Atlas Copco GA315 W User manual

Atlas Copco GA315 W User manual
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® regulator for GA-GR-ZA-ZEZR-ZT compressors".
·
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
1
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Installation proposals . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Cooling water requirements . . . . . . . . . . . . . . . . . . . . .
2.5.1 Type of the system . . . . . . . . . . . . . . . . . . . . . .
2.5.2 Cooling water parameters . . . . . . . . . . . . . . . .
15
15
21
27
28
28
28
29
3
Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . .
3.1.2 User manual . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.3 Outdoor/altitude operation . . . . . . . . . . . . . . . .
3.1.4 Moving/lifting . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.5 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Checking the display . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Manual unloading/loading . . . . . . . . . . . . . . . . . . . . . .
3.7 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Taking out of operation . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
31
31
31
31
33
34
34
34
34
34
36
4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Preventive maintenance schedule for the compressor . 37
2
Page
4.1.1 Regular service operations . . . . . . . . . . . . . . . .
4.1.2 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Service agreements . . . . . . . . . . . . . . . . . . . . . .
4.1.4 Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Fan motors on GA . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage after installation . . . . . . . . . . . . . . . . . . . . . . . .
Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
37
37
37
37
38
38
38
38
38
39
5
Adjustments and servicing procedures . . . . . . . . . . . . . . .
5.1 Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Oil/water separators . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
39
39
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
4.2
4.3
4.4
4.5
4.6
4.7
2920 1475 00
Instruction book
1 LEADING PARTICULARS
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
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.
1
2
3
4
5
6
Oil coolers
Control panel
Electric cabinet
Power supply inlet
Vibration damper
Vibration damper
7
8
9
10
11
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® control system
- Safety devices
- Air dryer with by-pass valves (Full-feature compressors
only)
Gear casing
Compressor element
Oil stop valve
Check valve
Unloader
12
13
14
M1
M25
Air receiver
Minimum pressure valve
Cooling fan
Drive motor
Fan motor
Fig. 1.1 Front view, GA110 FF
2920 1475 00
3
Instruction book
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
M1
M25/26
Oil coolers
Control panel
Electric cabinet
Power supply inlet
Vibration damper
Vibration damper
Gear casing
Oil stop valve
Check valve
Compressor element
Unloader
Air receiver
Safety valve
Minimum pressure
valve
Arrow, motor
rotation direction
Cooling fans
Air filters
Drive motor
Fan motors
Fig. 1.2 Front view, GA250 FF
1
2
3
4
5
6
7
8
9
By-pass valve
By-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
12
Oil 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
4
Rear view,
GA110 FF
1
2
3
4
5
6
7 M25
20
19
8
18
17
51329F
16
15
14
13 12
11 10
9
2920 1475 00
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
11
1
2
3
4
5
6
7
8
9
By-pass valve
Vent plugs
Air cooler
Air receiver
Oil filters
Condensate trap
Oil drain plugs
Air dryer
Electronic water drain
(option)
10 By-pass valves
11 DD filter (option)
12 Oil drain plug, air receiver
Fig. 1.4 Rear view, GA250 FF
2920 1475 00
10
4
12
9
8
7
6
5
50837F
5
Instruction book
20
1
4
3
1
2
3
4
5
6
Pipe coupling
Oil coolers
Arrow, motor rotation direction
Air cooler
Bolts
Filler plug (only to be used at initial
start-up)
7
Air inlet hose
8
Unloader
9
Arrow, rotation direction of drive motor
10
Compressor element
11
Check valve
12
Oil 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
2
19
M25
5
Y1
18
6
7
17
16
8
21
9
10
15
14
13
11
12
50852F
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
M25/26
Y1
Pipe coupling
Air cooler
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
Unloaders
Air receiver
Oil filters
Oil separator element
Receiver cover
Bolt
Minimum pressure valve
Safety valve
Pipe, air receiver to air cooler
Oil drain plug, air receiver
Bolts
Fan motors
Loading solenoid valve
Fig. 1.6 Side view, GA250 FF
6
Fig. 1.5 Side view, GA110 FF
4 1 M25
2
3 20 M26 4
18
17
6
16
15
14
10
Y1
6
10
13
12
5
5
7
11
50835F
19
8 7 9
8
2920 1475 00
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.
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
Check valve (16) prevents blow-back of compressed air.
Unloading
Minimum pressure valve (19) prevents the receiver pressure
from dropping below a minimum pressure. The valve has a
built-in check valve.
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
2920 1475 00
7
Instruction book
Fig. 1.7
1
2
3
4
5
6
7
8
8
GA90/160 Full-feature
during unloading
Air filter
Unloader
Unloading valve
Air cooler
Cooling fan
Oil coolers
Oil filters
Chamber, control pressure
9
10
11
12
13
14
15
16
By-pass opening
Blow-off channel
Chamber, receiver pressure
Valve
Shield
Compressor element
Oil stop valve
Check valve
17
18
19
20
21
22
23
24
Air receiver
Oil separator element
Minimum pressure valve
Check valve
Oil scavenging line
Safety valve
Oil filler plug
Oil level indicator
2920 1475 00
Instruction book
Fig. 1.8 GA200/315 during loading
25
26
27
28
29
30
31
32
33
Oil drain plug
By-pass valve
Air outlet valve (customer’s
installation)
Condensate trap
Channel
Flexible, receiver pressure
Insulating block
Condensate trap
Liquid – gas mixer
34
35
36
37
38
39
40
41
42
43
Thermostatic expansion valve
Sight-glass
Filter/dryer
Capillary tube
Fan control switch
High pressure switch
Fan
Fan motor
Condenser
Hot gas by-pass valve
44
45
46
47
48
49
50
E1
M1
Y1
Refrigerant compressor
Liquid separator
Low pressure switch
Air/refrigerant heat exchanger
Air/air heat exchanger
By-pass valves
By-pass valve
Elektronikon regulator
Drive motor
Loading solenoid valve
Figs. 1.7 and 1.8 Regulating system
2920 1475 00
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.
