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Atlas Copco ga55+ Instruction Book

Oil-injected rotary screw compressors
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Atlas Copco
Oil-injected rotary screw compressors
GA 55+, GA 75+, GA 90
Instruction book

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  • Page 1 Atlas Copco Oil-injected rotary screw compressors GA 55+, GA 75+, GA 90 Instruction book...
  • Page 3 Atlas Copco Oil-injected rotary screw compressors GA 55+, GA 75+, GA 90 From serial No. PNA922285 Instruction book Copyright notice 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.
  • Page 5: Table Of Contents

    Instruction book Table of contents Safety precautions....................10 ......................10 AFETY ICONS ..............10 AFETY PRECAUTIONS DURING INSTALLATION ..............12 AFETY PRECAUTIONS DURING OPERATION ............ 13 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description ..................... 15 ......................15 NTRODUCTION ........................ 19 IR FLOW ......................
  • Page 6 Instruction book 3.12 ....................57 VENT HISTORY MENU 3.13 ................... 58 ODIFYING GENERAL SETTINGS 3.14 ......................60 NFO MENU 3.15 ....................61 EEK TIMER MENU 3.16 ......................65 EST MENU 3.17 ....................66 SER PASSWORD MENU 3.18 ..................67 ROGRAMMABLE SETTINGS OSCi (optional)....................
  • Page 7 Instruction book ......................105 ICTOGRAPHS Operating instructions..................107 ..................107 EFORE INITIAL START ....................108 NITIAL START ....................111 EFORE STARTING ......................112 TARTING ....................114 URING OPERATION ..................116 HECKING THE DISPLAY ......................117 TOPPING ..................117 AKING OUT OF OPERATION Maintenance....................119 ................119 REVENTIVE MAINTENANCE SCHEDULE .....................121 RIVE MOTOR ....................122 IL SPECIFICATIONS ..................122...
  • Page 8 Instruction book 11.1 ....................132 EADINGS ON DISPLAY 11.2 ..............133 LECTRIC CABLE SIZE AND MAIN FUSES 11.3 ..............134 ETTINGS OF FAN MOTOR CIRCUIT BREAKER 11.4 ..............134 ETTINGS FOR MOTOR OVERLOAD RELAY 11.5 ....................135 RYER SWITCHES 11.6 ..............135 ERERENCE CONDITIONS AND LIMITATIONS 11.7 ....................
  • Page 10: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for file Warning Important note 1.2 Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
  • Page 11 Instruction book Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits.
  • Page 12: Safety Precautions During Operation

    Instruction book 1.3 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
  • Page 13: Safety Precautions During Maintenance Or Repair

    Instruction book 10. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure-relieving device or devices as required. Also consult following safety precautions: Safety precautions during installation...
  • Page 14 Instruction book 8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. 9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours of cleaning liquids. 10.
  • Page 15: General Description

    GA Workplace are enclosed in a sound-insulated bodywork. The compressors are controlled by the Atlas Copco Elektronikon®regulator. The electronic control module is fitted to the door on the right side. An electric cabinet comprising the motor starter is located behind this panel. A condensate trap with Electronic Water Drain (EWD) is provided.
  • Page 16 GA Workplace Full-Feature are enclosed in a sound-insulated bodywork. The compressors are controlled bythe Atlas Copco Elektronikon® regulator. The electronic control module is fitted to the door on the right side.An electric cabinet comprising the motor starter is located behind this panel. They are provided with an airdryer.
  • Page 17 Instruction book Front view, GA 55+ up to GA 90 Workplace Full-Feature Reference Name Electric cubicle Air filter Air receiver (oil separator vessel) Air outlet valve Air cooler Oil cooler Automatic condensate outlet Automatic condensate outlet, dryer Dryer Elektronikon® Graphic controller Compressor drive motor Vent plug (oil cooler) Emergency stop button...
  • Page 18 Instruction book Rear view, GA 55+ up to GA 90 Workplace Full-Feature Reference Name Compressor element CV/Vs Check valve/oil stop valve Cooling fan Compressor drive motor Condensate trap Compressed air outlet valve Dryer Air filter Oil cooler Air cooler Unloader 9096 3313 00...
  • Page 19: Air Flow

    Instruction book Coolers on water-cooled compressors Water-cooled air cooler and oil cooler Reference Name Air cooler Oil cooler 2.2 Air flow Flow diagrams 9096 3313 00...
  • Page 20 Instruction book Reference Description Intake air Air/oil mixture Wet compressed air Condensate Dry compressed air Note: The cooling fan is not provided on water-cooled compressors. Description Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. A mixof compressed air and oil flows into the air receiver/oil separator (AR) via check valve (CV).
  • Page 21: Oil System

