Instruction book for compressors GA30 - GA37 - GA45 GA30 W - GA37 W - GA45 W Important 1 This book applies exclusively to GA30-GA37-GA45 equipped with an electronic regulator with a liquid crystal display. This regulator is used from following serial number onwards AII-310 000 2.
Industrial Air Division 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.
Industrial Air Division 1 Leading particulars 1.1 General description 1.1.1 Air flow (Fig. 4b) GA are stationary, single-stage, oil-injected screw compressors driven by an electric motor. GA30, -37 and -45 are air-cooled, whereas GA30 W, -37 W and -45 W are water-cooled. Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. Compressed air and oil flow into air receiver/oil separator (AR) via check valve (CV).
Industrial Air Division AF. AR. BV. Ca. Co. CV. DP2. DP3. DP4. E. E1. FN2. I. MT. M1. M2. O. OF. Air filter Air receiver/oil separator Oil cooler by-pass valve Air cooler Oil cooler Check valve Oil drain plug, oil stop valve Oil drain plug, check valve Oil drain plug, gear casing Compressor element Electronic control module Fan Start button Air cooler moisture trap Compressor motor Fan motor Stop button Oil filter Fig. 2a. Front view of air-cooled GA45 Pack/Full-feature PT20.
Industrial Air Division Da. Dm. 1. 2. 3. Automatic condensate drain, air cooler moisture trap Condensate drain valve, air cooler moisture trap Pictograph, manual condensate drain Pictograph, automatic condensate drain Inlet for separate air dryer voltage supply Fig. 3. Condensate outlets The oil system is provided with a by-pass valve (BV). When the oil temperature is below 40°C (104°F) 1), by-pass valve (BV) shuts off the oil supply from oil cooler (Co).
Industrial Air Division Fig. 4a.
Industrial Air Division Fig. 4b.
Industrial Air Division AF. AR. AV. BV. Ca. Co. CV. Da. Dm. DP1. DP2. DP3. DP4. E. E1. FC. FN2. Gl.
Industrial Air Division Fig. 6a.
Industrial Air Division Fig. 6b. Dryer ID80/100 on GA Full-feature Fig. 6c.
Industrial Air Division SENSORS/LOADING SOLENOID VALVE PT20. Pressure sensor, air outlet TT11. Temperature sensor, compressor element outlet TT90. Temperature sensor, dewpoint 1) Y1. Loading solenoid valve MOTORS M1. Compressor motor M2. Fan motor, compressor coolers M3. Fan motor, electric cabinet 2) K11. K21. K22. K23. K25. Q15. T1/T2. 1X1. 1X2. 1X3. 1X4. ELECTRIC CABINET F1/F6. Fuses F7/8. Fuses 3) F21. Overload relay, compressor motor CONTROL MODULE (E1) I. Start button K01. Blocking relay K02.
Industrial Air Division 1.4.2 Control panel (Fig. 7a) 11 1 2 12 4 6 To control the compressor and to read and modify programmable parameters, the regulator is provided with a panel including: 8 Ref. Designation Function 1 Automatic operation LED Indicates that the regulator is automatically controlling the compressor: the compressor is loaded, unloaded, stopped and restarted depending on the air consumption and the limitations programmed in the regulator.
Industrial Air Division 1.4.2.1 General alarm LED (3-Fig. 7a) 1) - - - The LED blinks in case of a shut-down (due to either too high a compressor element outlet temperature or overload of the compressor motor or fan motor) 2); at the same time the shutdown screen appears. After eliminating the cause of the trouble and when the abnormal condition has disappeared, press key Rset (5). The LED blinks and the compressor is shut down if the sensor of the compressor element (TT11-Fig.
Industrial Air Division cools the air to close to the evaporating temperature of the refrigerant. More water and oil in the air condense. The cold air then flows through moisture trap (MT) where all the condensate is separated from the air. The condensate is automatically drained through outlet (Da). The cold dried air then flows through heat exchanger (5), where it is warmed up by the incoming air. Condensation in the air net cannot occur unless the air is cooled to below the pressure dewpoint.
Industrial Air Division 2 Operating instructions Safety precautions The operator must apply all relevant safety precautions, including those mentioned in this book. 2.1 Initial start-up 2.1.1 Remarks 1. Read the "User manual for electronic regulator for GA30-GA37GA45 compressors" to familiarize yourself with all regulator functions. 2. Consult section 7 for the dimension drawings, electrical connections and installation proposal. 2.1.
Industrial Air Division 2.2 Before starting If the compressor has not run for the past 6 months, it is strongly recommended to improve the lubrication of the compressor element at starting: remove bolts (7-Fig. 14b), lift unloader (UA) and pour 3/4 l of oil into the compressor element. Reinstall the unloader. 1. Check the oil level (Gl-Fig. 12). The pointer should be in the upper field of the green range or in the HIGH range.
Industrial Air Division Example: If operating at a pressure of 10 bar(e) in an ambient temperature of 20°C and at a relative air humidity of 100 %, the minimum temperature to prevent condensate from forming is 68°C. Regulate the cooling water flow during loaded operation to obtain a temperature between 70°C and approx. 75°C at the outlet of the compressor element. Fig. 10. Minimum compressor element outlet temperature for water-cooled compressors On water-cooled compressors also: 5.
Industrial Air Division 3. The display (4) will show a service message if one of the monitored components is to be serviced; replace the component and reset the relevant timer. Notes: - Whenever a shut-down, shut-down warning, service request, sensor error or motor overload message is displayed, the free spaces on the display between the function keys (5) are filled with blinking indicators (**). - When more than one message needs to be displayed (e.g.