1.2.5.2 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.
1.3.1 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.
1.3.2 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.
1.3 Elektronikon® control system
1.3.3 Service warning
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
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
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Instruction book
1.4 Control panel
1.4.1 LEDs/buttons/keys
Ref.
Designation
Function
1
Start button
Push button to start the
compressor. LED (8) lights up
indicating that the Elektronikon
regulator is operative.
2
Display
Indicates messages concerning the
compressor operating condition, a
service need or a fault.
3
Scroll keys
Keys to scroll upwards or
downwards through the display.
4
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.
5
Function keys
Keys to control and program the
compressor. See section 1.4.3.
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.
6
Voltage on LED
Indicates that the voltage is
switched on.
7
General alarm
LED
Is alight if a shut-down warning
condition exists. See section 1.3.
Warning
7
General alarm
LED
Blinks if a shut-down condition
exists, if an important sensor is out
of order or after an emergency
stop. See section 1.3.
8
Automatic
operation LED
Indicates that the regulator is
automatically controlling the
compressor.
9
Stop button
Push button to stop the
compressor. LED (8) goes out.
S2
Emergency
Push button to stop the compressor
immediately in case of emergency.
After remedying the trouble,
unlock the button by pulling it out.
Fig. 1.9 Control panel
1.3.4 Automatic restart after voltage failure
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.
1.3.5 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
Designation
Function
The following is a typical example of the main screen, showing
in short the status of the compressor:
Return
To return to a previously shown option or
menu
Compressor Outlet
7.0 bar
Extra
Automatically loaded
Menu
To find information regarding the installed
modules
Unload
F1
F3
F2
¯
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
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
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
Function
Add
To add compressor start/stop commands (day/
hour)
Back
To return to a previously shown option or
menu
Cancel
To cancel a programmed setting when
programming parameters
Delete
To delete compressor start/stop commands
Help
To find the Atlas Copco internet address
Limits
To show limits for a programmable setting
MainScreen
To return from a menu to the main screen (Fig.
1.12)
Menu
Starting from the main screen (Fig. 1.12), to
have access to submenus
Menu
Starting from a submenu, to return to a
previous menu
Modify
To modify programmable settings
Program
To program modified settings
Reset
To reset a timer or message
12
-
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.
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
Shows in short the operation status of the
compressor. It is the gateway to all functions.
See Fig. 1.12.
Status data
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
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Instruction book
Compressor Outlet
6.4 bar
Maximum Pressure 8.3 bar ↑
Automatic Operation
Local Control
↓
Automatically Loaded
Menu
Status Data
Unload
→
Running Hours
↓
Week Timer Active
Mainscreen
Help
Extra
1016 hrs
980 hrs ↓
Loaded Hours
Mainscreen
Help
-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
-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
Extra
All Conditions Are OK
Measured Data
Counters
-Oil Injection Element
-Compressor Outlet
-Element 1 Outlet
-Element 2 Outlet
-Cooling Medium
-Oil Separator
-Dryer LAT
-Emergency Stop
↓
Mainscreen
Menu
Help
Status Data
↑
Compressor Outlet 5.4 bar
Measured Data
→
Dp Oil Separator
Counters
↓
Dp Air Filter
1.1 bar
↓
0.02 bar
Menu
Mainscreen
-Module Hours
-Load Relay
Measured Data
↑
Running Hours
Counters
→
Loaded Hours
Test
↓
Motor Starts
1016 hrs
980 hrs
945 number ↓
Menu
Mainscreen
Loading Pressure
Loading Pressure 2
Counters
↑
Display Test
Test
→
Safety Valve Test
Modify Parameters
↓
6.4 bar
Unloading Pressure 7.0 bar
Menu
Mainscreen
-Remote Start/Stop
-Remote LoadUnload
-Remote pressure sensing
-Overload Motor
-Overload Fanmotor
-Starter Feedback Contact
-PB1 open/ PB2 closed
-Overload Dryer/Dryer Fan
6.0 bar ↓
Modify
→
↓
Menu
Parameters
↑
Compressor Outlet 5.4 bar
Protections
→
Dp Oil Separator
Service Plan
↓
Dp Air Filter
Menu
Test
↑
Parameters
Modify Parameters
→
Protections
Service
↓
Service Plan
→
↓
Menu
Mainscreen
↑
Service Timer
Service
→
Running Hours
Protections
↑
Service Timer
Service Plan
→
Running hours
Clock Function
↓
Service Plan
↑
Clock Function
→
Configuration
↓
Saved Data
↓
Mainscreen
130 hrs ↓
Service Plan
Menu
Modify Parameters
↑
Service
Saved Data
Mainscreen
Last Shutdown 1
Last Shutdown 2
→
Last Shutdown 3
Not Activated →
↑
Time
Date
→
Modify
Delete
10:54
03/05/01
Date Format DD/MM/YY
Menu
Modify
52407PEN
→
↓
↓
-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
Menu
Clock Function
Configuration
Menu
→
130 hrs
Menu
Menu
→
1.1 bar
- 0.011 bar ↓
Menu
Menu
Modify Parameters
-Unloading Pressure 2
-Y-Time
-Load Delay
-Nr Of Starts/ Day
-Minimum Stop Time
-Programmed Stop Time
-Permisive Start Time
-Communication Time-out
↓
-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.