    Instruction book Check valve (CV) prevents blow-back of compressed air when the compressor is stopped. Minimum pressurevalve (Vp) prevents the receiver pressure (AR) from dropping below a minimum pressure during unloadedoperation. 2.3 Oil system Flow diagram References Description For Workplace units, compressed air flow to the air outlet valve For Full- Feature units, compressed air flow to the air dryer Intake air Air/oil mixture...
  • Page 22: Cooling System

    Instruction book Air pressure forces the oil from air receiver/oil separator (AR) through oil filter (OF) and oil stop valve (Vs)to compressor element (E). Bypass valve (BV) starts opening the supply from cooler (Co) when the oil temperature has increased to theset point.
  • Page 23 Instruction book References Description Intake air Air/oil mixture Wet compressed air Condensate Water flow Description The cooling system comprises air cooler (Ca) and oil cooler (Co). On air-cooled compressors, the cooling air flow is generated by fan (FN). Water-cooled compressors are connected to a cooling water circuit. The water flows through the inlet pipe,the coolers and the outlet pipe.
  • Page 24: Condensate System

    Instruction book 2.5 Condensate system Water drains Reference Designation Automatic drain connection Automatic drain connection of the dryer (only on Full-Feature units) The compressors have an electronic water drain (EWD). The condensate from the air cooler accumulates ina collector. When the condensate reaches a certain level, it is discharged through the automatic drain outlet(Da).
  • Page 25: Regulating System

    Instruction book 2.6 Regulating system Flow diagram Loading When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results: • The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank pressure(1) via the solenoid valve. •...
  • Page 26: Electrical System

    Instruction book Electrical system General Also consult sections Electrical diagrams Electrical connections. Electrical components The electrical system comprises following components: Electric cubicle Reference Designation Control circuit fuses (F3 is only provided in case a phase F1/2/3 sequence relay is provided) Overload relay fan motor F16/F17/F18 For fane fuses...
  • Page 27 Instruction book Reference Designation Transformer Terminal strip (voltage supply) For dryer connection X103/X108/X108A/ Connectors X117 Earth terminal 9096 3313 00...
  • Page 28: Electrical Diagrams

    Instruction book Electrical diagrams Service diagram for GA55+ up to GA 90 9096 3313 00...
  • Page 29 Instruction book Fan motor cubicle Watercooled Version Service diagram for the cooling fan of water cooled compressors, typical Reference Designation Emergency stop Overload, compressor motor, fan motor and Phase Sequence Relay (PSR) Remote start/stop Fault, EWD Remote pressure sensing Remote load/unload (closed = load) Pressure drop over DD filter Pressure drop over PD filter Remote pressure set selection...
  • Page 30 Instruction book Reference Sensors / solenoid valves / electronic water drain Electronic water drain (EWD) PDT01 Pressure sensor, pressure difference across oil separator PT20 Pressure sensor, air outlet TT01 Temperature sensor, ambient air TT11 Temperature sensor, element outlet TT51 Temperature sensor, cooling water inlet (water-cooled compressors) TT52 Temperature sensor, cooling water outlet (water-cooled compressors) Temperature sensor, energy recovery water inlet/outlet (compressors equipped with the...
  • Page 31 Instruction book Optional equipment Reference Designation Analog/Digital input expansion module Electronic water drain (EWD) (Full-Feature) DPT11/12 Dual pressure transmitters K04' Auxiliary relay, load/unload for ES100 Auxiliary contact, compressor running for ES100 Phase sequence relay PDS11 Delta p switch for integrated DD filter PDS12 Delta p switch for integrated PD filter R1, K34...
  • Page 32: Air Dryer

    Instruction book Air dryer Flow diagram Reference Name Air inlet Air outlet Air/air heat exchanger Air/refrigerant heat exchanger/evaporator Condensate separator Automatic drain / condensate outlet Refrigerant compressor Refrigerant condenser Liquid refrigerant dryer/filter Thermostatic expansion valve Hot gas by-pass valve Condenser cooling fan Pressure switch, fan control Compressed air circuit Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air.
  • Page 33 Instruction book Refrigerant circuit Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most ofthe refrigerant condenses. The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to thermostatic expansion valve (8). Therefrigerant leaves the thermostatic expansion valve at evaporating pressure. The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further evaporationat constant pressure.
  • Page 34: Elektronikon Graphic Controller

    Instruction book Elektronikon® Graphic controller 3.1 Elektronikon® Graphic regulator Control panel ® Display of the Elektronikon Graphic controller Introduction In general, the Elektronikon regulator has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service •...
  • Page 35 The regulator has a built-in function to automatically restart the compressor if the voltage is restored aftervoltage failure. For compressors leaving the factory, this function is made inactive. If desired, the functioncan be activated. Consult the Atlas Copco Customer Centre. If activated and provided the regulator was in the automatic operation mode, the compressor will automatically restart if the supply voltage to the module is restored.
  • Page 36: Control Panel

