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Atlas Copco Stationary Air Compressors
GA90 - GA110 - GA132 - GA160 - GA200 - GA250 - GA315
GA90 W - GA110 W - GA132 W - GA160 W - GA200 W -
GA250 W - GA315 W
Instruction book
Important
1. For GA/GA W 90 up to 160, this book applies to compressors from serial number AIF-078 300 onwards.
2. For GA/GA W 200 up to 315, this book applies to compressors from serial number AIF-078 302 onwards.
3. This book must be used together with the "User manual for Elektronikon
ZR-ZT compressors".
® regulator for GA-GR-ZA-ZE-
· Copyright 2002, 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.
No. 2920 1475 00
Registration code: APC G³90/'99 / 38 / 963
2002-10 www.atlascopco.com
Instruction book
This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the beginning. The maintenance schedule comprises measures for keeping the machine in good condition.
Keep the book available for the operator and make sure that the machine is operated and that maintenance is carried out according to the instructions. Record all operating data, maintenance performed, etc. in an operator's logbook available from Atlas Copco.
Follow all relevant safety precautions, including those mentioned on the cover of this book.
Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further information.
In all correspondence mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data".
The company reserves the right to make changes without prior notice.
Contents
Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Main options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Air flow / regulating system . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Condensate drain system . . . . . . . . . . . . . . . . . . 7
1.2.3 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.5 Regulating system . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Elektronikon ® control system . . . . . . . . . . . . . . . . . . . . 10
1.3.1 Automatic control of the compressor . . . . . . . 10
1.3.2 Protecting the compressor . . . . . . . . . . . . . . . . 10
1.3.3 Service warning . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.4 Automatic restart after voltage failure . . . . . . . 11
1.3.5 Permissive start . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 LEDs/buttons/keys . . . . . . . . . . . . . . . . . . . . . . 11
1.4.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.3 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.4 Emergency stop button . . . . . . . . . . . . . . . . . . . 12
1.5 Menu-driven control programs . . . . . . . . . . . . . . . . . . . 12
1.5.1 Function of control programs . . . . . . . . . . . . . 12
1.5.2 Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.3 External compressor status indication . . . . . . . 14
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Installation proposals . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.5 Cooling water requirements . . . . . . . . . . . . . . . . . . . . . 28
2.5.1 Type of the system . . . . . . . . . . . . . . . . . . . . . . 28
2.5.2 Cooling water parameters . . . . . . . . . . . . . . . . 29
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . 31
3.1.2 User manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.3 Outdoor/altitude operation . . . . . . . . . . . . . . . . 31
3.1.4 Moving/lifting . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.5 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5 Checking the display . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6 Manual unloading/loading . . . . . . . . . . . . . . . . . . . . . . 34
3.7 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.8 Taking out of operation . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Preventive maintenance schedule for the compressor . 37
Page
4.1.1 Regular service operations . . . . . . . . . . . . . . . . 37
4.1.2 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.3 Service agreements . . . . . . . . . . . . . . . . . . . . . . 37
4.1.4 Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Motor greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.1 Fan motors on GA . . . . . . . . . . . . . . . . . . . . . . 37
4.2.2 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.6 Storage after installation . . . . . . . . . . . . . . . . . . . . . . . . 38
4.7 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5 Adjustments and servicing procedures . . . . . . . . . . . . . . . 39
5.1 Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4 Oil/water separators . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1 Readings on display . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2 Programmable settings . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Settings of safety valve . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4 Settings of overload relay, circuit breakers and fuses . 42
7.4.1 Motor overload relay and fuses for 50 Hz compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4.2 Motor overload relay and fuses for 60 Hz IEC compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4.3 Motor overload relay and fuses for 60 Hz CSA/
UL compressors . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4.4 Fan motor circuit breakers . . . . . . . . . . . . . . . . 44
7.4.5 Circuit breakers for dryer motor
(GA Full-feature) . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.6 Circuit breakers for dryer cooling fan motor
(GA Full-feature) . . . . . . . . . . . . . . . . . . . . . . . 45
7.4.7 Circuit breaker for control circuit . . . . . . . . . . 45
7.5 Compressor specifications . . . . . . . . . . . . . . . . . . . . . . 46
7.5.1 Reference conditions . . . . . . . . . . . . . . . . . . . . 46
7.5.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.5.3 Specific data of 7.5 bar - 50 Hz compressors . 46
7.5.4 Specific data of 8.5 bar - 50 Hz compressors . 47
7.5.5 Specific data of 10 bar - 50 Hz compressors . . 47
7.5.6 Specific data of 13 bar - 50 Hz compressors . . 48
7.5.7 Specific data of 100 psi - 60 Hz compressors . 48
7.5.8 Specific data of 125 psi - 60 Hz compressors . 49
7.5.9 Specific data of 150 psi - 60 Hz compressors . 49
7.5.10 Specific data of 200 psi - 60 Hz compressors . 50
7.6 Conversion list of SI units into British/American units 50
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Instruction book
1 LEADING PARTICULARS
1.1 General description
GA90 up to GA315 and GA90 W up to GA315 W are singlestage, oil-injected screw compressors, driven by an electric motor and enclosed in a sound-insulated bodywork.
GA90 up to GA315 are air-cooled, abbreviated as "GA". GA90
W up to GA315 W are water-cooled, abbreviated as "GA W".
GA Full-feature (FF) compressors are provided with an air dryer integrated in the bodywork. The system includes dryer by-pass valves.
The compressors are available for a maximum working pressure of:
- 7.5, 8.5, 10 or 13 bar(e) for 50 Hz versions
- 107, 132, 157 or 200 psig for 60 Hz versions
The compressors include mainly:
- Air filter(s)
- Compressor element 1)
- Air receiver/oil separator
- Air cooler
- Oil cooler(s)
- Drive motor
- Gear casing
- Unloader 1)
- Elektronikon
- Safety devices
- Air dryer with by-pass valves (Full-feature compressors only)
® control system
5
6
3
4
1 Oil coolers
2Control panel
Electric cabinet
Power supply inlet
Vibration damper
Vibration damper
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7
8
Gear casing
Compressor element
9 Oil stop valve
10 Check valve
11 Unloader
Fig. 1.1 Front view, GA110 FF
12Air receiver
13 Minimum pressure valve
14 Cooling fan
M1 Drive motor
M25 Fan motor
3
Instruction book
3
4
7
8
5
6
1 Oil coolers
2Control panel
Electric cabinet
Power supply inlet
Vibration damper
Vibration damper
9
10
11 Unloader
12Air receiver
13
14
Gear casing
Oil stop valve
Check valve
Compressor element
15
16
17
M1
Safety valve
Minimum pressure valve
Arrow, motor rotation direction
Cooling fans
Air filters
Drive motor
M25/26 Fan motors
Fig. 1.2 Front view, GA250 FF
7
8
5
6
9
3
4
1 By-pass valve
2By-pass valve
By-pass valve
Oil coolers
Vent plugs
Air cooler
Cooling fan
Unloader
Oil drain plug, air receiver
10 Air receiver
11 Oil cooler by-pass valve
12Oil filters
13 Condensate trap
14 Oil drain plug
15 Oil drain plug
16 Air dryer
17 Condensate outlets
18 DD filter (option)
19 Compressed air outlet
20 Air filter
M25 Fan motor
Fig. 1.3 Rear view,
GA110 FF
4
20
19
18
17
51329F
16
1 2 3 4 5 6 7 M25
15 14 13 12 11 10
8
9
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Instruction book
1.1.1 Main options
Full-feature
A refrigerant dryer is fully integrated in the bodywork of the compressor. This all-in-one feature reduces the required space for installation and provides savings on piping installation cost.
Integrated DD filter
Full-feature compressors can be provided with an integrated filter of the DD type to limit carry-over of solid particles and oil. By integrating a DD filter, the compressor delivers Quality
Air according to ISO 8573-1, Class 2.4.2.
Integrated OSD
The OSD (Oil Separating Device) separates the oil residues from the condensate water. The clean water can be drained into the sewer without any further treatment. The separated oil is collected and must be disposed of according to prevailing regulations.
Electronic drain
The EWD (Electronic Water Drain) assures proper draining of condensate and prevents water from entering the compressed air net. At any malfunction of the draining process, the EWD generates a warning message on the display of the Elektronikon regulator.
Energy recovery
The compressors can be provided with the Atlas Copco energy recovery systems to recover the major part of the compression heat in the form of hot water without any influence on the compressor performance.
Oil containing frame
This frame is installed under the machine and will collect oil from occasional leakage and avoid oil to spread over the floor.
Modulating control
The modulating control system is designed to maintain a narrow net pressure band (0.2 bar) by throttling the air inlet, thus reducing the air flow (50% - 100%).
Heavy-duty air intake filter
A two-stage heavy-duty air intake filter kit is available allowing the compressor to operate in heavily contaminated surroundings
(e.g. cement or mining industry). The larger dust particles are collected in the first stage of the filter. The filter efficiency
(SAE fine) is 99% at 1µm, 99.8% at 2µm and 99.9% at 3 µm.
Rain protection
If a GA compressor is installed outdoors, the rain protection prevents rain from entering the machine. At the same time it protects the display of the Elektronikon regulator against sun and rain.
High ambient temperature version
The GA HAT (High Ambient Temperature) version is specially designed for continuous operation in humid and high ambient temperature environment up to 50 degrees Celsius. This option is available for GA air and water-cooled compressors except for 13 bar (200 psi) and GA Full-feature compressors.
Phase Sequence Relay
The phase sequence relay prevents the drive motor from rotating in the wrong direction.
1 2 3
1 By-pass valve
2Vent plugs
3 Air cooler
4 Air receiver
5 Oil filters
6 Condensate trap
7 Oil drain plugs
8 Air dryer
9 Electronic water drain
(option)
10 By-pass valves
11 DD filter (option)
12Oil drain plug, air receiver
Fig. 1.4 Rear view, GA250 FF
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11
10
9 8 7 6 5
50837F
4
12
5
20
19
M25
15
14
13
18
17
16
21
12
1 4 3 2
50852F
5
Y1
6
7
8
9
10
11
Instruction book
5
6
3
4
7
8
1 Pipe coupling
2Oil coolers
9
Arrow, motor rotation direction
Air cooler
Bolts
Filler plug (only to be used at initial start-up)
Air inlet hose
Unloader
Arrow, rotation direction of drive motor
10 Compressor element
11 Check valve
12Oil drain plug, air receiver
13 Air receiver
14 Oil separator element
15 Oil filters
16 Receiver cover
17 Bolt
18 Minimum pressure valve
19 Cooling fan
20 Pipe, air receiver to air cooler
21 Safety valve
M25 Fan motor
Y1 Loading solenoid valve
Fig. 1.5 Side view, GA110 FF
5
6
3
4
1 Pipe coupling
2Air cooler
17
18
19
20
13
14
15
16
7
8
9
10
Oil coolers
Cooling fan
Air inlet hoses
Filler plugs (only to be used at initial start-up)
Check valves
Compressor elements
Arrow, rotation direction of drive motor
11
Unloaders
Air receiver
12Oil filters
Oil separator element
Receiver cover
Bolt
Minimum pressure valve
Safety valve
Pipe, air receiver to air cooler
Oil drain plug, air receiver
Bolts
M25/26 Fan motors
Y1 Loading solenoid valve
Fig. 1.6 Side view, GA250 FF
6
18
17
16
15
14
10
13
12
11
4 1 M25 2 3 20 M26 4
6
Y1
6
10
5
5
7
50835F
19 8 7 9 8
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Instruction book
PT 1000 thermal protection
The PT 1000 thermal protection provides protection of the drive motor. Five sensors are installed in the motor, two to measure the temperature of the bearings and three to measure the temperature of the windings. The readings can be called up on the display of the Elektronikon regulator. A message will appear on the display and the general alarm LED will light up if one of the temperatures exceeds the shut-down warning setting. If the temperature rises above the shut-down setting, the compressor will shut down and the general alarm LED starts blinking.