Menu
Fig. 1.11 Menu flow
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Instruction book
1.5.3 External compressor status indication
Program/
Function
Description
Counters
Calling up the:
- running hours
- number of motor starts
- regulator (module) hours
Terminal strip (1X7-Fig. 1.13) is provided with auxiliary
contacts for external indication of:
Test
Allows a display test.
Modify
parameters
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, …
Service
Calling up service plans and resetting the
timers after carrying out the service actions
belonging to a plan. See section 4.
Saved data
Calling up the saved data: last shut-down, last
emergency stop data
Indication
Relay Terminals
Max. load
on strip 1X7
Automatic operation
Warning
Shut-down
Compressor loading
Motor running
K07
K08
K09
K11
K21
Warning
11-12
13-14
15-16
17-18
19-20
10 A / 230 V AC
10 A / 230 V AC
10 A / 230 V AC
3 A / 230 V AC
6 A / 230 V AC
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
F2
¯
F3
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.
14
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
Delta contactor
Circuit breaker, fan
motor M25
(GA90/315)
Q26
Circuit breaker, fan
motor M26
(GA132/315)
T1/T2 Transformers
1X3/7 Terminal strips
Fig. 1.13 Electric cabinet, typical example
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Instruction book
2 INSTALLATION
2.1 Dimension drawings
Fig. 2.1 Dimension drawing, GA90 and GA110
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Instruction book
Fig. 2.2 Dimension drawing, GA90 W and GA110 W
16
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Instruction book
Fig. 2.3 Dimension drawing, GA132 and GA160
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17
Instruction book
Fig. 2.4 Dimension drawing, GA132 W and GA160 W
18
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Fig. 2.5 Dimension drawing, GA200 up to GA315
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19
Instruction book
Fig. 2.6 Dimension drawing, GA200 W up to GA315 W
20
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Instruction book
2.2 Installation proposals (Figs. 2.7 up to 2.10)
Fig. 2.7 Installation proposal, GA90 up to GA160
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Instruction book
Fig. 2.8 Installation proposal, GA90 W up to GA160 W
22
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Instruction book
Fig. 2.9 Installation proposal, GA200 up to GA315
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23
Instruction book
Ref.
Description
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.
3
The pressure drop over the air outlet pipe can be
calculated as follows:
2
Remove 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.
dp =
(L x 450 x Qc1.85) / (d5 x p)
dp =
pressure drop (recommended maximum =
0.1 bar)
length of outlet pipe in m
inner diameter of the outlet pipe in mm
absolute pressure at the compressor outlet in
bar(a)
free air delivery of the compressor in l/s
L
d
p
=
=
=
Qc =
Fig. 2.10 Installation proposal, GA200 W up to GA315 W
24
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Instruction book
Ref.
Description
Ref.
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
=
V =
dp =
p
Q
C
4
=
=
=
(30 x C x p x Q) / dp
recommended air net volume in l
pressure difference between unloading and
loading pressures in bar (recommended
minimum = 0.6)
compressor inlet pressure in bar absolute
free air delivery of compressor in l/s
correction factor, see below
Air consumption divided by
compressor air delivery
Correction factor C
0.9
0.8
0.7
0.5
0.3
0.2
0.1
0.10
0.15
0.20
0.25
0.20
0.15
0.10
Description
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).
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 =
N =
dT =
Qv = 0.1 N/dT (GA W)
required ventilation capacity in m3/s
shaft input of compressor in kW
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
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Instruction book
F21
K21
K22
K23
K25
K26
K30
K40
Compressor motor overload
relay
Line contactor
Star contactor
Delta contactor
Contactor, fan motor M25
(GA90/315)
Contactor, fan motor M26
(GA132/315)
Phase sequence relay (option)
Contactor, compressor motor
of air dryer (Full-feature only)
K41
K42
M1
M25
M26
M40
M41
Contactor, fan motor of dryer
(GA90/315 Full-feature)
Contactor, fan motor of dryer
(GA200/315 Full-feature)
Drive motor
Fan motor, GA90/315
Fan motor, GA132/315
Compressor motor, air dryer
(Full-feature only)
Fan motor, air dryer (GA90/
315 Full-feature)
M42
Q25
Q26
Q40
Q41
1X3
Fan motor, air dryer (GA200/
315 Full-feature)
Circuit breaker, fan motor M25
(GA90/315)
Circuit breaker, fan motor M26
(GA132/315)
Circuit breaker, compressor
motor of air dryer (Full-feature
only)
Circuit breaker, fan motor(s) of
air dryer (Full-feature only)
Earthing strip
Fig. 2.11 Electrical connections (typical example)
26
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Instruction book
2.3 Electric cable size
50 Hz compressors 6)
Type
230 V
400 V