    Instruction book 3.2 Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Shows the compressor operating condition and a Display number of icons to navigate through the menu. Pictograph Automatic operation Pictograph General alarm General alarm LED Flashes if a shut-down warning condition exists.
  • Page 37: Icon Used

    Instruction book Icons used Status icons Name Icon Description Stopped / Running When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating. Compressor status Motor stopped Running unloaded Running loaded Machine control mode Local start / stop Remote start / stop Network control...
  • Page 38 Instruction book Input icons Icon Description Pressure temperature Digital input Special protection System icons Icon Description Compressor element (LP, HP, ...) Dryer Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm 9096 3313 00...
  • Page 39 Instruction book Menu icons Icon Description Inputs Outputs Alarms (Warnings, shutdowns) Counters Test Settings Service Saved data Access key / User password Network Setpoint Navigation arrows Icon Description Down 9096 3313 00...
  • Page 40: Main Screen Menu

    Instruction book Main screen menu Control panel Function The Main screen menu shows the status of the compressor operation and is the gateway to all functionsimplemented in the regulator. The Main screen is shown automatically when the voltage is switched on. The display indicates: Main screen •...
  • Page 41 Instruction book Text on figures Reference Description Compressor Outlet Element Outlet Menu To call-up more information, select the icon using the scroll keys (1) and press the enter key (2). • Status bar (C) • Action buttons (D). These buttons are used: •...
  • Page 42: Calling Up Menus

    Instruction book 3.5 Calling up menus Control panel Control panel Description When the voltage is switched on, the main screen is shown automatically. • Highlight the menu button using the scroll keys (1) • Press the enter key (2) to select the menu, following screen appears: 9096 3313 00...
  • Page 43: Inputs Menu

    Instruction book • The screen shows a number of icons. Each icon indicates a menu item. As a standard, the pressure settingsicon is selected. The status bar shows the name of the menu that corresponds with the selected icon. Usethe scroll keys (1) to jump from one icon to another. •...
  • Page 44 Instruction book Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the inputs icon (see above, section Menu icon) •...
  • Page 45: Outputs Menu

    Instruction book Outputs menu Control panel Menu icon, outputs Function To call up information regarding the actually measured data and the status of some inputs such as the motor overload protection. Function Starting from the Main screen (see Main screen): •...
  • Page 46 Instruction book Text on figure Configuration Pressure Settings Mainscreen • Move the cursor to the outputs icon (see above, section Menu icon, using the scroll keys (1) • Press the enter key (2), a screen similar to the one below appears: Analog &...
  • Page 47: Counters

    Instruction book Counters Control panel Menu icon, counters Function To call up: • The running hours • The loaded hours • The number of motor starts • The number of hours that the regulator has been under tension • The number of load cycles 9096 3313 00...
  • Page 48 Instruction book Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the counters icon (see above, section Menu icon) •...
  • Page 49: Settings Menu

    Instruction book Settings menu Control panel Menu icon, settings Function To modify a number of parameters. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Menu screen 9096 3313 00...
  • Page 50: Service Menu

    Instruction book Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the settings icon (see above, section Menu icon) • Press the enter key (2), a screen similar to the one below appears: Settings menu screen 3.10 Service menu...
  • Page 51 Instruction book Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the service icon (see above, section Menu icon) • Press the enter key (2), following screen appears: • Scroll through the items to select the desired item and press the enter key (2). 9096 3313 00...
  • Page 52 Instruction book Overview The overview screen shows all the running and Real Time hours Example for service level (A): The first row from shows the running hours when the first service is needed (light green), the value on theright side of the status bar is the remaining time left (dark green). The second row shows the Real Time hours Service plans A number of service operations are grouped (called Level A, Level B, etc...).
  • Page 53 Instruction book Use the scroll keys (1) to select the value to be modified. Press the enter key (2), following screen appears: Modify the value as required using the up or down scroll key (1). Running hours can be modified in steps of 100 hours, real time hours can be modified in steps of 1 hour. Next Service 9096 3313 00...
  • Page 54: Setpoint Menu

    Instruction book The first row shows that service was done at 6223 Running hours and Real Time hours 7976. The following rows show the running hours and real time for the next service Levels (A, B, C) which need to be done at 7000 Running hours History The history screen shows a list of all service actions done in the past, these actions are sorted by date.
  • Page 55 Instruction book Function If necessary, the operator can program two different setpoints. This menu is also used to select the activesetpoint. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings...
  • Page 56 Instruction book Unloading pressure 2 Loading pressure 2 Back Modify • The screen shows the actual unloading and loading pressure settings for both pressure bands. To modify settings, move the cursor to the action button Modify and press the enter key, following screen appears: •...
  • Page 57: Event History Menu