DIN/BSP or ANSI/NPT connections
For GA90 up to 160 a BSP or NPT connection can be chosen.
For GA200 up to 315 a DIN or ANSI connection can be chosen.
HD Roto-fluid
Special oil for Atlas Copco GA oil-injected screw compressors.
It provides better cooling and extends the oil change interval to 8000 hours.
Cooling air outlet ducting
Diverts the cooling air in such a way that the hot air is not led to the cooling air inlet. This option is only available for aircooled compressors.
Lifting device
The lifting device is a solid steel beam construction bolted to the compressor. It allows the customer to lift the compressor by means of e.g. a crane.
It is AIB and CE approved and complies with all applicable safety standards.
1.2.2 Condensate drain system
A condensate trap (28) is installed downstream of the air cooler to prevent condensate from entering the air outlet pipe. The trap is provided with a float valve for automatically draining condensate and with a manual drain valve.
Full-feature compressors, which are provided with an air dryer, have a second condensate trap downstream of the dryer. This trap is also provided with a float valve for automatically draining condensate and with a manual drain valve.
1.2.3 Oil system 1)
Air pressure forces the oil from receiver (17) through oil coolers
(6), filters (7) and oil stop valve (15) to compressor element
(14) and the lubrication points.
Oil stop valve (15) prevents the compressor element from flooding with oil when the compressor is stopped.
Valve (26) by-passes oil coolers (6) when starting the compressor from cold condition, to ensure rapid warming of the oil to normal working temperature.
In air receiver (17) most of the oil is removed from the air centrifugally. Almost all of the remaining oil is removed by separator element (18).
1.2.4 Cooling system
On GA, the system includes air cooler (4) and oil coolers (6), cooled by one or two fans (5) 2).
GA W are provided with a cooling water system, including a combined oil and air cooler.
1.2 Air flow / regulating system (Figs. 1.7
and 1.8)
1.2.1 Air flow 1)
Air drawn through filter (1) and unloader (2) is compressed in compressor element (14). Compressed air and oil are discharged through check valve (16) to air receiver/oil separator
(17) in which the oil is separated from the compressed air. The air is blown through minimum pressure valve (19) to air cooler
(4). The cooled air is discharged through condensate trap (28) and outlet valve (27) towards the air net.
Check valve (16) prevents blow-back of compressed air.
Minimum pressure valve (19) prevents the receiver pressure from dropping below a minimum pressure. The valve has a built-in check valve.
1.2.5 Regulating system
The system keeps the net pressure within programmable pressure limits by automatically loading and unloading the compressor depending on the air consumption. It is controlled by Elektronikon® regulator (E1) which also protects the compressor and monitors components subject to service. See section 1.3.
1.2.5.1 GA/GA W 90/160
Unloading
If the air consumption is less than the air delivery of the compressor, the net pressure increases. When the net pressure reaches the upper limit of the working pressure (unloading
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Instruction book
Fig. 1.7
GA90/160 Full-feature during unloading
1 Air filter
2 Unloader
3 Unloading valve
4 Air cooler
5 Cooling fan
6 Oil coolers
7 Oil filters
8 Chamber, control pressure
8
9 By-pass opening
10 Blow-off channel
11 Chamber, receiver pressure
12 Valve
13 Shield
14 Compressor element
15 Oil stop valve
16 Check valve
17 Air receiver
18 Oil separator element
19 Minimum pressure valve
20 Check valve
21 Oil scavenging line
22 Safety valve
23 Oil filler plug
24 Oil level indicator
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Instruction book
25 Oil drain plug
26 By-pass valve
27 Air outlet valve (customers installation)
28 Condensate trap
29 Channel
30 Flexible, receiver pressure
31 Insulating block
32 Condensate trap
33 Liquid gas mixer
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Fig. 1.8 GA200/315 during loading
34 Thermostatic expansion valve
35 Sight-glass
36 Filter/dryer
37 Capillary tube
38 Fan control switch
39 High pressure switch
40 Fan
41 Fan motor
42 Condenser
43 Hot gas by-pass valve
Figs. 1.7 and 1.8 Regulating system
44 Refrigerant compressor
45 Liquid separator
46 Low pressure switch
47 Air/refrigerant heat exchanger
48 Air/air heat exchanger
49 By-pass valves
50 By-pass valve
E1 Elektronikon regulator
M1 Drive motor
Y1 Loading solenoid valve
9
Instruction book pressure), solenoid valve (Y1) is de-energized. The plunger of the valve moves downwards by spring force:
1. The plunger of solenoid valve (Y1) shuts off the supply of receiver pressure towards chamber (8).
2. Control pressure present in chamber (8) is vented to atmosphere through loading solenoid valve (Y1). Unloading valve (3) closes by spring force.
3. Valve (12) is pushed downwards releasing receiver pressure through flexible (30) and channels (10 and 29) towards the air inlet.
4. A small flow of air remains drawn in through hole (9) and channel (10), and is blown from receiver (17) via flexible
(30) to the air inlet.
5. Air delivery is stopped (0 %), the compressor runs unloaded.
Loading
When the net pressure decreases to the lower limit of the working pressure (loading pressure), solenoid valve (Y1) is energized. The plunger of solenoid valve (Y1) moves upwards against spring force:
1. The plunger of solenoid valve (Y1) opens the supply of receiver pressure towards chamber (8). Unloading valve
(3) opens against spring force.
2. Receiver pressure also pushes valve (12) upwards, shutting off blow-off channels (10 and 29).
3. Air delivery is resumed (100 %), the compressor runs loaded.
1.3.1 Automatic control of the compressor
The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor.
A number of programmable settings, e.g. the unloading and loading pressures, the minimum stop time and the maximum number of motor starts are taken into account.
The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases. In case the expected unloading period is too short, the compressor is kept running to prevent tooshort standstill periods.
Warning A number of time-based automatic start/stop commands may be programmed. Take into account that a start command will be executed (if programmed and activated), even after manually stopping the compressor.
1.2.5.2 GA/GA W 200/315
The operation of the system is similar to that of GA90/160, except that GA/GA W 200/315 are equipped with two compressor elements, each provided with an unloader, check valve and oil stop valve.
1.3.2 Protecting the compressor
Shut-down and motor overload
If the temperature at the outlet of the compressor or at the outlet of the compressor element exceeds the programmed shut-down level, the compressor will be stopped. This will be indicated on the control display.
The compressor will also be stopped in case of overload of the drive motor or in case of overload of the fan motor(s).
Consult the safety precautions as mentioned in section 4 and remedy the trouble. See also the User manual for Elektronikon regulator, section Status data menu.
Shut-down warning
If the regulator detects a temperature just below the programmed shut-down level, this will be indicated on the control panel to warn the operator before the shut-down level is reached.
The message disappears as soon as the warning condition disappears.
1.3Elektronikon
® control system
In general, the Elektronikon regulator has following functions:
- automatic control of the compressor
- protecting the compressor
- monitoring components - service warning
- automatic restart after voltage failure
1.3.3 Service warning
A number of service operations are grouped (called Level A,
B, C, ...). Each level has a programmed time interval. If a time interval is exceeded, a message will appear on display (2-Fig.
1.9) to warn the operator to carry out the service actions belonging to that level. See section 4.
10 2920 1475 00
Instruction book
1.4 Control panel
1.4.1 LEDs/buttons/keys
Ref. Designation Function
Fig. 1.9 Control panel
1.3.4 Automatic restart after voltage failure
The regulator has a built-in function to automatically restart the compressor if the voltage is restored after voltage failure.
For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult
Atlas Copco.
Warning If activated and provided the module was in the automatic operation mode, the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period.
The power recovery time (the period within which the voltage must be restored to have an automatic restart) can be set between 1 and 255 seconds or to Infinite. If the power recovery time is set to
Infinite, the compressor will always restart after a voltage failure, no matter how long it takes to restore the voltage. A restart delay can also be programmed, allowing e.g. two compressors to be restarted one after the other.
1
2Display
3
4
5
6
7
7
Start button
Scroll keys
Tabulator key Key to select the parameter indicated by a horizontal arrow.
Only the parameters followed by an arrow pointing to the right are accessible for modifying.
Function keys Keys to control and program the compressor. See section 1.4.3.
Voltage on LED Indicates that the voltage is switched on.
General alarm
LED
General alarm
LED
Push button to start the compressor. LED (8) lights up indicating that the Elektronikon regulator is operative.
Indicates messages concerning the compressor operating condition, a service need or a fault.
Keys to scroll upwards or downwards through the display.
8
9
Automatic operation LED
Stop button
S2Emergency
Is alight if a shut-down warning condition exists. See section 1.3.
Blinks if a shut-down condition exists, if an important sensor is out of order or after an emergency stop. See section 1.3.
Indicates that the regulator is automatically controlling the compressor.
Push button to stop the compressor. LED (8) goes out.
Push button to stop the compressor immediately in case of emergency.
After remedying the trouble, unlock the button by pulling it out.
1.3.5 Permissive start
After a start command (either automatic start by the electronic regulator or manual start), the permissive start function is operative: if the oil injection pressure at the compressor elements exceeds the programmed level, the compressor will not start (indicated as <<Start failure>>).
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Instruction book
1.4.2 Display
The following is a typical example of the main screen, showing in short the status of the compressor:
Compressor Outlet 7.0 bar
Automatically loaded
Menu Unload
F1 F2F3
Fig. 1.10 Example of the main screen
¯
1.4.3 Function keys (5-Fig. 1.9)
The keys are used:
- to call up or program settings
- to reset an active motor overload, shut-down or service message, or an emergency stop
- to have access to all data collected by the regulator
The functions of the keys vary depending on the displayed menu.
The actual function is indicated on the bottom line of the display just above the relevant key.
The most common functions are listed below:
Designation
Add
Back
Cancel
Delete
Help
Limits
MainScreen
Menu
Menu
Modify
Program
Reset
Designation
Return
Extra
Function
To return to a previously shown option or menu
To find information regarding the installed modules
1.4.4 Emergency stop button (S2-Fig. 1.9)
In case of emergency, press the button to stop the compressor immediately.
Pressing the button breaks the circuit to the drive motor. The circuit to the control circuit and other electrical components is not broken.
Warning - Before starting any maintenance or repairs, wait until the compressor has stopped and open the isolating switch (customer's installation) to switch off the voltage to the compressor.
- Close the air outlet valve and open condensate drain valves (1 and 2-Fig. 3.7)
Apply all relevant safety precautions, including those mentioned in this book.
Function
To add compressor start/stop commands (day/ hour)
To return to a previously shown option or menu
To cancel a programmed setting when programming parameters
To delete compressor start/stop commands
To find the Atlas Copco internet address
To show limits for a programmable setting
To return from a menu to the main screen (Fig.
1.12)
Starting from the main screen (Fig. 1.12), to have access to submenus
Starting from a submenu, to return to a previous menu
To modify programmable settings
To program modified settings
To reset a timer or message
1.5 Menu-driven control programs
To facilitate programming and controlling the compressor, menu-driven programs are implemented in the electronic module.
A simplified menu flow is shown in Fig. 1.11.
1.5.1 Function of control programs
Program/
Function
Description
Main screen
Status data
Shows in short the operation status of the compressor. It is the gateway to all functions.
