12,15 CONST SPEED 14 [rpm] 0 0
12,16 CONST SPEED 15 [rpm] 0 0
13 ANALOGUE INPUTS
14 RELAY OUTPUTS
14,01 RELAY RO1 OUTPUT READY READY
14,02 RELAY RO2 OUTPUT RUNNING RUNNING
14,03 RELAY RO3 OUTPUT FAULT(-1) FAULT(-1)
15 ANALOGUE OUTPUTS
15,01 ANALOGUE OUTPUT1 M1 TEMP MEAS M1 TEMP MEAS
16 SYST CTRL INPUTS
16,01 RUN ENABLE DI1 DI1
16,02 PARAMETER LOCK LOCKED LOCKED
16,03 PASS CODE 0 0
16,04 FAULT RESET SEL COMM.CW(7) COMM.CW(7)
16,05 USER MACRO IO CHG NOT SEL NOT SEL
16,06 LOCAL LOCK ON ON
16,07 PARAMETER SAVE DONE DONE
16,08 RUN ENA PTR 0X0 0X0
20 LIMITS
20,01 MINIMUM SPEED [rpm] 600 600
20,02 MAXIMUM SPEED [rpm] 2700 2850
20,03 MAXIMUM CURRENT [%Ihd] Maximum rating Maximum rating
20,04 TORQ MAX LIM1 [%] 300 300
20,05 OVERVOLTAGE CTRL ON ON
20,06 UNDERVOLTAGE CTRL ON ON
20,07 MINIMUM FREQ [Hz]
20,08 MAXIMUM FREQ [Hz]
20,11 P MOTORING LIM [%] 300 300
20,12 P GENERATING LIM [%] -300 -300
20,13 MIN TORQ SEL NEG MAX TORQ NEG MAX TORQ
20,14 MAX TORQ SEL MAX LIM1 MAX LIM1
20,15 TORQ MIN LIM1 [%] 0 0
20,16 TORQ MIN LIM2 [%] 0 0
20,17 TORQ MAX LIM2 [%] 300 300
20,18 TORQ MIN PTR 0X0 0X0
20,19 TORQ MAX PTR 0X0 0X0
20.20 MIN AI SCALE [%] 0 0
20,21 MAX AI SCALE [%] 300 300

Instruction book kit: Rebuild instruction for GA75VSD 400V
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21 START/STOP
21,01 START FUNCTION CNST DC MAGN CNST DC MAGN
21,02 CONST MAGN TIME [ms] 500 500
21,03 STOP FUNCTION COAST COAST
21,04 DC HOLD NO NO
21,05 DC HOLD SPEED [rpm] 5 5
21,06 DC HOLD CURR [%] 30 30
21,07 RUN ENABLE FUNC COAST STOP COAST STOP
21,08 SCALAR FLYSTART OFF OFF
21,09 START INTRL FUNC OFF2 STOP OFF2 STOP
21.10 ZERO SPEED DELAY [s] 0,5 0,5
22 ACCEL/DECEL
22,01 ACC/DEC SEL ACC/DEC 1 ACC/DEC 1
22,02 ACCEL TIME 1 [s] 15 15
22,03 DECEL TIME 1 [s] 15 15
22,04 ACCEL TIME 2 [s] 60 60
22,05 DECEL TIME 2 [s] 60 60
22,06 ACC/DEC RAMP SHPE [s] 0 0
22,07 EM STOP RAMP TIME [s] 0 0
22,08 ACC PTR 0X0 0X0
22,09 DEC PTR 0X0 0X0
23 SPEED CTRL
23,01 GAIN 20 20
23,02 INTEGRATION TIME [s] 1,5 1,5
23,03 DERIVATION TIME [ms] 0 0
23,04 ACC COMPENSATION [s] 0 0
23,05 SLIP GAIN [%] 100 100
23,06 AUTOTUNE RUN NO NO
25 CRITICAL SPEEDS
25,01 CRIT SPEED SELECT OFF OFF
26 MOTOR CONTROL
26,01 FLUX OPTIMIZATION NO NO
26,02 FLUX BRAKING YES YES
26,03 IR-COMPENSATION [%]
26,04 IR STEP-UP FREQ [Hz]
26,05 HEX FIELD WEAKEN OFF OFF
26,06 FLUX REF PTR 0X402710 0X402710
27 BRAKE CHOPPER
27,01 BRAKE CHOPPER CTL OFF OFF