    Instruction book 3.12 Event history menu Control panel Menu icon, event history Function To call up the last shut-down and last emergency stop data. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings...
  • Page 58: Modifying General Settings

    Instruction book • Using the scroll keys (1), move the cursor to the event history icon (see above, section Menu icon) • The list of last shut-down and emergency stop cases are shown. • Scroll through the items to select the desired shut-down or emergency stop item. •...
  • Page 59 Instruction book Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the settings icon (see above, section menu icon). • Press the enter key (2). • Navigate to the settings icon (see above) using the scroll keys (1) and press the enter key (2), following screen appears: •...
  • Page 60: Info Menu

    3.14 Info menu Control panel Menu icon, info Function To show the Atlas Copco internet address. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears:...
  • Page 61: Week Timer Menu

    Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the info icon (see above, section Menu icon) • Press the enter key (2), the Atlas Copco internet address appears on the screen. 3.15 Week timer menu...
  • Page 62 Instruction book Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the timer icon (see above, section Menu icon) • Press the enter key (2), following screen appears: • The screen shows two items, week schemes and week cycle. Programming week schemes •...
  • Page 63 Instruction book • Select the week to be programmed and press the enter key, following screen appears: • Select the day to be programmed and press the enter key, following screen appears: • Select the action to be programmed and press the enter key, a pop-up screen shows all possible actions: 9096 3313 00...
  • Page 64 Instruction book • Use the scroll keys (1) to select the action to be programmed and press the enter key. • Select the corresponding time field for the action and press the enter key. Program the time using the up or down scroll key, use the right and left scroll keys to jump between hours and minutes. Programming the week cycle A week cycle is a sequence of 10 weeks.
  • Page 65: Test Menu

    Instruction book 3.16 Test menu Control panel Menu icon, test Function •To carry out a display test, i.e. to check whether the display and LEDs are still intact. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: 9096 3313 00...
  • Page 66: User Password Menu

    Instruction book Text on figure Configuration Pressure Settings Mainscreen • Using the scroll keys (1), move the cursor to the test icon (see above, section Menu icon) • Press the enter key (2), following screen appears: • The safety valve test can only be performed by authorized personnel and is protected by a security code.
  • Page 67: Programmable Settings

    Instruction book Function If the password option is activated, it is impossible for not authorized persons to modify any setting. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2), following screen appears: Text on figure Configuration Pressure Settings...
  • Page 68 Instruction book Minimum Factory Maximum setting setting setting Unloading pressure bar(e) Unloading pressure bar(e) Unloading pressure bar(e) 10.3 10.8 Unloading pressure bar(e) 12.5 Loading pressures Loading pressure (7.5 bar compressors) bar(e) Loading pressure (8 bar compressors) bar(e) Loading pressure (10 bar compressors) bar(e) Loading pressure (13 bar compressors) bar(e)
  • Page 69 The built-in service timers will give a Service warning message after their respective preprogrammed time interval has elapsed. Also see sectionPreventive maintenance schedule. Consult Atlas Copco if a timer setting has to be changed. The intervals must not exceed the nominal intervals and must coincide logically. See section Modifying general settings. Terminology...
  • Page 70 Instruction book Term Explanation Use only Atlas Copco oil separators. The recommended maximum pressure drop over the Oil separator oil separator element is 1 bar . Once the compressor has automatically stopped, it will remain stopped for the minimum Minimum stop stop time (approx.
  • Page 71: Osci (Optional)

    Instruction book OSCi (optional) 4.1 Introduction Compressed air produced by oil-injected compressors contains a small quantity of oil. During the cooling of the air in the aftercooler and in the refrigeration dryer (on compressors with built-in refrigeration dryer), oil- containing condensate is formed. The OSCi is a condensate treatment device, designed to separate the major part of this oil from the condensate and to sorb it in its replaceable filters, thus preventing contamination of the environment.
  • Page 72 Instruction book 4.2 Operation General Condensate flow scheme Condensate inlet Foam cover Oleophilic filter Service drains with valve Air injection connection OGC filter Activated carbon filter Condensate test outlet Condensate outlet The OSCi 3790 housing consists of 3 interconnected vessels. The oil-containing condensate is injected (1) indiscontinuous bursts at a downward angle into the first vessel which acts as expansion chamber.
  • Page 73 Instruction book A level switch (7 - View of OSCi), connected to the Elektronikon® regulator of the compressor monitors the condensate level in the second vessel. During normal operation this switch is in the closed position, so that any abnormality (a too high condensate level) opens the electric circuit and triggers the alarm, which is made visible on the Elektronikon®...
  • Page 74 Instruction book View of OSCi Clamping ring Foam cover Location of sample bottles and connection material (during shipping only) Service drains with valve Fixation bolts Wire and tube clamp Overflow switch Filter position sensor and visual indication of the filter position 9096 3313 00...
  • Page 75 Instruction book Detail views View of OSCi inlet Filter position sensor Condensate inlet connections View of OSCi outle 9096 3313 00...
  • Page 76 Instruction book Condensate outlet Condensate test outlet Condensate outlet connection of the OSCi Condensate sample valve Manual drain connections of the EWD's 9096 3313 00...
  • Page 77: Putting Into Operation (Commissioning)