See Fig. 1.12.
Calling up the status of the compressor protection functions:
- shut-down
- shut-down warning
- service warning
- warning
Resetting of a shut-down, motor overload and service condition.
Measured data Calling up:
- actually measured data
- the status of a number of inputs
12 2920 1475 00
Instruction book
Compressor Outlet 6.4 bar
Automatically Loaded
↓
Menu Unload
Automatic Operation
Local Control
Week Timer Active
Mainscreen Help Extra
↓
Maximum Pressure 8.3 bar
↑
Running Hours 1016 hrs
Loaded Hours 980 hrs ↓
Mainscreen Help Extra
-Motor Starts
-Module Hours
-Load Relay
-Compressor Outlet
-Dp oilseparator
-Dp Air Filter
-Oil injection element
-Compressor Outlet
-Element 1 Outlet
-Element 2 Outlet
-Cooling medium
-Oil separator
-Dryer LAT
-Emergency Stop
-Remote Start/Stop
-Remote Load/Unload
-Remote pressure sensing
-Overload Motor
-Overload Fanmotor
-Starter Feedback Contact
-PB 1 open/ PB2 closed
-Overload dryerdryer fan
Status Data
Measured Data
Counters
Mainscreen
Status Data
Measured Data
Counters
Mainscreen
Measured Data
Counters
Test
Mainscreen
Counters
Test
Modify Parameters
Mainscreen
↑
→
↓
↑
→
↓
Test
Modify Parameters
Service
Mainscreen
↑
→
↓
→
↓
All Conditions Are OK
Menu Help
↑
→
↓
Compressor Outlet 5.4 bar
Dp Oil Separator 1.1 bar
Dp Air Filter 0.02 bar
↓
Menu
Running Hours 1016 hrs
Loaded Hours 980 hrs
Motor Starts 945 number
↓
Menu
Display Test
Safety Valve Test
Menu
Parameters
Protections
Service Plan
Menu
→
↓
→
↓
Modify Parameters
Service
Saved Data
Mainscreen
↑
→
↓
Modify Parameters
Service
Saved Data
Mainscreen
↑
→
Service Timer
Running Hours
→
130 hrs
↓
Menu
Last Shutdown 1
Last Shutdown 2
Last Shutdown 3
Menu
→
↓
-Oil Injection Element
-Compressor Outlet
-Element 1 Outlet
-Element 2 Outlet
-Cooling Medium
-Oil Separator
-Dryer LAT
-Emergency Stop
-Module Hours
-Load Relay
-Remote Start/Stop
-Remote LoadUnload
-Remote pressure sensing
-Overload Motor
-Overload Fanmotor
-Starter Feedback Contact
-PB1 open/ PB2 closed
-Overload Dryer/Dryer Fan
Loading Pressure 6.4 bar
Unloading Pressure 7.0 bar
Loading Pressure 2 6.0 bar
↓
Menu Modify
Parameters
Protections
Service Plan
Menu
Protections
Service Plan
Clock Function
Menu
↑
→
↓
↑
→
↓
↑
→
↓
Service Plan
Clock Function
Configuration
Menu
Service Plan
Clock Function
Configuration
Menu
↑
→
-Unloading Pressure 2
-Y-Time
-Load Delay
-Nr Of Starts/ Day
-Minimum Stop Time
-Programmed Stop Time
-Permisive Start Time
-Communication Time-out
Compressor Outlet 5.4 bar
Dp Oil Separator 1.1 bar
Dp Air Filter - 0.011 bar
↓
Menu
Service Timer
Running hours
Menu
→
130 hrs
↓
-Oil Injection Element
-Compressor Outlet
-Element 1 Outlet
-Element 2 Outlet
-Cooling Medium
-Oil Separator
-Dryer LAT
-Emergency Stop
-Remote Start/Stop
-Remote Load/Unload
-Remote Pressure Sensing
-Overload Motor
-Overload Fanmotor
-Starter Feedback Contact
-PB1 open/ PB2 closed
-Overload Dryer/Dryer Fan
Clock Function
Not Activated
→
Menu Modify Delete
Time 10:54
Date 03/05/01
Date Format DD/MM/YY ↓
Menu Modify
52407PEN
-Language In Use
-Pressure Unit
-Temperature Unit
-Vibration Unit
-Level Unit
-Pressure Band Used
-Start Mode
-CCM (control mode)
-Automatic Restart
-Password
-Node ID
-Digital Presband Selec.
Fig. 1.11 Menu flow
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Instruction book
Program/
Function
Counters
Test
Modify parameters
Service
Saved data
Description
1.5.3 External compressor status indication
Terminal strip (1X7-Fig. 1.13) is provided with auxiliary contacts for external indication of:
Calling up the:
- running hours
- number of motor starts
- regulator (module) hours
Allows a display test.
Modifying the settings for:
- parameters: loading and unloading pressures
- protections: compressor outlet pressure, air filter pressure drop, .... (see Fig. 1.11)
- service plans: timers for service plans
- clock functions: automatic compressor start/stop/pressure band commands
- configuration: time, date, display language,
Calling up service plans and resetting the timers after carrying out the service actions belonging to a plan. See section 4.
Calling up the saved data: last shut-down, last emergency stop data
Indication Relay Terminals on strip 1X7
Max. load
Automatic operation K07 11-1210 A / 2
Warning
Shut-down
K08
K09
13-14
15-16
Compressor loading K11 17-18
Motor running K21 19-20
10 A / 230 V AC
10 A / 230 V AC
3 A / 230 V AC
6 A / 230 V AC
Warning Stop the compressor and switch off the voltage before connecting external equipment.
1.5.2 Main screen
When the voltage is switched on, the main screen is shown automatically, showing in short the operation status of the compressor.
Compressor Outlet 7.0 bar
Automatically loaded
Menu
F1 F2F3
Fig. 1.12 Main screen, typical example
¯
If the function keys or arrow keys are not used for some minutes, the display will automatically return to the Main screen.
Whenever displayed on a submenu screen, press the key
Mainscreen to return to the Main screen.
Footnotes chapter 1
1) GA/GA W 90 up to 160 have one compressor element and one unloader. GA/GA W 200 up to 315 have two compressor elements, each provided with an unloader, check valve and oil stop valve.
2) GA90 and GA110 are provided with one fan. GA132 up to GA315 are provided with two fans.
F0/1 Circuit breakers
F3/4/5 Circuit breakers, control circuit
F21 Compressor motor overload relay
K11 Auxiliary relay, loading
K21 Line contactor
K22 Star contactor
K23
Q25
Q26
Delta contactor
Circuit breaker, fan motor M25
(GA90/315)
Circuit breaker, fan motor M26
(GA132/315)
T1/T2Transformers
1X3/7 Terminal strips
Fig. 1.13 Electric cabinet, typical example
14 2920 1475 00
Instruction book
2 INSTALLATION
2.1 Dimension drawings
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Fig. 2.1 Dimension drawing, GA90 and GA110
15
Instruction book
16
Fig. 2.2 Dimension drawing, GA90 W and GA110 W
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Instruction book
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Fig. 2.3 Dimension drawing, GA132 and GA160
17
Instruction book
18
Fig. 2.4 Dimension drawing, GA132 W and GA160 W
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Instruction book
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Fig. 2.5 Dimension drawing, GA200 up to GA315
19
Instruction book
20
Fig. 2.6 Dimension drawing, GA200 W up to GA315 W
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Instruction book
2.2 Installation proposals (Figs. 2.7 up to 2.10)
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Fig. 2.7 Installation proposal, GA90 up to GA160
21
Instruction book
22
Fig. 2.8 Installation proposal, GA90 W up to GA160 W
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Instruction book
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Fig. 2.9 Installation proposal, GA200 up to GA315
23
Instruction book
Ref. Description
1 Install the compressor on a level floor suitable for taking the weight of the compressor. For ventilation proposal
1, the minimum distance between the top of the bodywork and the ceiling is 1200 mm.
2Remove the plastic plug (if provided) from the compressor air outlet pipe (3-Fig. 3.5/7-Fig. 3.6) and fit the air outlet valve 1) to the pipe. Close the valve and connect it to the net.
3
Ref. Description
The pressure drop over the air outlet pipe can be calculated as follows: dp = (L x 450 x Qc 1.85
) / (d 5 x p) dp = pressure drop (recommended maximum =
0.1 bar)
L = length of outlet pipe in m d = inner diameter of the outlet pipe in mm p = absolute pressure at the compressor outlet in bar(a)
Qc = free air delivery of the compressor in l/s
24
Fig. 2.10 Installation proposal, GA200 W up to GA315 W
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Instruction book
Ref. Description Ref. Description
It is recommended that the connection of the compressor air outlet pipe is made on top of the main air net pipe to minimize carry-over of possible remainder of condensate.
As a rule of thumb, following formula can be used to calculate the recommended volume of the air net:
V = (30 x C x p x Q) / dp
V = recommended air net volume in l dp = pressure difference between unloading and loading pressures in bar (recommended minimum = 0.6) p = compressor inlet pressure in bar absolute
Q = free air delivery of compressor in l/s
C = correction factor, see below
Air consumption divided by Correction factor C compressor air delivery
0.9
0.8
0.7
0.5
0.10
0.15
0.20
0.25
0.3
0.20
0.20.15
0.1
0.10
collector. For draining of purified condensate water, an oil/water separator (type OSD) can be integrated in the bodywork. It is recommended to provide a funnel to allow visual inspection of the condensate flow.
5-Fig. 2.8 - 8-Fig. 2.10
For GA W, fit a water shut-off valve and water drain valve in the compressor water inlet pipe and outlet pipe.
Remove the plastic plugs (if provided) from the compressor water pipes and connect the pipes to the cooling water circuit.
6-Fig. 2.7/2.9/2.10 - 7-Fig. 2.8
Location of the Elektronikon regulator.
7-Fig. 2.7/2.9/2.10 - 8-Fig. 2.8
See section 2.3 for the recommended size of the supply cables. Check that the electrical connections correspond to the local codes. The installation must be earthed and protected against short circuits by fuses in all phases.
An isolating switch must be installed near the compressor.
8-Fig. 2.7 - 9-Fig. 2.8/2.10
Location of a pipe coupling 3).
4 The inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor is avoided. The maximum air velocity through the grids is 5 m/s.
The required ventilation to limit the compressor room temperature can be calculated as follows:
Qv = 0.92 N/dT (GA) Qv = 0.1 N/dT (GA W)
Qv = required ventilation capacity in m 3 /s
N = shaft input of compressor in kW dT = temperature increase in compressor room
If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is 30 Pa. The maximum pressure drop depends on the ambient temperature. The fan capacity should match the compressor fan capacity at a pressure head equal to the pressure drop caused by the cooling air outlet ducts. Consult Atlas Copco.