500 V
GA90
GA110
GA132
GA160
2x (3x120mm²+70mm²)
2x (3x150mm²+95mm²)
2x (3x185mm²+95mm²)
2x (3x240mm²+120mm²)
3x95mm²+50mm²
3x120mm²+70mm²
2x (3x95mm²+50mm²)
2x (3x120mm²+70mm²)
3x70mm²+35mm²
3x95mm²+50mm²
3x120mm²+70mm²
2x (3x70mm²+35mm²)
Type
230 V
400 V
500 V
2x (3x150mm²+70mm²)
2x (3x185mm²+95mm²)
2x (3x120mm²+70mm²)
2x (3x150mm²+70mm²)
GA200
GA250
60 Hz IEC compressors 6)
Type
220/230 V
380 V
440/460 V
GA90
GA110
GA160
2x (3x120mm²+70mm²)
2x (3x150mm²+95mm²)
3x120mm²+70mm²
2x (3x70mm²+35mm²)
2x (3x95mm²+50mm²)
3x95mm²+50mm²
2x (3x50mm²+25mm²)
2x (3x95mm²+50mm²)
Type
220/230 V
380 V
440/460 V
2x (3x150mm²+70mm²)
2x (3x185mm²+95mm²)
2x (3x240mm²+120mm²) 4) or
4x (3x70mm²+35mm²) 5)
2x (3x120mm²+70mm²)
2x (3x150mm²+70mm²)
2x (3x185mm²+95mm²)
GA200
GA250
GA315
60 Hz CSA/UL compressors 7)
Type
440/460 V
575 V
GA90
GA110
GA160
3xAWG0000+AWG2
2x (3xAWG00+AWG4)
2x (3xAWG000+AWG3)
3xAWG00+AWG4
3xAWG000+AWG3
2x (3xAWG00+AWG4)
Type
440/460 V
575 V
GA200
2x (3xMCM400+AWG0) 4) or
4x (3xAWG00+AWG4) 5)
2x (3xMCM500+AWG0) 4) or
4x (3xAWG000+AWG3) 5)
4x (3xAWG000+AWG3) 5)
2x (3xMCM250+AWG2) 4) or
4x (3xAWG1+AWG6) 5)
2x (3xMCM300+AWG0) 4) or
4x (3xAWG0+AWG4) 5)
4x (3xAWG00+AWG4) 5)
GA250
GA315
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Instruction book
2.4 Pictographs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fig. 2.12 Pictographs, control panel
17
18
19
20
21
22
23
Start
Keys to scroll through display
Key to go to next field on display
Voltage on
Alarm
Automatic operation
Stop
Oil the gaskets, screw on the
filters and tighten by hand
(approx. one half turn)
Cooling water inlet
Cooling water outlet
Consult the Instruction book
before maintenance or repair
Condensate outlet
Automatic condensate drain
Automatic condensate drain for
optional oil/water separator (type
OSD)
Manual condensate drain
Stop the compressor before
cleaning the coolers
Warning: under tension
Read Instruction book before
starting the compressor
Switch off the voltage and depressurize the compressor before
maintenance or repair
Before connecting the compressor
electrically, consult the Instruction
book for the motor rotation
direction
Torques for steel (Fe) or brass
(CuZn) bolts
Consult the Instruction book
before greasing
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.
28
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.
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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.
The Rysnar Index is calculated as follows :
RSI = 2*pH - pH
s
where
pH =
measured pH (at room temperature) of
water sample
pH at saturation
pH =
s
The pH is calculated by using :
s
2.5.2 Cooling water parameters
pH =
(9.3 + A + B) - (C + D)
A:
depends on the total solids concentration
(mg/l).
B:
depends on the highest cooling water
temperature (°C),
For GA/GR units take T = 75°C
C:
depends on the calcium hardness
(ppm CaCO ).
s
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.
3
depends on the HCO - concentration or
3
M-alkalinity (mval/l).
D:
The values from A, B, C and D are found in the
table below.
Total dissolved solids
(mg/l)
A
Temperature
(°C)
B
Ca-hardness
(ppm CaCO )
C
M-Alkalinity
(mval/l)
D
50 - 300
400 - 1000
0.1
0.2
0-1
2-6
7-9
10 - 13
14 - 17
18 - 21
22 - 27
28 - 31
32 - 37
38 - 44
45 - 50
51 - 56
57 - 63
64 - 71
72 - 80
2.6
2.5
2.4
2.3
2.2
2.1
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
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
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
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
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
2920 1475 00
3
29
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
Very high scale formation
Water cannot be used
4.0 < RSI < 5.5
High boiler scale formation
Regular control and descaling operation necessary
5.6 < RSI < 6.2
Slight boiler scale formation
Water treatment not necessary
Occasional inspection recommended
6.3 < RSI < 6.8
Neutral water
Water treatment not necessary
Occasional inspection recommended
6.9 < RSI < 7.5
Slight corrosion at higher temperature
Water treatment not necessary
Occasional inspection recommended
7.6 < RSI < 9.0
Strong corrosion
Regular control necessary, use of corrosion inhibitor
recommended
9.1 < RSI < 11
Very strong corrosion
Regular control necessary, use of corrosion inhibitor required
RSI > 11
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.
In a closed system, the following limits apply: TDS < 3000
mg/l (< 3800 µS/cm)
The RSI only indicates the equilibrium of scaling – descaling.
A cooling water showing good RSI conditions can still be
unsuitable due to other factors.
For an open system, the following limits apply: TDS < 450
mg/l (< 580 µS/cm)
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.
30
Chlorides (Cl-)
Chloride ions will create pitting corrosion on stainless steel.
Their concentration should be limited :
Closed cooling system :
Open cooling system :
Chlorides < 500 ppm
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.