    Instruction book 4.3 Putting into operation (commissioning) 1. Verify that the OSCi drain valves (4) are closed. 2. Unscrew the clamping ring (1) of the cover of the first vessel of the OSCi and take off the cover (2). 3. Take out the CDROM and the box (3) with the test bottle and the reference bottle and keep them in a safe place nearby the compressor.
  • Page 78: Pictographs

    Instruction book 5. Connect an outlet tube leading to the sewage system (19 mm inner diameter). Since the OSCi functions at atmospheric pressure, the outlet piping must always be positioned below the outlet connection on the OSCi vessel 3, unless a pump (able to run dry) is installed (not provided). 6.
  • Page 79: Data Displayed During Normal Opetation

    Instruction book 4.6 Data displayed during normal operation The normal starting display on the Elektronikon® Graphic will look like indicated on the following Picture.Press the enter arrow to reach the following display. Reference Description Reference Description Compressor outlet Unload Element outlet Menu Load Regulation...
  • Page 80: Warning

    Instruction book Reference Description OSCi overflow Warnings Service required This warning indicates that the remaining filter lifetime has dropped below 10%. In this case a service kit with new filters needs to be ordered. The “service” LED will light up at the right side of the Elektronikon® Graphic.
  • Page 81 Instruction book Reference Description Reference Description Protections Service Reset Level Once the filter has reached a lifetime below 10%, this warning will remain active until new filters are inserted correctly (sensor arm in tower 1 should rest on the filter edge!). When the new filters are installed correctly and the percentage is above 10% (normally between 90% and 100%), press enter to reset the status.
  • Page 82: Maintenance

    Instruction book In this display you can see that an overflow warning is issued (blinking “Yes”), indicating that the water level in the OSCi is too high. By fixing the problem (see section Problem solving, fault 2 or 3), this warning will disappear automatically.
  • Page 83 Instruction book 3. Compare the turbidity of the sample with the reference 15 ppm turbidity bottle. 4. If the turbidity of the test sample is more intense than the reference turbidity, a request for servicing should be initiated, to be carried out within 2 weeks time. The vertical position of the test outlet ensures that there is enough clean activated carbon left above this position to keep the condensate under 15 ppm for at least 2 weeks (valid for a GA 90 with dryer which runs 24 h/day at reference conditions).
  • Page 84 Instruction book 11. Pour clean water along the inner edge of vessel 1 until water flows out of the outlet tube (1-View of OSCi outlet), or until the water reaches the bottom of the sensor chamber (visible through the sight- glass).
  • Page 85: Services Kits

    Instruction book Service kits Your Atlas Copco Customer Centre 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.
  • Page 86 Instruction book Condition Fault Remedy Water is present on the floor A connection is leaking. A Stop the compressor. Open the side around the compressor (and on push-in coupling is leaking. panel and inspect the OSCi (remove the compressor frame). the covers from the vessels).
  • Page 87 Instruction book Condition Fault Remedy No enough airflow during Disconnect the strainer (4-View of OSCi the test. inlet) and take out the strainer. Clean the strainer and the nozzle with compressed air and dry tissue. Check that the air tube does not touch any other components and is not hindered in any way.
  • Page 88: Energy Recovery (Optional)

    The Atlas Copco energy recovery (ER) systems are designed to recover most of the above-mentioned heat by transforming it into warm or hot water without any adverse influence on the compressor performance.
  • Page 89: Energy Recovery Systems

    Location of oil cooler bypass valve (BV1) Field installation The main components are assembled ex-factory as a compact unit which fits inside the bodywork of the compressor. Consult Atlas Copco for installing and connecting the energy recovery unit. Energy recovery systems General The energy recovery systems can be applied as low temperature rise/high water flow systems or as high temperature rise/low water flow systems.
  • Page 90: Operation