5-Fig. 2.7/2.9/2.10 - 6-Fig. 2.8
Remove the plastic plugs (if provided) from the condensate outlets (Fig. 3.7) and fit the manual condensate drain valves (1 and 2-Fig. 3.7). 2) Lay out the drain piping towards the condensate collector. The drain pipes must not dip into the water of the drain
2920 1475 00 25
Instruction book
F21 Compressor motor overload relay
K21 Line contactor
K22 Star contactor
K23 Delta contactor
K25 Contactor, fan motor M25
(GA90/315)
K26 Contactor, fan motor M26
(GA132/315)
K30 Phase sequence relay (option)
K40 Contactor, compressor motor of air dryer (Full-feature only)
K41 Contactor, fan motor of dryer
M1
M41
(GA90/315 Full-feature)
K42Contactor, fan motor of dryer
(GA200/315 Full-feature)
Drive motor
M25 Fan motor, GA90/315
M26 Fan motor, GA132/315
M40 Compressor motor, air dryer
(Full-feature only)
Fan motor, air dryer (GA90/
315 Full-feature)
M42Fan motor, air dryer (GA2
315 Full-feature)
Q25 Circuit breaker, fan motor M25
(GA90/315)
Q26 Circuit breaker, fan motor M26
(GA132/315)
Q40 Circuit breaker, compressor motor of air dryer (Full-feature only)
Q41 Circuit breaker, fan motor(s) of air dryer (Full-feature only)
1X3 Earthing strip
Fig. 2.11 Electrical connections (typical example)
26 2920 1475 00
Instruction book
2.3Electric cable size
50 Hz compressors 6)
Type 230 V
GA90
GA110
GA132
GA160
2x (3x120mm²+70mm²)
2x (3x150mm²+95mm²)
2x (3x185mm²+95mm²)
2x (3x240mm²+120mm²)
400 V
3x95mm²+50mm²
3x120mm²+70mm²
2x (3x95mm²+50mm²)
2x (3x120mm²+70mm²)
500 V
3x70mm²+35mm²
3x95mm²+50mm²
3x120mm²+70mm²
2x (3x70mm²+35mm²)
Type
GA200
GA250
230 V
60 Hz IEC compressors 6)
Type 220/230 V
GA90
GA110
GA160
2x (3x120mm²+70mm²)
2x (3x150mm²+95mm²)
400 V
2x (3x150mm²+70mm²)
2x (3x185mm²+95mm²)
380 V
3x120mm²+70mm²
2x (3x70mm²+35mm²)
2x (3x95mm²+50mm²)
500 V
2x (3x120mm²+70mm²)
2x (3x150mm²+70mm²)
440/460 V
3x95mm²+50mm²
2x (3x50mm²+25mm²)
2x (3x95mm²+50mm²)
Type
GA200
GA250
GA315
220/230 V 380 V 440/460 V
2x (3x150mm²+70mm²)
2x (3x185mm²+95mm²)
2x (3x120mm²+70mm²)
2x (3x150mm²+70mm²)
2x (3x240mm²+120mm²) 4) or 2x (3x185mm²+95mm²)
4x (3x70mm²+35mm²) 5)
60 Hz CSA/UL compressors 7)
Type
GA90
GA110
GA160
440/460 V 575 V
3xAWG0000+AWG23xAWG00+AWG4
2x (3xAWG00+AWG4)
2x (3xAWG000+AWG3)
3xAWG000+AWG3
2x (3xAWG00+AWG4)
Type
GA200
GA250
GA315
440/460 V 575 V
2x (3xMCM400+AWG0) 4) or 2x (3xMCM250+AWG2) 4) or
4x (3xAWG00+AWG4) 5) 4x (3xAWG1+AWG6) 5)
2x (3xMCM500+AWG0) 4) or 2x (3xMCM300+AWG0) 4) or
4x (3xAWG000+AWG3) 5)
4x (3xAWG000+AWG3) 5)
4x (3xAWG0+AWG4) 5)
4x (3xAWG00+AWG4) 5)
2920 1475 00 27
2.4 Pictographs
Fig. 2.12 Pictographs, control panel
Instruction book
1 Start
2Keys to scroll through display
3 Key to go to next field on display
4 Voltage on
5 Alarm
6 Automatic operation
7 Stop
8 Oil the gaskets, screw on the filters and tighten by hand
(approx. one half turn)
9 Cooling water inlet
10 Cooling water outlet
11 Consult the Instruction book before maintenance or repair
12Condensate outlet
13 Automatic condensate drain
14 Automatic condensate drain for optional oil/water separator (type
OSD)
15 Manual condensate drain
16 Stop the compressor before cleaning the coolers
17 Warning: under tension
18 Read Instruction book before starting the compressor
19 Switch off the voltage and depressurize the compressor before maintenance or repair
20 Before connecting the compressor electrically, consult the Instruction book for the motor rotation direction
21 Torques for steel (Fe) or brass
(CuZn) bolts
22 Consult the Instruction book before greasing
23 Switch off the voltage before removing the protecting cover inside the electric cabinet
Figs. 2.12 and 2.13 Pictographs
Fig. 2.13 Pictographs, other locations (typical examples)
2.5 Cooling water requirements
The cooling water quality must meet certain minimum requirements.
No general recommendation can encompass the effects of all combinations of the various compounds, solids and gases typically found in cooling water in interaction with different materials.
This recommendation is a general guide line for acceptable coolant quality.
2.5.1 Type of the system
Closed system
In a closed system, the same cooling water is circulating through a system without contact with air.
28 2920 1475 00
Instruction book
Open system
An open system is a pass-through system, or a circulating system with a cooling tower. In the latter case, the composition of the water that enters the cooler must be considered, and not the composition of the make-up water. Due to the evaporative effect in the cooling tower, much higher concentrations of ions can be obtained in the circulating water than in the make-up water.
2.5.2 Cooling water parameters
The Rysnar stability index (RSI)
The Rysnar Index (RSI) is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate.
The adhesion of scaling depositions and their effect are different on different materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by the saturation pH value (pH s
).
The saturation pH value is determined by the relationship between the calcium hardness, the total alkalinity, the total solids concentration and the temperature.
The Rysnar Index is calculated as follows :
RSI = 2*pH s
- pH where pH = measured pH (at room temperature) of water sample pH s
= pH at saturation
The pH s
is calculated by using : pH s
= (9.3 + A + B) - (C + D)
A : depends on the total solids concentration
(mg/l).
B :
C :
D : depends on the highest cooling water temperature (°C),
For GA/GR units take T = 75°C depends on the calcium hardness
(ppm CaCO
3
).
depends on the HCO
M-alkalinity (mval/l).
3
concentration or
The values from A, B, C and D are found in the table below.
Total dissolved solids
(mg/l)
50 - 300
400 - 1000
A
0.1
0.2
Temperature
(°C) B
32 - 37
38 - 44
45 - 50
51 - 56
57 - 63
64 - 71
72 - 80
0 - 1
2 - 6
7 - 9
10 - 13
14 - 17
18 - 21
22 - 27
28 - 31
1.4
1.3
1.2
1.8
1.7
1.6
1.5
2.2
2.1
2.0
1.9
2.6
2.5
2.4
2.3
Ca-hardness
(ppm CaCO
3
) C
10 - 11
12 - 13
14 - 17
18 - 22
23 - 27
28 - 34
35 - 43
44 - 55
56 - 69
70 - 87
88 - 110
111 - 138
138 - 174
175 - 220
230 - 270
280 - 340
350 - 430
440 - 550
560 - 690
700 - 870
880 - 1000
1.8
1.9
2.0
2.1
1.4
1.5
1.6
1.7
2.2
2.3
2.4
2.5
2.6
1.0
1.1
1.2
1.3
0.6
0.7
0.8
0.9
M-Alkalinity
(mval/l) D
0.20 - 0.22
0.24 - 0.26
0.28 - 0.34
0.36 - 0.44
0.46 - 0.54
0.56 - 0.70
0.72 - 0.88
0.90 - 1.10
1.12 - 1.38
1.40 - 1.76
1.78 - 2.20
2.22 - 2.78
2.80 - 3.54
3.54 - 4.40
4.6 - 5.4
5.6 - 7.0
7.2 - 8.8
9.0 - 11.0
11.2 - 13.8
14.0 - 17.6
17.8 - 20.0
2.2
2.3
2.4
2.5
1.8
1.9
2.0
2.1
2.6
2.7
2.8
2.9
3.0
1.4
1.5
1.6
1.7
1.0
1.1
1.2
1.3
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Instruction book
The interpretation of the values obtained is :
RSI < 6
RSI 6 - 7
RSI > 7 boiler scale formation neutral water corrosive water
A more detailed interpretation follows below :
RSI Tendency of the water Action
RSI < 3.9
4.0 < RSI < 5.5
6.3 < RSI < 6.8
6.9 < RSI < 7.5
7.6 < RSI < 9.0
9.1 < RSI < 11
RSI > 11
Very high scale formation
High boiler scale formation
5.6 < RSI < 6.2Slight boiler scale formation
Neutral water
Water cannot be used
Regular control and descaling operation necessary
Water treatment not necessary
Occasional inspection recommended
Water treatment not necessary
Occasional inspection recommended
Slight corrosion at higher temperature Water treatment not necessary
Occasional inspection recommended
Strong corrosion Regular control necessary, use of corrosion inhibitor recommended
Regular control necessary, use of corrosion inhibitor required Very strong corrosion
Very strong corrosion in complete water system Water should not be used
This table indicates that distilled or demineralised water should never be used, as their RSI is > 11.
The RSI only indicates the equilibrium of scaling descaling.
A cooling water showing good RSI conditions can still be unsuitable due to other factors.
From the table above, the RSI index should be between 5.6
and 7.5, otherwise contact a specialist.
pH
The effect of pH is already calculated in the Rysnar index, but the pH itself has some additional limitations : 6.8 < pH
Total dissolved solids (TDS)
This is the sum of all ions in the water. It can be derived from the dry residue after evaporation (but not including suspended solids), or it can be estimated from the electrical conductivity.
In a closed system, the following limits apply: TDS < 3000 mg/l (< 3800 µS/cm)
For an open system, the following limits apply: TDS < 450 mg/l (< 580 µS/cm)
Chlorides (Cl )
Chloride ions will create pitting corrosion on stainless steel.
Their concentration should be limited :
Closed cooling system : Chlorides < 500 ppm
Open cooling system : Chlorides < 150 ppm
However, if the water is scaling, lower limits should be used.
(See The Rysnar stability index (RSI)).
Free chlorine (Cl
2
)
Continuously, a level of 0.5 ppm should not be exceeded.
For shock treatments, a maximum limit of 2 ppm for maximum
30 minutes/day applies.
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Instruction book
Sulphates (SO4 -)
Closed cooling system : Sulphates < 400 ppm
Open cooling system : Sulphates < 150 ppm
Carbonate hardness
Closed cooling system : 50-1000 ppm CaCO
Open cooling system : 50-500 ppm CaCO 3
3
HCO
3
/ SO
4
2 should be >1
Ammonia
< 0.5 ppm
Copper
< 1 ppm
Iron and Manganese
< 1 ppm
Organics
No algae.
No oil.
Suspended solids
Non-soluble particles, size < 1mm.
< 10 ppm
3 OPERATING INSTRUCTIONS
3.1 Initial start-up
3.1.1 Safety precautions
The operator must apply all related safety precautions including those mentioned in this book.
3.1.2 User manual
Read the "User manual for Elektronikon regulator " to familiarize yourself with all regulator functions.
3.1.3 Outdoor/altitude operation
If the compressor is installed outdoors or if the air inlet temperature can be below 0 degrees Celsius, precautions must be taken. In this case, and also if operating at high altitude, consult Atlas Copco.
3.1.4 Moving/lifting
The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude from the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment must be placed in such a way that the compressor will be lifted perpendicularly. Lift smoothly and avoid twisting.
Footnotes chapter 2
1) To be provided by the customer.
2) GA Full-feature (provided with an integrated dryer) have two condensate traps and two drain valves. Compressors without dryer have one trap and one valve.
3) Available as an option.
4) Split up in 2 cables connected to line and delta contactor.
5) Split up in 2x 2 cables connected to line and delta contactor.
6) For PVC cable (70 degrees Celsius), at ambient of 40 degrees
Celsius.