Industrial Air Division 3 Maintenance Attention Before starting any maintenance, press stop button O (9-Fig. 7a), wait until the compressor has stopped (approx. 30 seconds), press stop button (S3-Fig. 7a) and switch off the voltage. Apply all relevant safety precautions, including those mentioned in this book. 3.4.2 Mineral oil for hydraulics A yellow-painted blocking device is delivered loose. The device can be fitted around the closed outlet valve (AV-Fig.
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Industrial Air Division 1) Whichever interval comes first. The local Sales Company may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor. Remark For overhauling valves or carrying out preventive maintenance, service kits are available (Fig. 11). Consult the Parts list for the contents of the kits. Notes 1. More frequently when operating in a dusty atmosphere. 2. Use an oil filter as specified in the Parts list.
Industrial Air Division 3.6 Oil filter change (Fig. 12) 3.8 Service kits To change the filter without spilling oil: 1. Run the compressor unloaded for 3 minutes. 2. Stop the compressor and depressurize by unscrewing oil filler plug (FC) one turn to permit any pressure in the system to escape. 3. Remove vent plug (VP-Fig. 2a or 2b), wait 5 minutes, remove drain plug (DP2-Fig. 2b) and catch the oil in a receptacle. 4. Remove oil filter (OF-Fig. 14a). 5. Clean the filter seat on the manifold.
Industrial Air Division F025 Label indicating that it is not allowed to carry out any maintenance or repair as long as the compressor is in operation, pressurized or if the voltage is switched on. Fig. 13. Safety label Fig. 14a. View of minimum pressure valve Refit the side panel and fit the bracket (3) in its original lifted position. On water-cooled compressors: Consult Atlas Copco for cleaning. 4.3 Safety valve (SV-Fig.
Industrial Air Division 4.4 Fan control switch on GA Full-feature 4.6 Expansion valve on GA Full-feature The switch (S3-Fig. 9) is factory-adjusted and must be replaced if the switch-on or cut-out pressure deviates from the values given in section 6.2. The valve (11-Fig. 4a) is a regulator which keeps the evaporator pressure, and consequently also the temperature, stable. The valve is controlled by its own outlet pressure.
Industrial Air Division 1. Push button (I) is pressed, compressor starts running, but does not load after a delay time a. Solenoid valve (Y1) out of order a. Replace valve b. Inlet valve (IV) stuck in closed position b. Consult Atlas Copco c. Leak in control air flexibles c. Replace leaking flexible d. Minimum pressure valve (Vp) leaking (when net is depressurized) d. Consult Atlas Copco 2. a. a. b. b.
Industrial Air Division 6 Principal data 6.1 Readings on display (4-Fig. 7a) 1) Ref.: Reading: Shown: Sensor: Ref.: Reading: Shown: Sensor: Air outlet pressure Modulates between programmed unloading and loading pressures. On main display (Fig. 7b), when: - switching on voltage - selecting main display with keys Menu and Main (5-Fig. 7a) - keys of module are not used for four minutes PT20-Fig. 2b Compressor element outlet temperature Approx.
Industrial Air Division 6.3 Settings of motor overload relay and fuses Compressor type Supply voltage Frequency Max.
Industrial Air Division 6.5.2 Specific data of GA30/GA30 W 1) Compressor type 7.5 10 13 100 125 150 175 Frequency ....................................................... Hz Number of compression stages ...................... Maximum (unloading) pressure (for Pack compressors) ................................... bar(e) Maximum (unloading) pressure (for Full-feature compressors) ......................... bar(e) Nominal working pressure .............................. bar(e) Minimum working pressure ..
Industrial Air Division 6.5.4 Specific data of GA45/GA45 W 1) Compressor type 7.5 10 13 100 125 150 175 Frequency ....................................................... Hz Number of compression stages ...................... Maximum (unloading) pressure (for Pack compressors) ................................... bar(e) Maximum (unloading) pressure (for Full-feature compressors) ......................... bar(e) Nominal working pressure .............................. bar(e) Minimum working pressure ..
Industrial Air Division 7 Installation 7.1 Dimension drawings (Figs. 15) Fig. 15a.
Industrial Air Division Fig. 15b.
Industrial Air Division 7.2 Electric cable section Attention - Local regulations remain applicable if they are stricter than the values proposed below. - The voltage drop must not exceed 5% of the nominal voltage. If may be necessary to use cables with a larger section than those stated to comply with this requirement.
Industrial Air Division Fig. 16a. Installation proposal Fig. 16b.
Industrial Air Division The required ventilation to limit the compressor room temperature can be calculated as follows: If oil vapour and odours are undesirable, a filter of the QD type (optional) should be installed downstream of the PD filter. For alternatives 1 and 3: Qv = 0.
Industrial Air Division 7.4 Electrical connections General 1. Check the fuses and the setting of the overload relay. See section 6.3. 2. Connect the power supply to terminals (L1, L2 and L3). Connect the earth conductor to connector (PE) and the neutral conductor (if provided) to connector (N). Consult section 7.2. On GA Full-feature (Fig. 17): 1. For compressor supply voltages of 3 x 400 V plus neutral or 3 x 230 V, the wiring is provided ex-factory. Check that the wiring is as shown. 2.
Industrial Air Division 7.5 Pictographs Fig. 18 shows typical examples of pictographs used for GA compressors. 1. 2. 3. 4. 5. 6. 7. 8. 9.