    To minimize these problems, the water should meet anumber of requirements. See section Cooling water requirements. If in any doubt, consult Atlas Copco. Operation General The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable compressor operation and optimum energy recovery.
  • Page 91 Instruction book Reference Designation Thermostatic bypass valve of ER unit Oil/water heat exchanger (ER unit) Compressor element Oil cooler (compressor) Water inlet BV2 starts closing the bypass line and opening the oil supply line from the ER heat exchanger (HE) at the lower limit of its temperature range.
  • Page 92 Instruction book Attention: It is only allowed to turn the handle completely in or out. No in-between position is allowed! The oil cooler bypass valve (BV1) starts closing the bypass line and opening the oil supply line from the main oil cooler (Co) at the lower limit of its temperature range.
  • Page 93: Maintenance

    To clean the oil side, soak the heat exchanger in a degreasing solution. To remove scale formation in the water compartment, a proper descaling process should be applied. Consult Atlas Copco. 9096 3313 00...
  • Page 94: Energy Recovery Data

    Instruction book Energy recovery data Reference conditions See section Reference conditions and limitations. Effective working pressure Consult section Compressor data for the normal working pressure. Maximum allowed pressure of the heat exchanger Oil side 15 bar Water side 10 bar Reading settings In addition to other data, the following temperatures can be read on the Elektronikon display: For air-cooled units:...
  • Page 95 Instruction book Data for low temperature rise/high water flow systems Parameter Unit GA55 GA75 GA90 Recoverable energy 48.4 66.0 79.2 Water flow l/min 69.3 94.5 113.4 Temperature at inlet °C Temperature at outlet °C Data for high temperature rise/low water flow systems Parameter Unit GA55...
  • Page 96: Installation

    Instruction book Installation Dimension drawings Centre of gravity 9096 3313 00...
  • Page 97 Instruction book Unit with dryer with dryer with dryer without without without dryer dryer dryer Type 1150 1145 Dimensions in mm: +/- 50 mm (1.97 in) Weight Type Unit Weight, unit with dryer Weight, unit without dryer GA55 1580 1430 GA75 1680 1530...
  • Page 98: Installation Proposal

    Instruction book 6.2 Installation proposal Compressor room example 9096 3313 00...
  • Page 99 Instruction book Minimum free area to be reserved for the compressor installation Ventilation proposals (on air-cooled compressors) Cooling systems (on water-cooled compressors) Description Install the compressor unit on a solid, level floor suitable for taking the weight. Position of the compressed air outlet valve. The maximum total pipe length (including interconnecting piping between compressor and receiver) can be calculated as follows: 1.
  • Page 100: Electrical Connections

    Instruction book By-pass system to by-pass the dryer during service operations (available as an option, consult Atlas Copco). On water-cooled compressors: Water flow and pressure to be adjusted depending upon local conditions. For cooling water quality see section Cooling water requirements.
  • Page 101 Instruction book Electrical connections for GA 9820 3138 12-00 Reference Designation Customer's installation 415V,K21, K23 with 3 fuses type 1 Star connection 415 V 9096 3313 00...
  • Page 102: Cooling Water Requirements

    Instruction book Reference Designation Delta connection: 200/220/230 V - 50/60 Hz Instructions 1. Provide an isolating switch. 2. Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals. 3. Check the fuses and the setting of the overload relay. See section Settings of overload relay and fuses.
  • Page 103 Instruction book • B : depends on the highest cooling water temperature (°C),For GA/GR units take T = 75 °C • C : depends on the calcium hardness (ppm CaCO3) • D : depends on the HCO3- concentration or M-alkalinity (mval/l) •...
  • Page 104 Instruction book Tendency of the water Action Regular control necessary, use of 7.6 < RSI < 9.0 Strong corrosion corrosion inhibitor recommended Regular control necessary, use of 9.1 <RS I<11 Very strong corrosion corrosion inhibitor required Very strong corrosion in the RSI >...
  • Page 105: Pictographs

    Instruction book 14. Additives If it should be necessary to use additives in the cooling water, take into account that the cooling capacity will change. Remarks: • Chloride and sulphate are interactive. In pass-through systems the sum of the squares must not exceed 85000.
  • Page 106 Instruction book Reference Designation Torques for steel (Fe) or brass (CuZn) bolts Lightly oil gasket of oil filter, screw it on and tighten by hand (approx. half a turn) Warning: stop the compressor before repairing fans Warning: switch off the voltage before removing protecting cover inside electric cubicle Consult the instruction book before carrying out maintenance Cooling water outlet Cooling water inlet...
  • Page 107: Operating Instructions

    Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below 0 °C , precautions must be taken. In this case, and also if operating above 1000 m , consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Take care not to damage the bodywork during lifting or transport.
  • Page 108: Initial Start-Up