7) For PVC cable (90 degrees Celsius), at ambient of 40 degrees
Celsius.
3.1.5 Initial start-up
1. Consult section 2 for the electric cable size, installation proposals and dimension drawings.
2. Read the "User manual for Elektronikon ® regulator" to familiarize yourself with all regulator functions.
3. A sticker dealing in short with the operation instructions is delivered with the literature set. Affix the sticker next to the control panel.
4. Stick labels near the control panel warning the operator that:
- the compressor may automatically restart after voltage failure
- the compressor is automatically started and stopped
- the compressor may be remotely controlled
5. A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect the compressor against corrosion. Remove the plates.
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Instruction book
50542F
1 2
50543F
1 2 1
1 Bush (to be removed)
2Vibration damper
Fig. 3.1 Transport fixations, gear casing of GA/GA W 90/160
1 Bush (to be removed)
2Vibration damper
Fig. 3.2 Transport fixations, drive motor of GA/GA W 90/160
2
1
50839F 1 2
50843F
1 Bush (to be removed)
2Vibration damper
Fig. 3.3 Transport fixations, gear casing of GA/GA W 200/315
1 Bushes (to be removed)
2Vibration damper
Fig. 3.4 Transport fixations, drive motor of GA/GA W 200/315
6. The gear casing supports, motor support and air receiver supports are secured to the frame, immobilizing the vibration dampers during transport.
For GA/GA W 90 up to GA/GA W 160, remove bushes (1-
Fig. 3.1) from both gear casing supports as well as bushes
(1-Fig. 3.2) from the motor support. Also remove the bushes
(or transport bolts) fitted next to the air receiver supports.
For GA/GA W 200 up to GA/GA W 315, remove bushes
(1-Fig. 3.3) from both gear casing supports as well as bushes
(1-Fig. 3.4) from the motor support. Also remove the bushes fitted next to the air receiver supports.
7. Check the wires at transformer (T1-Fig. 1.13) for correct connection, the settings of overload relay (F21) and circuit breakers (Q25/26/40/41) 1) 7), and that overload relay (F21) is set for automatic resetting. See section 7.4.
8. Remove filler plugs (6-Figs. 1.5/1.6). Pour approx. 1 l of oil into the compressor elements. Reinstall the plugs.
9. Close drain valves (1 and 2-Fig. 3.7). 2)
10. For GA W, check that the cooling water drain valves 6) in the inlet and outlet lines are closed and that the water shutoff valves 6) are open. Open the water regulating valve (4-
Fig. 3.10) and check for water flow.
11. Check that the compressor is filled with oil: the pointer of oil level indicator (4-Fig. 3.11) should be in the green range.
32 2920 1475 00
Instruction book
12. For GA Full-feature, check that valve (2-Figs. 1.3/3.6) is closed and that valves (1 and 3-Figs. 1.3/3.6) are open.
13. For compressors provided with an OSD oil/water separator
5): fill the vessel with water to the level of the water outlet and re-install the cover.
14. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of the drive motor
(M1-Figs. 1.1 and 1.2) while the motor is coasting to a stop.
If the rotation direction is wrong, switch off the voltage and reverse two incoming electric lines.
The correct direction of rotation is indicated for the drive motor by arrow (9-Figs. 1.5/1.6) on the gear casing and for the fan motors by arrows (15-Fig. 1.2) on the motor housings.
4 5 1 6 7 2 3
50845F
3.2 Before starting
Attention
- The operator must apply all relevant safety precautions, including those mentioned in this instruction book.
- In case the water system was drained (see section 3.7), close the drain valves.
1. Switch on the voltage. Voltage on LED (6-Fig. 3.8) lights up.
2. Close condensate drain valves (1 and 2-Fig. 3.7). 2)
3. Open air outlet valve (3-Fig. 3.5/7-Fig. 3.6).
4. Check oil level indicator (4-Fig. 3.11): the pointer should be in the green or orange range 4).
1 By-pass valve
2By-pass valve
3 By-pass valve
4 Voltage supply inlet
5 Air inlet
6 Data plate
7 Location of air outlet valve
Fig. 3.6 Air inlet/outlet and dryer by-pass valves, GA200/315
5. For GA Full-feature (provided with an integrated dryer), check that valve (2-Fig. 1.3/3.6) is closed and that valves
(1 and 3-Fig. 1.3/3.6) are open.
6. On GA W open the water shut-off valves 6) and regulating valve (4-Fig. 3.10).
1 2 3
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1 Voltage supply inlet
2Data plate
3 Location of air outlet valve
Fig. 3.5 Air outlet, GA90/160
50844F
1 2
3
3
4 5
6 1 2 4
1 Manual condensate drain
2Manual condensate drain (Full-feature only)
3 Automatic condensate drain for optional oil/water separator (type OSD)
4 Automatic condensate drain
5 Automatic condensate drain (Full-feature only)
6 Automatic drain for optional DD filter
Fig. 3.7 Location of condensate outlets
5
6
33
Instruction book
3.3 Starting
1. Press start button (1-Fig. 3.8). The compressor starts running in unloaded condition. Automatic operation LED
(8) lights up.
2. Approx. 10 seconds later (programmable), the compressor starts running loaded. The message on display (2) changes from <<Automatically unloaded>> to <<Automatically loaded>>.
On GA W also:
3. Regulate the cooling water flow (using valve 4-Fig. 3.10)
with the compressor running loaded. Adjust the water flow to obtain the most suitable air temperature at the outlet of the compressor elements, i.e. between 2 and approx. 7 degrees Celsius above the relevant temperature in Fig. 3.9.
Attention
- For optimum operation, the cooling water outlet temperature must never exceed the value specified in section 7.5.
- Consult Atlas Copco if condensate should be formed during frequent unloading periods.
Fig. 3.8 Control panel
3.4 During operation
1. When automatic operation LED (8-Fig. 3.8) is alight, starting and stopping of the motor is controlled automatically.
2. Check the readings on display (2-Fig. 3.8). See section
3.5.
3. To unload the compressor manually, press key <<Unload>>
(5-Fig. 3.8) 8). To put the compressor back into automatic operation, press key <<Load>> (5) 8).
4. For GA Full-feature provided with an OSD oil/water separator: regularly check that the vessel is filled; if necessary, gently top up with water to the level of the water outlet and re-install the cover.
Important
- If the compressor is stopped, it may start automatically. See also section 1.3.1.
3.5 Checking the display (2-Fig. 3.8)
1. Regularly check the display for readings and messages.
Normally, the main screen (Fig. 1.12) is shown, indicating the compressor outlet pressure, the status of the compressor and the functions of the keys below the display.
2. Always check the display and remedy the trouble if alarm
LED (7) is alight or blinks. See section 1.3. Also consult the "User manual for Elektronikon regulator", section
"Submenu STATUS DATA".
3. The display will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded. Carry out the service actions of the indicated plans or replace the component and reset the relevant timer. Consult your Atlas
Copco Customer Centre. See also section 4.1.
Warning Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop button (S2-Fig. 3.8) and switch off the voltage. Close the air outlet valve and open the manual condensate drain valve(s). 3)
4. Regularly check the actual compressor status by pressing the ¯ key from the main screen.
3.6 Manual unloading/loading (Fig. 3.8) 8)
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and restarts the compressor automatically. LED (8) is then alight.
Manually unloading
Press key <<Unload>> (5). LED (8) goes out. The message
<<Manually Unloaded>> appears on the display. The compressor remains running unloaded unless it is loaded again manually.
Manually loading
Press key <<Load>> (5). LED (8) lights up. The command
<<Load>> does not force the compressor in loaded condition, but it will switch the compressor to automatic operation again: the compressor will be loaded if the air net pressure drops below the programmed level.
3.7 Stopping
1. Press stop button (9-Fig. 3.8). LED (8) goes out. The message <<Programmed stop>> appears. The compressor runs unloaded for 30 seconds and then stops.
34 2920 1475 00
Instruction book
Example: ambient temperature 20 degrees Celsius, relative humidity 100 % and working pressure 10 bar(e). The minimum allowable temperature at the outlet of the compressor elements is 68 degrees Celsius. Regulate the cooling water flow to obtain a temperature between 70 and approx. 75 degrees Celsius at the outlet of the compressor elements.
Fig. 3.9 Minimum allowable air temperature at outlet of compressor elements (for water-cooled compressors)
2. To stop the compressor in case of emergency, press button
(S2-Fig. 3.8). Alarm LED (7) blinks. After remedying the fault, unlock the button by pulling it out.
3. Close air outlet valve (3-Fig. 3.5/7-Fig. 3.6).
4. Open condensate drain valves (1 and 2-Fig. 3.7). 2)
5. On GA W, close the water shut-off valves 6).
6. On GA W, if the compressor is installed in a room where
freezing temperatures are expected, drain the cooling system by opening the drain valves in the water inlet and outlet pipes (customer's installation).
7. Switch off the voltage.
3
4
2
1
1 Water outlet
2Water inlet
3 Combined oil and air coolers
4 Regulating valve, water flow
Fig. 3.10 Water system of GA W (typical example)
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50847F
35
Instruction book
Important
- After pressing stop button (9), the compressor will run unloaded for 30 seconds. The compressor stops after this period. A start command during this period is ignored.
- After stopping, the compressor is prevented from restarting within a programmable time (20 seconds). A start command given during this minimum stop time will be memorized; automatic operation LED (8) lights up. The compressor will start when the minimum stop time has run out.
3.8 Taking out of operation
At the end of the service life of the compressor, proceed as follows:
1. Stop the compressor and close the air outlet valve.
2. Switch off the voltage and disconnect the compressor from the mains.
3. Depressurize the compressor by opening valves (1 and 2-
Fig. 3.7) 2) 3) and loosening plug (5-Fig. 3.11) one turn.
4. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net.
5. Drain the water, oil and condensate circuits.
6. Disconnect the compressor condensate piping from the condensate drain net.
7. Disconnect the cooling water pipes from the compressor.
50544F
1 2 3 4 5
1 Oil filters
2Air receiver
3 Oil separator element
4 Oil level sight-glass
5 Oil filler plug
6 Oil drain plug
Fig. 3.11 Air receiver
6
Footnotes chapter 3
1) GA90 and GA110 have one fan motor and circuit breaker, GA132 up to GA315 have two fan motors and circuit breakers.
2) GA Full-feature (provided with an integrated dryer) have two condensate traps and two drain valves. Compressors without dryer have one trap and one valve.
3) On compressors with optional OSD separator, a valve is fitted underneath the condensate trap. Close the valve after repairing.
4) If the compressor has only just stopped, wait one minute before checking the level.
5) Available as an option.
6) Customers installation.
7) GA W are equipped with a ventilation fan in the roof. Check that it withdraws heat from the bodywork.
8) If the <<Load>> or <<Unload>> function is not indicated on the bottom line of display (2-Fig. 3.8), press key <<Menu>> (5) until function <<Main Screen>> appears above key (F1), then press key <<Main Screen>>.
36 2920 1475 00
Instruction book
4 MAINTENANCE
Warning Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop button (S2-
Fig. 3.8) and switch off the voltage. Close the air outlet valve and open the manual condensate drain valve(s). 1)
Take precautions to avoid an accidental restart. Apply all relevant safety precautions, including those mentioned in this book.
4.1 Preventive maintenance schedule for the compressor 2)
4.1.1 Regular service operations
To ensure safe operation and long service life carry out following operations at the interval (period or running hours) which comes first. The "longer interval" checks must also include the "shorter interval" checks.
The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the environmental and working conditions of the compressor.
