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".
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.
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".
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.
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.
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 sol
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.
Instruction book Fig. 1.
Instruction book Fig. 1.
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.
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.
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.
Instruction book Compressor Outlet 6.4 bar Maximum Pressure 8.
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.
Instruction book 2 INSTALLATION 2.1 Dimension drawings Fig. 2.
Instruction book Fig. 2.
Instruction book Fig. 2.
Instruction book Fig. 2.
Instruction book Fig. 2.
Instruction book Fig. 2.
Instruction book 2.2 Installation proposals (Figs. 2.7 up to 2.10) Fig. 2.
Instruction book Fig. 2.
Instruction book Fig. 2.
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.
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.
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
Instruction book 2.
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.
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.
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.
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.
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.
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.
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 <> to <>. On GA W also: 3. Regulate the cooling water flow (using valve 4-Fig. 3.10) with the compressor running loaded.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