    This results in loading and unloading of the compressor at the closing and opening pressures of the external pressure switch respectively. See section Electrical system to locate the connectors. • LAN control: The compressor is controlled via a local network. Consult Atlas Copco. 7.2 Initial start-up Safety The operator must apply all relevant Safety precautions. Procedure...
  • Page 109 Instruction book 9096 3313 00...
  • Page 110 Instruction book Electric cubicle, GA 55+ upto GA90 Consult the sections Electric cable size, Installation proposal Dimension drawings The following transport fixtures, painted red, must be removed: • Bolts (1) • Bushes (2) • Supports (3) Check that the electrical connections correspond to the applicable codes and that all wires are clamped tight to their terminals.
  • Page 111: Before Starting

    Instruction book Check the oil level. See section Oil and oil filter change. Provide labels, warning the operator that: • The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco). • The compressor is automatically controlled and may be restarted automatically. On water-cooled compressors, close the cooling water drain valves.
  • Page 112: Starting

    Instruction book Procedure See section Initial start-up for location of the oil system components. Check oil level (Gl), top up if necessary. The pointer should be in the upper field of the green range or in the orange range. If the pointer registers in the LOW range, depressurize the oil system (see section Problem solving).
  • Page 113 C above the relevant temperature in the figure below. For optimum operation, the cooling water outlet temperature must never exceed the valve specified in section Compressor data. Consult Atlas Copco if condensate should form during frequent unloading periods. 9096 3313 00...
  • Page 114: During Operation

    Instruction book • (A): Air inlet temperature • (B): Condensation temperature • (C): Working pressure • (D): Relative air humidity 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 .
  • Page 115 Instruction book Position of the oil level gauge Regularly check the oil level during loaded operation. The pointer of level gauge (Gl) must register in the green range. If the oil level is too low, press stop button (9). Wait until the compressor has stopped and depressurised and push the emergency stop button (10) to avoid the compressor to start unexpectedly.
  • Page 116: Checking The Display

    Instruction book Air filter Position of the service indicator Regularly check the service indicator. If the coloured part of service indicator (VI) shows full out, replace the air filter element. Reset the service indicator by pushing the knob in the extremity of the indicator body. Drains Regularly check that condensate is discharged during operation.
  • Page 117: Stopping

    Instruction book 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, see section Service menu.
  • Page 118 Instruction book Procedure Step Action Stop the compressor and close the air outlet valve. Press the test button on top of the electronic water drain(s) until the air system between air receiver and outlet valve is fully depressurized. Consult section Condensate system locate the drain valve.
  • Page 119: Maintenance

    For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits). Service contracts Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work. Consult your Atlas Copco Customer Centre. General When servicing, replace all removed gaskets, O-rings and washers.
  • Page 120 Instruction book Intervals The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor. The longer interval checks must also include the shorter interval checks. Service plans for compressors with an Elektronikon® Graphic controller Besides the daily and 3-monthly checks, preventive service operations are specified in the schedule below.
  • Page 121: Drive Motor

    On water cooled units: Check for possible water leakage. 8000 (2) If Atlas Copco Roto-Xtend Duty Fluid is used, change oil and oil filter have the oil separator element replaced. The oil separator element must be replaced when the pressure drop over it exceeds 1 bar.
  • Page 122: Oil Specifications

    It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of field experience and research in our labs. See section Preventive maintenance schedule for replacement intervals and section Service Kits for part number information.
  • Page 123 Instruction book Procedure Oil system components Oil drain plugs 9096 3313 00...
  • Page 124: Disposal Of Used Material

    Run the compressor, e.g. twice a week, until warm. Load and unload the compressor a few times. If the compressor is going to be stored without running from time to time, protective measures must be taken. Consult Atlas Copco. 9096 3313 00...
  • Page 125: Service Kits

    Service kits For overhauling and for preventive maintenance, a wide range of service kits is available. Service kits comprise all parts required for servicing the component and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low.
  • Page 126: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filter Location of air filter Air filter Service indicator Recommendations 1. Never remove the element while the compressor is running. 2. For minimum downtime, replace the dirty element by a new one. 3. Discard the element when damaged. 9096 3313 00...
  • Page 127: Coolers

    Then clean with an air jet in the reverse direction to normal flow. Use low pressure air; if necessary the pressure may be increased up to 6 bar(e) . • If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco. • Remove the cover used during cleaning.
  • Page 128: Safety Valves

    Instruction book Safety valves Location of safety valve Operating Operate the safety valve by unscrewing the cap one or two turns and retighten it. Testing Before removing the valve, depressurise the compressor. See section Problem solving. Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure stamped on the valve, it needs to be replaced.
  • Page 129: Problem Solving