Period Running hours Operation
Daily
Daily
Daily --
3-monthly --
8
8
3-monthly --
3-monthly 500
Check readings on display
Check that condensate is discharged during loading
Check oil level. Before starting, the level should be in the middle of the sight-glass
Clean compressor
Check for possible leaks
Check coolers; clean if necessary
4.1.2 Service kits
Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits. Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. See also section 4.7.
4.1.3 Service agreements
Atlas Copco Customer Centres have a range of service agreements to suit your needs:
- An Inspection plan
- A Preventive maintenance plan
- A Total responsibility plan
Contact your Customer Centre to agree on a tailor-made service agreement. It will ensure optimum operational efficiency, minimize downtime and reduce the total life cycle costs.
4.1.4
Service plan
A number of service operations are grouped (called Level A,
Level B, Level C, ...). Each level stands for a number of service actions to be carried out at the time intervals programmed in the Elektronikon regulator.
When reaching a level, a message will appear on the screen.
After carrying out all service actions, the interval timers are to be reset using the key "Reset" in menu "Service". Consult your
Atlas Copco Customer Centre.
4.2 Motor greasing
4.2.1 Fan motors on GA
GA132 up to GA315 have two fan motors (M25/26-Fig. 1.6).
GA90 and GA110 have one fan motor (M25-Fig. 1.5). The bearings of the fan motor(s) are greased for life. Contact your
Customer Centre for the replacement interval of the motor bearings.
2920 1475 00 37
Instruction book
4.2.2 Drive motor (M1-Figs. 1.1/1.2)
Contact your Customer Centre for the recommended grease type, the greasing quantity and interval for the motor bearings.
Important
Never mix greases of different brands or types.
4.3Oil specifications
It is strongly recommended to use following oils:
Roto-Inject Fluid is a high-quality lubricant ensuring optimum lubrication for a service life of up to 4000 running hours.
HD Roto-FluidPlus is a very cost-effective oil ensuring optimum lubrication for a service life of up to 8000 running hours.
Important
Never mix oils of different brands or types.
1
4.4 Oil change
1. Run the compressor until warm. Stop the compressor and switch off the voltage. Wait a few minutes and depressurize by unscrewing plug (5-Fig. 3.11) only one turn to permit any pressure in the system to escape.
2. On GA, loosen vent plugs (5-Fig. 1.3/2-Fig. 1.4) on top of the coolers.
3. Drain the oil by removing the drain plugs. Plugs are provided on the air receiver (6-Fig. 3.11), oil stop valves
(3-Fig. 4.1), check valves (6-Fig. 4.1), oil coolers (on GA only) (14 and 15-Fig. 1.3) and gearbox (2-Fig. 4.1). GA W are additionally provided with a plug in the oil flexible between the oil filter housing and the oil coolers. Tighten the plugs after draining.
4. Remove filler plug (5-Fig. 3.11). Fill the air receiver with oil until the level reaches the filler opening. Reinstall and tighten plug (5-Fig. 3.11). Tighten the vent plugs (5-Fig.
1.3/2-Fig. 1.4).
5. Run the compressor loaded for a few minutes to allow the oil cooler by-pass valve to open. Stop the compressor and wait a few minutes.
6. Depressurize the system by unscrewing plug (5-Fig. 3.11) only one turn to permit any pressure in the system to escape.
Remove the plug. Fill the air receiver with oil until the level reaches the filler opening. Tighten plug (5-Fig. 3.11).
7. After carrying out the service actions of the related service plan, the service warning must be reset. See also section
4.1.
8
7 6 5 4 3 2
50545F
4.5 Oil filter change
1. Stop the compressor, switch off the voltage and depressurize by unscrewing plug (5-Fig. 3.11) only one turn to permit any pressure in the system to escape.
2. Provide an oil pan to avoid possible oil spilling. Remove oil filters (1-Fig. 3.11).
3. Clean the filter seats on the manifold. Oil the gaskets of the new filters and screw them into place until the gaskets contact their seats, then tighten by hand.
4. Tighten filler plug (5-Fig. 3.11).
5. After carrying out the maintenance operations of the related service plan, the service warning must be reset. See also section 4.1.
38
1 Unloader
2Oil drain plug
3 Oil drain plug
4 Oil stop valve
5 Compressor element
6 Oil drain plug
7 Check valve
8 Air receiver
Fig. 4.1 Compressor element
4.6 Storage after installation
Run the compressor, e.g. twice a week, until warm. Load and unload the compressor a few times to operate the components of the unloading/loading system.
If the compressor is going to be stored without running from time to time, protective measures must be taken. Consult Atlas
Copco.
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Instruction book
4.7 Service kits
Service kits
Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. All service kits are mentioned in the relevant Parts Lists.
Atlas Copco Roto-injectfluid
Atlas Copco Roto-injectfluid (see section 4.3) can be ordered in following quantities:
Quantity
20-litre can
Ordering number
2901 0522 00
209-litre drum 2901 0045 01
5 ADJUSTMENTS AND SERVICING
PROCEDURES
5.1 Air filters (17-Fig. 1.2/20-Fig. 1.3)
1. Stop the compressor and switch off the voltage. Remove the filters.
2. Fit the new filters.
3. After carrying out the service actions of the related service plan, the service warning must be reset. See also section
4.1.
5.2 Coolers
Keep the coolers clean to maintain the cooling efficiency.
Stop the compressor and switch off the voltage. On GA, unscrew bolts (5-Fig. 1.5/20-Fig. 1.6) and rotate the fans away from the cooler block. Blow air from the compressor elements compartment through the coolers towards the drive motor compartment. Remove any dirt. Reposition and fix the fans.
Make sure that the fans rotate freely.
Note
If it should be necessary to wash the coolers with a cleansing agent, consult Atlas Copco.
On GA W, consult Atlas Copco for cleaning.
5.3Safety valve (17-Fig. 1.6)
Operating
Operate the safety valve by unscrewing the cap one or two turns and retightening it.
Testing
The valve can be tested on a separate compressed air line. If the valve does not open at the pressure specified in section 7.3, consult Atlas Copco.
Warning Never run the compressor without safety valves.
No adjustments are allowed.
Footnotes chapter 4
1) On compressors with optional OSD separator, a valve is fitted underneath the condensate trap. Close the valve after repairing.
2) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or
Product Liability.
5.4 Oil/water separators (Fig. 5.1)
As an option, an oil/water separation system can be integrated inside the bodywork to separate the major part of the oil from the condensate. The condensate meets the requirements of the environmental codes.
2920 1475 00 39
Instruction book
6
3
4
5
1
2
1
4
5
6
2 3
51446F
1 Water outlet
2Oil outlet
3 Water vessel
4 Condensate inlet
5
6
7
8
Filter
Oil collector
Pre-filter
Pressure gauge
Fig. 5.1 OSD90/315 oil separators (option)
7
8
The system includes an OSD315 oil/water separator (shown at the left) connected to the condensate trap downstream of the air cooler. The condensate is led from the condensate trap through inlet (4) and filter (5) towards water vessel (3) where the oil rises due to the difference in specific mass. The water flows through condensate outlet (1) to the outside of the bodywork. The oil flows into collector (6), which must be emptied regularly.
For Full-feature compressors, the system also includes an
OSD90 (shown at the right) connected to the dryer condensate trap. OSD90 are additionally provided with a pre-filter (7) and a pressure gauge (8).
Servicing procedure
1. Stop the compressor, press emergency stop button (S2-Fig.
3.8) and switch off the voltage.
2. Close the outlet valve and open the valve underneath the air cooler condensate trap.
3. Oil the gaskets of the new filters, fill the filters with water and fit them.
4. On OSD90, unscrew the pre-filter housing, fit a new prefilter and fit the housing using a new O-ring.
5. Inspect the strainer/restrictors at the inlet of the separator vessels, clean and reinstall them. Close the valve underneath the condensate trap.
6 PROBLEM SOLVING
Warning Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop button (S2-Fig. 3.8) and switch off the voltage. Close the air outlet valve and open the manual condensate drain valve(s). 1)
Take precautions to avoid an accidental restart.
Apply all relevant safety precautions, including those mentioned in this book.
Faults and suggested remedies
1 A shut-down warning message appears on the display
LED (7-Fig. 3.8) will light up indicating that the temperature at the outlet of the compressor elements is too high. See below. The message disappears as soon as the cause of the trouble is remedied
2 Unit is shut down
LED (7-Fig. 3.8) will blink indicating either that the outlet temperature is too high (see below) or that the motor overload relay has tripped. Consult the "User manual for
Elektronikon regulator" to remedy the trouble and to reset the message (section "Submenu STATUS DATA")
3 Condensate is not discharged from condensate trap(s) during loading a Discharge pipe of condensate trap clogged a Check and correct as necessary b Float valve of condensate trap(s) malfunctioning b Remove float valve assembly, clean and check
5 Compressor air delivery or pressure below normal a Air consumption exceeds air delivery of compressor a Check equipment connected b Choked air filters b Replace filters c Air leakage c Check and correct
6 Compressor element outlet temperature or delivery air temperature above normal a Insufficient cooling air a Check for cooling air restriction. Improve ventilation of compressor room. Avoid recirculation of cooling air b On GA W, cooling water temperature too high or flow too low b See section 7.5. Increase water flow and check temperature
Footnote chapter 6
1) On compressors with optional OSD separator, a valve is fitted underneath the condensate trap. Close the valve after repairing.
40 2920 1475 00
Instruction book c Oil level too low c Check and correct as necessary d Oil coolers clogged d Consult Atlas Copco e Air cooler clogged e Consult Atlas Copco f On GA W, restriction in cooling water system due to dirt or formation of scale f Consult Atlas Copco
7 If an oil/water separator (OSD) is provided: turbulence in separator vessel a Air leakage through condensate flexible towards vessel a Remove float valve assembly, clean and check
7 PRINCIPAL DATA
7.1 Readings on display
Normally the main screen (Fig. 1.12) is shown, indicating the actual air outlet pressure and the actual compressor status.
The ¯ key allows the operator to call up other information about the condition of the compressor (see section 3.5).
The readings below are valid when operating at reference conditions (section 7.5.1):
Maximum unloading pressure . . . . . . . . . . . . . . . . . . . . . . . . . See section 7.5
Compressor outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . Depends on programmed unloading and loading pressures
Pressure drop over air filters . . . . . . . . . . . . . . . . . . . . . . . . . . Below 0.050 bar
Pressure difference over oil separator . . . . . . . . . . . . . . . . . . . Below 0.8 bar
Oil injection pressure at the compressor elements . . . . . . . . . . Depends on programmed unloading and loading pressures
Compressor outlet temperature:
-for GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 29°C
-for GA Full-feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 26°C
-for GA W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 25°C
-for GA W Full-feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 22°C
Compressor element outlet temperature. . . . . . . . . . . . . . . . . . Between 55 and 100°C
Cooling air inlet temperature (on GA) . . . . . . . . . . . . . . . . . . Below 40°C 8)
Cooling water temperature (on GA W) . . . . . . . . . . . . . . . . . . Below 50°C
Pressure dewpoint (GA Full-feature) . . . . . . . . . . . . . . . . . . . Approx. 3°C 6)
Pressure drop over DD filter (option) . . . . . . . . . . . . . . . . . . . Below 0.35 bar
7.2 Programmable settings
A number of regulation parameters (e.g. loading and unloading pressures) and protection settings (e.g. shut-down level for the compressor element temperature) are programmable. The "User manual for Elektronikon regulator" deals elaborately with this matter (section "Submenu MODIFY PARAMETERS").