2920 1475 00
Instruction book
3 OPERATING INSTRUCTIONS
Sulphates (SO4--)
Closed cooling system :
Open cooling system :
Sulphates < 400 ppm
Sulphates < 150 ppm
Carbonate hardness
Closed cooling system :
Open cooling system :
HCO - / SO
3
24
3.1 Initial start-up
3.1.1 Safety precautions
50-1000 ppm CaCO
3
50-500 ppm CaCO
3
The operator must apply all related safety precautions including
those mentioned in this book.
should be >1
Ammonia
< 0.5 ppm
Copper
3.1.2 User manual
Read the "User manual for Elektronikon regulator " to
familiarize yourself with all regulator functions.
< 1 ppm
Iron and Manganese
3.1.3 Outdoor/altitude operation
< 1 ppm
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.
Organics
No algae.
No oil.
Suspended solids
3.1.4 Moving/lifting
Non-soluble particles, size < 1mm.
< 10 ppm
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.
3.1.5 Initial start-up
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.
2920 1475 00
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.
31
Instruction book
50542F
1
2
1
50543F
2
Bush (to be removed)
Vibration damper
1
1
2
Fig. 3.1 Transport fixations, gear casing of GA/GA W 90/160
2
1
Bush (to be removed)
Vibration damper
Fig. 3.2 Transport fixations, drive motor of GA/GA W 90/160
2
1
1
2
1
50839F
Bush (to be removed)
Vibration damper
1
2
2
50843F
Bushes (to be removed)
Vibration damper
Fig. 3.3 Transport fixations, gear casing of GA/GA W 200/315
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 (1Fig. 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 (4Fig. 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.
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
2
1
5
7 2 3
6
50845F
1
2
3
4
5
6
7
By-pass valve
By-pass valve
By-pass valve
Voltage supply inlet
Air inlet
Data plate
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).
51542F
3.2 Before starting
4
3
2
1
3
3
5
4
5
6
50844F
1
2
3
Voltage supply inlet
Data plate
Location of air outlet valve
Fig. 3.5 Air outlet, GA90/160
2920 1475 00
1
2
3
4
5
6
6
1
2
4
Manual condensate drain
Manual condensate drain (Full-feature only)
Automatic condensate drain for optional oil/water
separator (type OSD)
Automatic condensate drain
Automatic condensate drain (Full-feature only)
Automatic drain for optional DD filter
Fig. 3.7 Location of condensate outlets
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.
Fig. 3.8 Control panel
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.
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.
34
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.
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
2
3
4
Water outlet
Water inlet
Combined oil and air coolers
Regulating valve, water flow
Fig. 3.10 Water system of GA W (typical example)
2920 1475 00
1
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 2Fig. 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
1
2
3
4
5
6
2
3
4
5
6
Oil filters
Air receiver
Oil separator element
Oil level sight-glass
Oil filler plug
Oil drain plug
Fig. 3.11 Air receiver
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) Customer’s 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 (S2Fig. 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
8
Check readings on display
Daily
8
Check that condensate is discharged during loading
Daily
--
Check oil level. Before starting, the level should be in the middle of the sight-glass
3-monthly
--
Clean compressor
3-monthly
--
Check for possible leaks
3-monthly
500
Check coolers; clean if necessary
4.1.2 Service kits
4.1.4
Service plan
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.
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.
4.1.3 Service agreements
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.
Atlas Copco Customer Centres have a range of service
agreements to suit your needs:
4.2 Motor greasing
-
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.
2920 1475 00
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.
37
Instruction book
4.2.2 Drive motor (M1-Figs. 1.1/1.2)
4.4 Oil change
Contact your Customer Centre for the recommended grease
type, the greasing quantity and interval for the motor bearings.
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.
Important
Never mix greases of different brands or types.
4.3 Oil 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
8
4.5 Oil filter change
5 4
7 6
1
2
3
4
5
6
7
8
3
2
Unloader
Oil drain plug
Oil drain plug
Oil stop valve
Compressor element
Oil drain plug
Check valve
Air receiver
50545F
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.
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.
Fig. 4.1 Compressor element
38
2920 1475 00
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
209-litre drum
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.
Ordering number
2901 0522 00
2901 0045 01
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.
5.3 Safety 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
5.4 Oil/water separators (Fig. 5.1)
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.
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
2
1
2
3
4
5
6 PROBLEM SOLVING
3
Warning
1
7
4
5
51446F
6
1
2
3
4
Water outlet
Oil outlet
Water vessel
Condensate inlet
5
6
7
8
Take precautions to avoid an accidental restart.
Apply all relevant safety precautions, including
those mentioned in this book.
8
6
Filter
Oil collector
Pre-filter
Pressure gauge
Fig. 5.1 OSD90/315 oil separators (option)
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)
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
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.
40
5
a
a
b
b
c
c
Compressor air delivery or pressure below normal
Air consumption exceeds air delivery of compressor
Check equipment connected
Choked air filters
Replace filters
Air leakage
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.
2920 1475 00
Instruction book
c
c
d
d
e
e
f
f
Oil level too low
Check and correct as necessary
Oil coolers clogged
Consult Atlas Copco
Air cooler clogged
Consult Atlas Copco
On GA W, restriction in cooling water system due to dirt or
formation of scale
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 . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure drop over air filters . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure difference over oil separator . . . . . . . . . . . . . . . . . . .
Oil injection pressure at the compressor elements . . . . . . . . . .
Compressor outlet temperature:
-for GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-for GA Full-feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-for GA W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-for GA W Full-feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor element outlet temperature . . . . . . . . . . . . . . . . . .
Cooling air inlet temperature (on GA) . . . . . . . . . . . . . . . . . .
Cooling water temperature (on GA W) . . . . . . . . . . . . . . . . . .
Pressure dewpoint (GA Full-feature) . . . . . . . . . . . . . . . . . . .