    Instruction book Problem solving 10.1 Problem solving Warning Before carrying out any maintenance, repair work or adjustment, press the stop button, wait until the compressor has stopped (approx. 30 seconds) and close the air outlet valve. Press the test button on top of the electronic water drain unit the air system between the air receiver and outlet valve is fully depressurized.
  • Page 130 Have valve checked malfunctioning Minimum Have valve checked pressure valve malfunctioning S afety valve out of order Have valve replaced Compressor element out Consult Atlas Copco of order Oil separator element Have element replaced clogged Condition Fault Remedy Compressor element outlet...
  • Page 131 Instruction book Condition Fault Remedy Air cooler clogged Clean cooler Compressor element Consult Atlas Copco out of order Customer Centre 9096 3313 00...
  • Page 132: Technical Data

    Instruction book Technical data 11.1 Readings on display Display of the Elektronikon® Important The readings mentioned below are valid under the reference conditions (see section Reference conditions and limitations). Reference Reading Air outlet pressure Modulates between programmed unloading and loading pressures. Compressor element For air-cooled units: approx.
  • Page 133: Electric Cable Size And Main Fuses

    Instruction book 11.2 Electric cable size and main fuses Important • The voltage on the compressor terminals must not deviate more than 10% of the nominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1).
  • Page 134: Settings Of Fan Motor Circuit Breaker

    Instruction book Recommended cable size GA 55+ GA 55+ W orkpla ce Full- W orkpla ce Fe a ture Frequenc y Hz V oltage (V ) Cable s iz e Cable s iz e 4 x 70 4 x 70 GA 75+ GA 75+ W orkpla ce W orkpla ce...
  • Page 135: Dryer Switches

    Instruction book Maximum allowed fuse ratings 11.5 Dryer switches General The regulating and safety devices are factory-adjusted to give optimum performance of the dryer. Do not alter the setting of any of the devices. 11.6 Reference conditions and limitations Reference conditions Air inlet pressure (absolute) Air inlet temperature °C...
  • Page 136: Compressor Data

    Instruction book On water-cooled units also: Maximum cooling water outlet °C temperature Maximum cooling water inlet bar(e) pressure 11.7 Compressor data Reference conditions All data specified below apply under reference conditions, see section Reference conditions and limitations. GA55 Units 7.5 bar 8 bar 1 0 b a r Frequency...
  • Page 137 Instruction book Units 7.5 bar 8 bar 1 0 b ar Temperature of air leaving outlet valve °C (approx.), Full- Feature units Pressure dew point, Full-Feature °C units D2rive motor, 1LG6 22 8- 2 1 LG 6 22 8- 2 1 LG 6 22 8-2 SIEMENS Motor shaft speed...
  • Page 138 Instruction book Urnits 7 .5 b ar 7 .5 b ar 7 . 5 b a r l/min Cooling water consum ption (at water inlet temperature between 35 and 40 °C and temperatur rise of 10 °C),water-cooled units Oil capactiry, air-cooled units Oil capacity, water-cooled units...
  • Page 139 Instruction book Units 7.5 bar 8 bar 1 0 bar 13 bar Power consumption dryer at full load, Full-Feature units Power consumption dryer at no load, Full-Feature units Power consumption dryer at no load, Full-Feature units R404a R404a R404a R404a Refrigerant type, Full-Feature units Refrigerant type,...
  • Page 140 Instruction book (1): from approx. April 30, 2009 onwards GA 90 Units 7.5 bar 8 bar 1 0 bar 13 bar Frequency bar(e) Maximum (unloading) pressure, units without dryer bar(e) 7.25 7.75 9.75 12.75 Maximum (unloading) pressure, Full- Feature units Reference working bar(e) 12.5...
  • Page 141: Technical Data Elektronikon Controller

    Instruction book Units 7. 5 bar 8 bar 10 bar 13 bar Refrigerant type, Full- R4 04 a R40 4a R 404 a R40 4a Feature units R410A R4 10 A R 41 0A R4 10 A Refrigerant type, Full- Feature units (1) Refrigerant quantity, 2.55...
  • Page 142 Instruction book Digital outputs Parameter Value Number of outputs 9 (Elektronikon® Graphic controller-p.n. 1900 5200 10..1900 5200 19) Type Relay (voltage free contacts) Rated voltage AC 250 V AC /10 A max. Rated voltage DC 30 V DC /10 A max. Digital inputs Parameter Value...
  • Page 143: Instruction For Use Of Air Receiver

    Instruction book Instructions for use of air receiver 12.1 Instructions for use Instructions This vessel can contain pressurised air; this can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator and must be operated within the limits specified on the data plate.
  • Page 144: Guideline For Instruction

    Instruction book Guidelines for inspection 13.1 Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.
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  • Page 150 In order to be First in Mind-First in Choice ® for all your quality compressed air needs, Atlas Copco delivers the products and services that help to increase your business’ efficiency and profitability. Atlas Copco's pursuit of innovation never ceases, driven by our need for reliability and effeciency.

This manual is also suitable for:

Ga75+Ga90