Instruction book kit: Rebuild instruction for GA75VSD 400V
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30 FAULT FUNCTIONS
30,01 AI<MIN FUNCTION NO NO
30,02 PANEL LOSS FAULT FAULT
30,03 EXTERNAL FAULT NOT SEL NOT SEL
30,04 MOTOR THERM PROT NO NO
30,05 MOT THERM P MODE DTC DTC
30.10 STALL FUNCTION FAULT FAULT
30,11 STALL FREQ HI [Hz] 20 20
30,12 STALL TIME [s] 20 20
30,13 UNDERLOAD FUNC NO NO
30,14 UNDERLOAD TIME [s] 600 600
30,15 UNDERLOAD CURVE 1 1
30,16 MOTOR PHASE LOSS FAULT FAULT
30,17 EARTH FAULT FAULT FAULT
30,18 COMM FLT FUNC NO NO
30,19 MAIN REF DS T-OUT [s] 3 3
30.20 COMM FLT RO/AO ZERO ZERO
30,21 AUX DS T-OUT [s] 3 3
30,22 IO CONFIG FUNC WARNING WARNING
31 AUTOMATIC RESET
31,01 NUMBER OF TRIALS 0 0
32 SUPERVISION
33 INFORMATION
34 PROCESS VARIABLE
35 MOT TEMP MEAS
35,01 MOT1 TEMP AI1 SEL 1xPT100 1xPT100
35,02 MOT 1 TEMP ALM L [C] 130 130
35,03 MOT 1 TEMP FLT L [C] 150 150
35,04 MOT2 TEMP AI2 SEL NOT IN USE NOT IN USE
40 PID CONTROL
42 BRAKE CONTROL
42 STANDARD MODBUS
52,01 STATION NUMBER 1 1
52,02 BAUDRATE 9600 9600
52,03 PARITY EVEN EVEN
60 MASTER/FOLLOWER
70 DDCS CONTROL
83 ADAPT PROG CTRL
84 ADAPTIVE PROGRAM
85 USER CONSTANTS
90 D SET REC ADDR
92 D SET TR ADDR
92,02 MAIN DS ACT1 102 102
92,03 MAIN DS ACT2 305 305
92,04 AUX DS ACT3 306 306
92,05 AUX DS ACT4 308 308
92,06 AUX DS ACT5 306 306



Instruction book kit: Rebuild instruction for GA75VSD 400V
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5 Test

5.1 Normal operation

Start the compressor (All functions start/stop)
Put the set point pressure on 7 bar(e)
Check the motor speed and converter speed
Stop the compressor (NOT with the Emergency Stop button)

5.2 Communication
Pull the communication connector (2x2) on the compressor controller and start on the
compressor controller.
(You should get the converter time out and compressor shall not start)
Put the communication connector back in reset the compressor and start the compressor.
Check that the compressor is running and pull the communication connector (2x2) MkIV
during operation
(You should get the converter time out and compressor shall stop)
Put the communication connector back in reset the compressor and start the compressor.
Check that the compressor is running. Stop the compressor and unscrew the wire 44 on
terminal 1x5:44 and start the compressor
(You should get converter format failure and compressor stops)
Screw the bridge back in and start the compressor see that the compressor is running fine and
unscrew the wire during operation.(you should get converter format failure).
Restore all wiring and start the compressor.

5.3 Temperature test

Pull the temperature sensor element outlet and start the machine
(you should get sensor error and compressor stops)
Reset the compressor and put the temperature sensor back in and pull the temperature
sensor during operation.
(you should get sensor error and compressor stops)


5.4 Converter test

When the compressor is standing still push the start button on the converter.
The converter is not allowed to start.