Pressure drop over DD filter (option) . . . . . . . . . . . . . . . . . . .
See section 7.5
Depends on programmed unloading and loading pressures
Below 0.050 bar
Below 0.8 bar
Depends on programmed unloading and loading pressures
Approx. 29°C
Approx. 26°C
Approx. 25°C
Approx. 22°C
Between 55 and 100°C
Below 40°C 8)
Below 50°C
Approx. 3°C 6)
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").
7.3 Settings 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.
2920 1475 00
41
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
Class gL/gG
Type 2 2) (A)
Type 1 1) (A)
90
90
90
110
110
110
132
132
132
160
160
160
200
200
250
250
230
400
500
230
400
500
230
400
500
230
400
500
400
500
400
500
197
110
87
229
134
107
270
161
128
345
191
154
233
186
289
234
2x (3x250)
3x224
3x200
2x (3x300)
3x250
3x224
2x (3x400)
2x (3x250)
3x250
2x (3x500)
2x (3x250)
2x (3x200)
2x (3x400)
2x (3x224)
2x (3x315)
2x (3x400)
M2CA 280SMB-4
M2CA 280SMB-4
M2CA 280SMB-4
M2CA 280MLB-4
M2CA 280MLB-4
M2CA 280MLB-4
M2CA 315SMA-4
M2CA 315SMA-4
M2CA 315SMA-4
M2CA 315MB-4
M2CA 315MB-4
M2CA 315MB-4
M2CA 315LA-4
M2CA 315LA-4
M2CA 315LC-4
M2CA 315LC-4
3x400
3x400
3x400
3x500
3x400
3x400
3x500
3x400
3x400
3x800
3x400
3x400
3x500
3x355
2x (3x500)
3x500
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
Class gL/gG
Type 2 2) (A)
Type 1 1) (A)
90
90
90
110
110
110
160
160
200
200
250
250
315
315
220-230
380
440-460
220-230
380
440-460
380
440-460
380
440-460
380
440-460
380
440-460
208
122
104
257
149
129
195
169
242
204
284
246
319
278
2x (3x250)
3x224
3x200
2x (3x300)
3x250
3x224
2x (3x250)
3x250
2x (3x400)
2x (3x400)
2x (3x400)
2x (3x400)
2x (3x500)
2x (3x400)
42
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
3x400
3x400
3x400
3x500
3x400
3x400
3x400
3x400
3x500
3x500
2x (3x500)
3x500
3x800
2x (3x500)
2920 1475 00
Instruction book
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)
Max. fuse ratings
CSA HRC
UL Class K5
(A)
(A)
90
90
110
110
160
160
200
200
250
250
315
315
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)
GA / GA W Motor type, Siemens
Supply
voltage
(V)
Max. setting of
overload relay F21
(A)
Max. fuse ratings
CSA HRC
UL Class K5
(A)
(A)
90
90
110
110
160
160
200
200
250
250
315
315
440-460
575
440-460
575
440-460
575
440-460
575
440-460
575
440-460
575
100
76
121
93
167
128
215
165
245
187
274
209
3x200
3x200
2x (3x175)
3x200
2x (3x200)
2x (3x175)
2x (3x300)
2x (3x200)
2x (3x300)
2x (3x300)
2x (3x300)
2x (3x300)
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
3x175
3x175
2x (3x175)
3x175
2x (3x200)
2x (3x175)
2x (3x300)
2x (3x250)
2x (3x300)
2x (3x300)
2x (3x300)
2x (3x300)
With WEG motor
2920 1475 00
W21 125/4 444/5TSD
W21 125/4 444/5TSD
W21 150/4 444/5TSD
W21 150/4 444/5TSD
W21 200/4 504/5TSD
W21 200/4 504/5TSD
W21 250/4 449TCHZ
W21 250/4 449TCHZ
W21 300/4 5008TD
W21 300/4 5008TD
W21 350/4 5008TD
W21 350/4 5008TD
3x175
3x175
2x (3x175)
3x175
2x (3x200)
2x (3x175)
2x (3x300)
2x (3x250)
2x (3x300)
2x (3x300)
2x (3x300)
2x (3x300)
43
Instruction book
7.4.4 Fan motor circuit breakers
Fan type
Frequency
(Hz)
Supply voltage
(V)
Circuit breaker
Max. setting of
circuit breaker (A)
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)
50
50
50
230
400
500
Q25/26
Q25/26
Q25/26
12.4
7.2
5.7
Cooling fan for air and oil coolers (GA200/250)
Cooling fan for air and oil coolers (GA200/250)
Cooling fan for air and oil coolers (GA200/250)
50
50
50
230
400
500
Q25/26
Q25/26
Q25/26
17.1
9.9
7.7
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)
60
60
60
60
220-230
380
440-460
575
Q25/26
Q25/26
Q25/26
Q25/26
14.3
8.6
7.2
5.7
Cooling fan for air and oil coolers (GA200/315)
Cooling fan for air and oil coolers (GA200/315)
Cooling fan for air and oil coolers (GA200/315)
Cooling fan for air and oil coolers (GA200/315)
60
60
60
60
220-230
380
440-460
575
Q25/26
Q25/26
Q25/26
Q25/26
20.2
11.7
9.9
7.7
Bodywork ventilation fan (GA90/250 W)
Bodywork ventilation fan (GA90/250 W)
Bodywork ventilation fan (GA90/250 W)
50
50
50
230
400
500
Q25
Q25
Q25
2.5
1.4
1.1
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
220-230
380
440-460
575
Q25
Q25
Q25
Q25
2.1
1.4
1.1
1.1
7.4.5 Circuit breakers for dryer motor (GA Full-feature)
Type
Frequency
(Hz)
Supply voltage
(V)
Max. setting of circuit breaker Q40
(A)
GA90/110 dryer motor
GA90/110 dryer motor
GA90/110 dryer motor
50
50
50
230
400
500
19
11
9
GA132/160 dryer motor
GA132/160 dryer motor
GA132/160 dryer motor
50
50
50
230
400
500
28
16
13
GA200/250 dryer motor
GA200/250 dryer motor
50
50
400
500
27
22
GA90/110 dryer motor