7.3Settings of safety valve
11 bar(e) for 7.5 bar and 8.5 bar CE version
15 bar(e) for all other versions
Important
Some compressors with a specific approval may have valves with other settings. Always consult the data stamped on the valve or consult Atlas Copco.
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Instruction book
7.4 Settings of overload relay, circuit breakers and fuses
7.4.1 Motor overload relay and fuses for 50 Hz compressors
GA / GA W Motor type, ABB Supply voltage
(V)
Max. setting of overload relay F21
(A)
Max. fuse ratings
Class gL/gG
Type 2 2) (A)
Class gL/gG
Type 1 1) (A)
90
90
90
110
110
110
132
132
M2CA 280SMB-4
M2CA 280SMB-4
M2CA 280SMB-4
M2CA 280MLB-4
M2CA 280MLB-4
M2CA 280MLB-4
M2CA 315SMA-4
M2CA 315SMA-4
132M2
160
160
160
200
200
250
250
M2CA 315MB-4
M2CA 315MB-4
M2CA 315MB-4
M2CA 315LA-4
M2CA 315LA-4
M2CA 315LC-4
M2CA 315LC-4
500
230
400
500
400
500
400
500
230
400
500
230
400
500
230
400
345
191
154
233
186
289
234
197
110
87
229
134
107
270
161
2x (3x250)
3x224
3x200
2x (3x300)
3x250
3x224
2x (3x400)
2x (3x250)
2x (3x500)
2x (3x250)
2x (3x200)
2x (3x400)
2x (3x224)
2x (3x315)
2x (3x400)
3x400
3x400
3x400
3x500
3x400
3x400
3x500
3x400
3x400
3x800
3x400
3x400
3x500
3x355
2x (3x500)
3x500
200
200
250
250
315
315
90
90
90
110
110
110
160
160
7.4.2 Motor overload relay and fuses for 60 Hz IEC compressors
GA / GA W Motor type, ABB Supply voltage
(V)
Max. setting of overload relay F21
(A)
Max. fuse ratings
Class gL/gG
Type 2 2) (A)
Class gL/gG
Type 1 1) (A)
M2CA 280MB-4
M2CA 280MB-4
M2CA 280MB-4
M2CA 315SMA-4
M2CA 315SMA-4
M2CA 315SMA-4
M2CA 315 MB-4
M2CA 315 MB-4
M2CA 315 LA-4
M2CA 315 LA-4
M2CA 315 LB-4
M2CA 315 LB-4
M2CA 315 LC-4
M2CA 315 LC-4
220-230
380
440-460
220-230
380
440-460
380
440-460
380
440-460
380
440-460
380
440-460
242
204
284
246
319
278
208
122
104
257
149
129
195
169
2x (3x250)
3x224
3x200
2x (3x300)
3x250
3x224
2x (3x250)
3x250
2x (3x400)
2x (3x400)
2x (3x400)
2x (3x400)
2x (3x500)
2x (3x400)
3x400
3x400
3x400
3x500
3x400
3x400
3x400
3x400
3x500
3x500
2x (3x500)
3x500
3x800
2x (3x500)
42 2920 1475 00
Instruction book
90
90
110
110
160
160
200
200
250
250
315
315
7.4.3 Motor overload relay and fuses for 60 Hz CSA/UL compressors
With Siemens motor
GA / GA W Motor type, Siemens Supply voltage
(V)
Max. setting of overload relay F21
(A)
CSA HRC
(A)
Max. fuse ratings
UL Class K5
(A)
1LA6 283-4
1LA6 283-4
1LA6 288-4
1LA6 288-4
1LA6 316-4
1LA6 316-4
1LA6 317-4
1LA6 317-4
1LA8 315-4
1LA8 315-4
1LA8 317-4
1LA8 317-4
440-460
575
440-460
575
440-460
575
440-460
575
440-460
575
440-460
575
105
80
130
100
166
128
208
159
242
184
269
206
3x200
3x200
2x (3x175)
3x200
2x (3x200)
2x (3x175)
2x (3x300)
2x (3x200)
2x (3x300)
2x (3x300)
2x (3x300)
2x (3x300)
3x175
3x175
2x (3x175)
3x175
2x (3x200)
2x (3x175)
2x (3x300)
2x (3x250)
2x (3x300)
2x (3x300)
2x (3x300)
2x (3x300)
90
90
110
110
160
160
200
200
250
250
315
315
With WEG motor
GA / GA W Motor type, Siemens Supply voltage
(V)
W21 125/4 444/5TSD 440-460
W21 125/4 444/5TSD 575
W21 150/4 444/5TSD 440-460
W21 150/4 444/5TSD 575
W21 200/4 504/5TSD 440-460
W21 200/4 504/5TSD 575
W21 250/4 449TCHZ 440-460
W21 250/4 449TCHZ 575
W21 300/4 5008TD 440-460
W21 300/4 5008TD 575
W21 350/4 5008TD 440-460
W21 350/4 5008TD 575
Max. setting of overload relay F21
(A)
100
76
121
93
167
128
215
165
245
187
274
209
CSA HRC
(A)
Max. fuse ratings
UL Class K5
(A)
3x200
3x200
2x (3x175)
3x200
2x (3x200)
2x (3x175)
2x (3x300)
2x (3x200)
2x (3x300)
2x (3x300)
2x (3x300)
2x (3x300)
3x175
3x175
2x (3x175)
3x175
2x (3x200)
2x (3x175)
2x (3x300)
2x (3x250)
2x (3x300)
2x (3x300)
2x (3x300)
2x (3x300)
2920 1475 00 43
Instruction book
7.4.4 Fan motor circuit breakers
Fan type Frequency Supply voltage
(Hz) (V)
Cooling fan for air and oil coolers (GA90/160)
Cooling fan for air and oil coolers (GA90/160)
Cooling fan for air and oil coolers (GA90/160)
Cooling fan for air and oil coolers (GA200/250) 50
Cooling fan for air and oil coolers (GA200/250) 50
Cooling fan for air and oil coolers (GA200/250) 50
50
50
50
Cooling fan for air and oil coolers (GA90/160)
Cooling fan for air and oil coolers (GA90/160)
Cooling fan for air and oil coolers (GA90/160)
Cooling fan for air and oil coolers (GA90/160)
Cooling fan for air and oil coolers (GA200/315) 60
Cooling fan for air and oil coolers (GA200/315) 60
Cooling fan for air and oil coolers (GA200/315) 60
Cooling fan for air and oil coolers (GA200/315) 60
60
60
60
60
Bodywork ventilation fan (GA90/250 W)
Bodywork ventilation fan (GA90/250 W)
Bodywork ventilation fan (GA90/250 W)
Bodywork ventilation fan (GA90/315 W)
Bodywork ventilation fan (GA90/315 W)
Bodywork ventilation fan (GA90/315 W)
Bodywork ventilation fan (GA90/315 W)
60
60
60
60
50
50
50
230
400
500
230
400
500
220-230
380
440-460
575
220-230
380
440-460
575
230
400
500
220-230
380
440-460
575
Circuit breaker Max. setting of circuit breaker (A)
Q25
Q25
Q25
Q25
Q25
Q25
Q25
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
Q25/26
14.3
8.6
7.2
5.7
20.2
11.7
9.9
7.7
12.4
7.2
5.7
17.1
9.9
7.7
2.5
1.4
1.1
2.1
1.4
1.1
1.1
7.4.5 Circuit breakers for dryer motor (GA Full-feature)
Type
GA90/110 dryer motor
GA90/110 dryer motor
GA90/110 dryer motor
GA132/160 dryer motor
GA132/160 dryer motor
GA132/160 dryer motor
GA200/250 dryer motor
GA200/250 dryer motor
GA90/110 dryer motor
GA90/110 dryer motor
GA90/110 dryer motor
GA90/110 dryer motor
GA160 dryer motor
GA160 dryer motor
GA160 dryer motor
GA200/315 dryer motor
GA200/315 dryer motor
GA200/315 dryer motor
Frequency
(Hz)
60
60
60
60
60
60
60
60
60
60
50
50
50
50
50
50
50
50
Supply voltage
(V)
230
400
500
230
400
500
400
500
220-230
380
440-460
575
380
440-460
575
380
440-460
575
Max. setting of circuit breaker Q40
(A)
22
19
15
25
15
13
10
38
33
25
28
16
13
19
11
9
27
22
44 2920 1475 00
Instruction book
7.4.6 Circuit breakers for dryer cooling fan motor (GA Full-feature)
Type Frequency
(Hz)
Supply voltage
(V)
Max. setting of circuit breaker Q41
(A)
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA200/250 dryer cooling fan motor
GA200/250 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA200/315 dryer cooling fan motor
GA200/315 dryer cooling fan motor
GA200/315 dryer cooling fan motor
60
60
60
60
60
60
60
50
50
50
50
50
230
400
500
400
500
220-230
380
440-460
575
380
440-460
575
3.6
2.2
1.9
1.4
8.8
7.7
5.9
2.5
1.4
1.1
6.2
5.1
7.4.7 Circuit breaker for control circuit (Q1)
Type Frequency
(Hz)
Supply voltage
(V)
Transformer
T1 250 VA
(A)
GA90/160
GA90/160
GA90/160
GA200/250
GA200/250
GA90/160
GA90/160
GA90/160
GA90/160
GA200/315
GA200/315
GA200/315
60
60
60
60
60
60
60
50
50
50
50
50
230
400
500
400
500
220-230
380
440-460
575
380
440-460
575
1.6
0.9
0.8
0.6
0.9
0.8
0.6
1.5
0.9
0.7
0.9
0.7
Transformer
T1 400 VA
(A)
Transformer
T1 630 VA
(A)
2.4
1.4
1.1
1.4
1.1
2.4
1.4
3.7
2.2
1.21.9
0.921.4
1.4
1.2
0.92
2.2
1.9
1.4
3.6
2.2
1.8
2.2
1.8
Transformer
T1 800 VA
(A)
4.5
2.8
2.2
2.8
2.2
4.7
2.8
1.8
2.8
2.4
1.8
2920 1475 00 45
Instruction book
7.5 Compressor specifications
7.5.1 Reference conditions
Absolute inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(a)
Relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . %
Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C
Nominal effective working pressure . . . . . . . . . . . . . . . . . . . . bar(e)
Cooling water inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . °C
1
0
20
See sections below
20
7.5.2 Limitations
Maximum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . °C
Minimum air inlet temperature. . . . . . . . . . . . . . . . . . . . . . . . . °C
Maximum effective working pressure . . . . . . . . . . . . . . . . . . . bar(e)
Maximum cooling water inlet temperature . . . . . . . . . . . . . . . °C
Maximum cooling water outlet temperature (open systems) . . °C
Maximum cooling water outlet temperature (recirculating systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C
Maximum cooling water inlet pressure . . . . . . . . . . . . . . . . . . bar(e)
40 8)
0
See sections below
40
50
60
10
7.5.3 Specific data of 7.5 bar - 50 Hz compressors 3)
Compressor type 90 110 132
Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 7.5
Maximum working pressure, Full-feature . . . . . . . . bar(e) 7.25
Maximum working pressure, Full-feature with DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.9
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 7
Nominal working pressure, Full-feature with DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.9
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A)
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . l/s
1490
103
110
100
106
69
63
71
2.0
0.7
7.5
7.25
6.9
7
6.9
1490
124
131
121
127
75
63
7.5
7.25
6.9
7
6.9
1490
147
156
142
150
93
85
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . dB(A) 727274
71
2.5
0.8
71
3.0
0.9
160
7.5
7.25
6.9
7
74
71
3.6
1.1
6.9
1490
178
188
173
182
100
85
200 250
7.5
7.25
6.9
7
7.5
7.25
6.9
7
6.9
1490
224
241
216
232
130
113
6.9
1490
272
289
264
280
130
113
75 75
7272
4.2
1.3
5.6
1.6
46 2920 1475 00
Instruction book
7.5.4 Specific data of 8.5 bar - 50 Hz compressors 3)
Compressor type 90 110 132
Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 8.5
Maximum working pressure, Full-feature . . . . . . . . bar(e) 8.25
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7.9
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 8
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7.9
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A)
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . l/s
1490
103
110
100
106
69
63
71
2.0
0.7
8
8.5
8.25
7.9
7.9
1490
124
131
121
127
75
63
8.5
8.25
7.9
8
7.9
1490
149
158
144
152
93
85
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . dB(A) 727274
71
2.5
0.8
71
3.0
0.9
160
8.5
8.25
7.9
8
74
71
3.6
1.1
7.9
1490
179
189
174
183
100
85
200 250
8.5
8.25
7.9
8
8.5
8.25
7.9
8
7.9
1490
223
239
207
222
130
113
7.9
1490
277
294
262
277
130
113
75 75
7272
4.2
1.3
5.6
1.6
7.5.5 Specific data of 10 bar - 50 Hz compressors 3)
Compressor type 90 110 132
Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 10
Maximum working pressure, Full-feature . . . . . . . . bar(e) 9.75
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 9.4
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 9.5
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 9.4
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A)
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . l/s
1490
102
108
99
104
69
63
71
2.0
0.7
10
9.75
9.4
9.5
9.4
1490
124
131
121
127
75
63
10
9.75
9.4
9.5
9.4
1490
146
155
141
149
93
85
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . dB(A) 727274
71
2.5
0.8
71
3.0
0.9
160
10
9.75
9.4
9.5
74
71
3.6
1.1
9.4
1490
178
187
173
181
100
85
200 250
10
9.75
9.4
9.5
10
9.75
9.4
9.5
9.4
1490
224
240
216
231
130
113
9.4
1490
273
290
265
281
130
113
75 75
7272
4.2
1.3
5.6
1.6
2920 1475 00 47
Instruction book
7.5.6 Specific data of 13 bar - 50 Hz compressors 3)
Compressor type 90 110 132 160 200 250
Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 13
Maximum working pressure, Full-feature . . . . . . . . bar(e) 12.75
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 12.4
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 12.5
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 12.4
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A)
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . l/s
1490
104
110
101
106
69
63
71
2.0
0.7
13
12.75
12.4
12.5
12.4
1490
124
130
121
126
75
63
13
12.75
12.4
12.5
12.4
1490
149
158
144
152
93
85
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . dB(A) 727274
71
2.5
0.8
71
3.0
0.9
13
12.75
12.4
12.5
74
71
3.6
1.1
12.4
1490
182
191
177
185
100
85
13 13
12.75
12.75
12.4
12.5
12.4
12.5
12.4
1490
241
258
233
250
130
113
12.4
1490
289
306
281
298
130
113
75 75
7272
4.2
1.3
5.6
1.6
7.5.7 Specific data of 100 psi - 60 Hz compressors 3)
Compressor type 90
Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 7.4
Maximum working pressure, Full-feature . . . . . . . . bar(e) 7.15
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.8
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 6.9
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.8
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature W 7) . . . . . . . . . . . . . kW
1790
109
116
105
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l
112
69
63
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . dB(A) 76
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . l/s
2.0
0.7
160
7.4
7.15
6.8
6.9
78
71
3.6
1.1
6.8
1790
178
188
171
181
100
85
110
7.4
7.15
6.8
6.9
76
71
2.5
0.8
6.8
1790
133
140
128
134
75
63
200 250 315
7.4
7.15
6.8
6.9
7.4
7.15
6.8
6.9
7.4
7.15
6.8
6.9
6.8
1790
217
234
208
225
130
113
6.8
1790
254
271
245
262
130
113
6.8
1790
291
309
282
300
130
113
76 76 76
727272
4.2
1.3
5.6
1.6
6.9
1.8
48 2920 1475 00
Instruction book
7.5.8 Specific data of 125 psi - 60 Hz compressors 3)
Compressor type 90
Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 9.1
Maximum working pressure, Full-feature . . . . . . . . bar(e) 8.85
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 8.5
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 8.6
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 8.5
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature W 7) . . . . . . . . . . . . . kW
1790
109
116
105
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l
112
69
63
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . dB(A) 76
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . l/s
2.0
0.7
160
9.1
8.85
8.5
8.6
78
71
3.6
1.1
8.5
1790
175
184
168
176
100
85
110
9.1
8.85
8.5
8.6
76
71
2.5
0.8
8.5
1790
128
136
124
131
75
63
200 250 315
9.1
8.85
8.5
8.6
9.1
8.85
8.5
8.6
9.1
8.85
8.5
8.6
8.5
1790
220
236
211
227
130
113
8.5
1790
257
273
248
264
130
113
8.5
1790
294
312
285
303
130
113
76 76 76
727272
4.2
1.3
5.6
1.6
6.9
1.8
7.5.9 Specific data of 150 psi - 60 Hz compressors 3)
Compressor type 90 110 160 200 250 315
Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 10.8
Maximum working pressure, Full-feature . . . . . . . . bar(e) 10.55
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 10.210.210.210.210.210.2
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e)
Nominal working pressure, Full-feature with
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
10.3
10.8
10.55
10.3
10.8
10.8
10.55
10.55
10.3
10.3
10.8
10.55
10.3
10.8
10.55
10.3
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 10.210.210.210.210.210.2
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature W 7) . . . . . . . . . . . . . kW
1790
110
117
106
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l
113
69
63
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . dB(A) 76
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . l/s
2.0
0.7
1790
132
139
127
133
75
63
76
71
2.5
0.8
1790
178
187
171
179
100
85
78
71
3.6
1.1
1790
222
238
211
227
130
113
76
4.2
1.3
1790
260
277
248
264
130
113
76
727272
5.6
1.6
1790
303
320
285
303
130
113
76
6.9
1.8
2920 1475 00 49
Instruction book
7.5.10
Specific data of 200 psi - 60 Hz compressors 3)
Compressor type 90 110 160 250 315
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 13.8
Maximum working pressure, Full-feature . . . . . . . . . . . . . . . . bar(e) 13.55
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 13.213.213.213.213.2
Nominal working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e)
Nominal working pressure, Full-feature with
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min
13.3
13.8
13.55
13.3
13.8
13.8
13.8
13.55
13.55
13.55
13.3
13.3
13.3
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 13.213.213.213.213.2
Power input, GA 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW
Power input, GA Full-feature W 7) . . . . . . . . . . . . . . . . . . . . . kW
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
113
69
63
Sound pressure level, GA 4). . . . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 76
1790
111
118
107
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 71
Maximum cooling water flow, GA W 9) . . . . . . . . . . . . . . . . . l/s
Minimum cooling water flow, GA W 10) . . . . . . . . . . . . . . . . l/s
2.0
0.7
1790
134
141
129
136
75
63
76
71
2.5
0.8
1790
178
187
171
179
100
85
78
71
3.6
1.1
1790
269
285
260
276
130
113
76
5.6
1.6
1790
307
323
298
314
130
113
76
7272
6.9
1.8
7.6 Conversion list of SI units into British/American units
1 bar = 14.504 psi
1 g = 0.035 oz
1 kg = 2.205 lb
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 l/s = 2.117 cfm
1 mm = 0.039 in
1 mbar = 0.401 in water column
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x degrees Celsius = (32 + 1.8 x) degrees Fahrenheit 5)
Footnotes chapter 7
1) Disturbance or destruction of the contactor and/or overload relay may occur (if damaged, the component must be replaced).
2) No damage will occur at the overload relay.
3) At reference conditions (see section 7.5.1).
4) According to PNEUROP PN8NTC2.2 at 1 m distance under free field conditions with a tolerance of 3 dB.
5) A temperature difference of 1 degree Celsius = a temperature difference of 1.8 degrees Fahrenheit.
6) At ambient of 20 degrees Celsius and 80% relative humidity.
7) At supply voltage of 400 V (50 Hz) or 440 V (60 Hz). Data may slightly differ at other voltages or for units with DD filter.
8) 50 degrees Celsius for HAT (High Ambient Temperature) versions.
9) At a temperature rise of 10 degrees Celsius.
10) At a temperature rise of 35 degrees Celsius.
50 2920 1475 00
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Table of contents
- 3 1 Leading particulars
- 3 1.1 General description
- 5 1.1.1 Main options
- 7 1.2 Air flow / regulating system
- 7 1.2.1 Air flow
- 7 1.2.2 Condensate drain system
- 7 1.2.3 Oil system
- 7 1.2.4 Cooling system
- 7 1.2.5 Regulating system
- 10 control system
- 10 1.3.1 Automatic control of the compressor
- 10 1.3.2 Protecting the compressor
- 10 1.3.3 Service warning
- 11 1.3.4 Automatic restart after voltage failure
- 11 1.3.5 Permissive start
- 11 1.4 Control panel
- 11 1.4.1 LEDs/buttons/keys
- 12 1.4.2 Display
- 12 1.4.3 Function keys
- 12 1.4.4 Emergency stop button
- 12 1.5 Menu-driven control programs
- 12 1.5.1 Function of control programs
- 14 1.5.2 Main screen
- 14 1.5.3 External compressor status indication
- 15 2 Installation
- 15 2.1 Dimension drawings
- 21 2.2 Installation proposals
- 27 2.3 Electric cable size
- 28 2.4 Pictographs
- 28 2.5 Cooling water requirements
- 28 2.5.1 Type of the system
- 29 2.5.2 Cooling water parameters
- 31 3 Operating instructions
- 31 3.1 Initial start-up
- 31 3.1.1 Safety precautions
- 31 3.1.2 User manual
- 31 3.1.3 Outdoor/altitude operation
- 31 3.1.4 Moving/lifting
- 31 3.1.5 Initial start-up
- 33 3.2 Before starting
- 34 3.3 Starting
- 34 3.4 During operation
- 34 3.5 Checking the display
- 34 3.6 Manual unloading/loading
- 34 3.7 Stopping
- 36 3.8 Taking out of operation
- 37 4 Maintenance
- 37 4.1.1 Regular service operations
- 37 4.1.2 Service kits
- 37 4.1.3 Service agreements
- 37 4.1.4 Service plan
- 37 4.2 Motor greasing
- 37 4.2.1 Fan motors on GA
- 38 4.2.2 Drive motor
- 38 4.3 Oil specifications
- 38 4.4 Oil change
- 38 4.5 Oil filter change
- 38 4.6 Storage after installation
- 39 4.7 Service kits
- 39 5 Adjustments and servicing procedures
- 39 5.1 Air filters
- 39 5.2 Coolers
- 39 5.3 Safety valve
- 39 5.4 Oil/water separators
- 40 6 Problem solving
- 41 7 Principal data
- 41 7.1 Readings on display
- 41 7.2 Programmable settings
- 41 7.3 Settings of safety valve
- 42 compressors
- 43 UL compressors
- 44 7.4.4 Fan motor circuit breakers
- 44 (GA Full-feature)
- 45 7.4.7 Circuit breaker for control circuit
- 46 7.5 Compressor specifications
- 46 7.5.1 Reference conditions
- 46 7.5.2 Limitations
- 47 7.5.5 Specific data of 10 bar - 50 Hz compressors
- 48 7.5.6 Specific data of 13 bar - 50 Hz compressors