GA90/110 dryer motor
GA90/110 dryer motor
GA90/110 dryer motor
60
60
60
60
220-230
380
440-460
575
25
15
13
10
GA160 dryer motor
GA160 dryer motor
GA160 dryer motor
60
60
60
380
440-460
575
22
19
15
GA200/315 dryer motor
GA200/315 dryer motor
GA200/315 dryer motor
60
60
60
380
440-460
575
38
33
25
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
50
50
50
230
400
500
2.5
1.4
1.1
GA200/250 dryer cooling fan motor
GA200/250 dryer cooling fan motor
50
50
400
500
6.2
5.1
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
GA90/160 dryer cooling fan motor
60
60
60
60
220-230
380
440-460
575
3.6
2.2
1.9
1.4
GA200/315 dryer cooling fan motor
GA200/315 dryer cooling fan motor
GA200/315 dryer cooling fan motor
60
60
60
380
440-460
575
8.8
7.7
5.9
7.4.7 Circuit breaker for control circuit (Q1)
Type
(Hz)
Supply
voltage
(V)
Transformer
T1 250 VA
(A)
Transformer
T1 400 VA
(A)
Transformer
T1 630 VA
(A)
Transformer
T1 800 VA
(A)
GA90/160
GA90/160
GA90/160
50
50
50
230
400
500
1.5
0.9
0.7
2.4
1.4
1.1
3.6
2.2
1.8
4.5
2.8
2.2
GA200/250
GA200/250
50
50
400
500
0.9
0.7
1.4
1.1
2.2
1.8
2.8
2.2
GA90/160
GA90/160
GA90/160
GA90/160
60
60
60
60
220-230
380
440-460
575
1.6
0.9
0.8
0.6
2.4
1.4
1.2
0.92
3.7
2.2
1.9
1.4
4.7
2.8
2.4
1.8
GA200/315
GA200/315
GA200/315
60
60
60
380
440-460
575
0.9
0.8
0.6
1.4
1.2
0.92
2.2
1.9
1.4
2.8
2.4
1.8
2920 1475 00
Frequency
45
Instruction book
7.5 Compressor specifications
7.5.1 Reference conditions
Absolute inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal effective working pressure . . . . . . . . . . . . . . . . . . . .
Cooling water inlet temperature . . . . . . . . . . . . . . . . . . . . . . . .
bar(a)
%
°C
bar(e)
°C
1
0
20
See sections below
20
°C
°C
bar(e)
°C
°C
40 8)
0
See sections below
40
50
°C
bar(e)
60
10
7.5.2 Limitations
Maximum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . .
Minimum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum effective working pressure . . . . . . . . . . . . . . . . . . .
Maximum cooling water inlet temperature . . . . . . . . . . . . . . .
Maximum cooling water outlet temperature (open systems) . .
Maximum cooling water outlet temperature (recirculating
systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum cooling water inlet pressure . . . . . . . . . . . . . . . . . .
7.5.3 Specific data of 7.5 bar - 50 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . .
Maximum working pressure, Full-feature
with DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature
with DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA W Full-feature 7) . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . .
46
90
110
132
160
200
250
bar(e)
bar(e)
7.5
7.25
7.5
7.25
7.5
7.25
7.5
7.25
7.5
7.25
7.5
7.25
bar(e)
bar(e)
6.9
7
6.9
7
6.9
7
6.9
7
6.9
7
6.9
7
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
6.9
1490
103
110
100
106
69
63
72
71
2.0
0.7
6.9
1490
124
131
121
127
75
63
72
71
2.5
0.8
6.9
1490
147
156
142
150
93
85
74
71
3.0
0.9
6.9
1490
178
188
173
182
100
85
74
71
3.6
1.1
6.9
1490
224
241
216
232
130
113
75
72
4.2
1.3
6.9
1490
272
289
264
280
130
113
75
72
5.6
1.6
2920 1475 00
Instruction book
7.5.4 Specific data of 8.5 bar - 50 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . .
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA W Full-feature 7) . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . .
90
110
132
160
200
250
bar(e)
bar(e)
8.5
8.25
8.5
8.25
8.5
8.25
8.5
8.25
8.5
8.25
8.5
8.25
bar(e)
bar(e)
7.9
8
7.9
8
7.9
8
7.9
8
7.9
8
7.9
8
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
7.9
1490
103
110
100
106
69
63
72
71
2.0
0.7
7.9
1490
124
131
121
127
75
63
72
71
2.5
0.8
7.9
1490
149
158
144
152
93
85
74
71
3.0
0.9
7.9
1490
179
189
174
183
100
85
74
71
3.6
1.1
7.9
1490
223
239
207
222
130
113
75
72
4.2
1.3
7.9
1490
277
294
262
277
130
113
75
72
5.6
1.6
90
110
132
160
200
250
bar(e)
bar(e)
10
9.75
10
9.75
10
9.75
10
9.75
10
9.75
10
9.75
bar(e)
bar(e)
9.4
9.5
9.4
9.5
9.4
9.5
9.4
9.5
9.4
9.5
9.4
9.5
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
9.4
1490
102
108
99
104
69
63
72
71
2.0
0.7
9.4
1490
124
131
121
127
75
63
72
71
2.5
0.8
9.4
1490
146
155
141
149
93
85
74
71
3.0
0.9
9.4
1490
178
187
173
181
100
85
74
71
3.6
1.1
9.4
1490
224
240
216
231
130
113
75
72
4.2
1.3
9.4
1490
273
290
265
281
130
113
75
72
5.6
1.6
7.5.5 Specific data of 10 bar - 50 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . .
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA W Full-feature 7) . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . .
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Instruction book
7.5.6 Specific data of 13 bar - 50 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . .
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA W Full-feature 7) . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . .
90
110
132
160
200
250
bar(e)
bar(e)
13
12.75
13
12.75
13
12.75
13
12.75
13
12.75
13
12.75
bar(e)
bar(e)
12.4
12.5
12.4
12.5
12.4
12.5
12.4
12.5
12.4
12.5
12.4
12.5
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
12.4
1490
104
110
101
106
69
63
72
71
2.0
0.7
12.4
1490
124
130
121
126
75
63
72
71
2.5
0.8
12.4
1490
149
158
144
152
93
85
74
71
3.0
0.9
12.4
1490
182
191
177
185
100
85
74
71
3.6
1.1
12.4
1490
241
258
233
250
130
113
75
72
4.2
1.3
12.4
1490
289
306
281
298
130
113
75
72
5.6
1.6
90
110
160
200
250
315
bar(e)
bar(e)
7.4
7.15
7.4
7.15
7.4
7.15
7.4
7.15
7.4
7.15
7.4
7.15
bar(e)
bar(e)
6.8
6.9
6.8
6.9
6.8
6.9
6.8
6.9
6.8
6.9
6.8
6.9
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
6.8
1790
109
116
105
112
69
63
76
71
2.0
0.7
6.8
1790
133
140
128
134
75
63
76
71
2.5
0.8
6.8
1790
178
188
171
181
100
85
78
71
3.6
1.1
6.8
1790
217
234
208
225
130
113
76
72
4.2
1.3
6.8
1790
254
271
245
262
130
113
76
72
5.6
1.6
6.8
1790
291
309
282
300
130
113
76
72
6.9
1.8
7.5.7 Specific data of 100 psi - 60 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . .
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature W 7) . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . .
48
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Instruction book
7.5.8 Specific data of 125 psi - 60 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . .
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature W 7) . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . .
90
110
160
200
250
315
bar(e)
bar(e)
9.1
8.85
9.1
8.85
9.1
8.85
9.1
8.85
9.1
8.85
9.1
8.85
bar(e)
bar(e)
8.5
8.6
8.5
8.6
8.5
8.6
8.5
8.6
8.5
8.6
8.5
8.6
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
8.5
1790
109
116
105
112
69
63
76
71
2.0
0.7
8.5
1790
128
136
124
131
75
63
76
71
2.5
0.8
8.5
1790
175
184
168
176
100
85
78
71
3.6
1.1
8.5
1790
220
236
211
227
130
113
76
72
4.2
1.3
8.5
1790
257
273
248
264
130
113
76
72
5.6
1.6
8.5
1790
294
312
285
303
130
113
76
72
6.9
1.8
90
110
160
200
250
315
bar(e)
bar(e)
10.8
10.55
10.8
10.55
10.8
10.55
10.8
10.55
10.8
10.55
10.8
10.55
bar(e)
bar(e)
10.2
10.3
10.2
10.3
10.2
10.3
10.2
10.3
10.2
10.3
10.2
10.3
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
10.2
1790
110
117
106
113
69
63
76
71
2.0
0.7
10.2
1790
132
139
127
133
75
63
76
71
2.5
0.8
10.2
1790
178
187
171
179
100
85
78
71
3.6
1.1
10.2
1790
222
238
211
227
130
113
76
72
4.2
1.3
10.2
1790
260
277
248
264
130
113
76
72
5.6
1.6
10.2
1790
303
320
285
303
130
113
76
72
6.9
1.8
7.5.9 Specific data of 150 psi - 60 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . .
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature W 7) . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . .
2920 1475 00
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Instruction book
7.5.10
Specific data of 200 psi - 60 Hz compressors 3)
Compressor type
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature . . . . . . . . . . . . . . . .
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power input, GA Full-feature W 7) . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . . . . . . . . .
Maximum cooling water flow, GA W 9) . . . . . . . . . . . . . . . . .
Minimum cooling water flow, GA W 10) . . . . . . . . . . . . . . . .
90
110
160
250
315
bar(e)
bar(e)
13.8
13.55
13.8
13.55
13.8
13.55
13.8
13.55
13.8
13.55
bar(e)
bar(e)
13.2
13.3
13.2
13.3
13.2
13.3
13.2
13.3
13.2
13.3
bar(e)
r/min
kW
kW
kW
kW
l
l
dB(A)
dB(A)
l/s
l/s
13.2
1790
111
118
107
113
69
63
76
71
2.0
0.7
13.2
1790
134
141
129
136
75
63
76
71
2.5
0.8
13.2
1790
178
187
171
179
100
85
78
71
3.6
1.1
13.2
1790
269
285
260
276
130
113
76
72
5.6
1.6
13.2
1790
307
323
298
314
130
113
76
72
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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