Atlas Copco GA 90 Instruction Book
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Atlas Copco GA 90 Instruction Book

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GA 90, GA 110, GA 132, GA 160, GA 200, GA 250, GA 315

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  • Page 1 GA 90, GA 110, GA 132, GA 160, GA 200, GA 250, GA 315...
  • Page 3 Atlas Copco GA 90, GA 110, GA 132, GA 160, GA 200, GA 250, GA 315 Instruction book Original instructions 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 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................5 ...........................5 AFETY ICONS ......................5 AFETY PRECAUTIONS GENERAL ...................5 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................10 ..........................10 NTRODUCTION .........................14 IR AND OIL SYSTEM ....................17 OOLING AND CONDENSATE SYSTEM ........................19...
  • Page 5 Instruction book 3.15 ......................39 ODIFYING PROTECTION SETTINGS 3.16 ........................40 ODIFYING SERVICE PLANS 3.17 ......................41 ROGRAMMING CLOCK FUNCTION 3.18 ....................45 ODIFYING CONFIGURATION SETTINGS 3.19 ..........................47 ERVICE MENU 3.20 ...........................49 AVED DATA MENU 3.21 GA90 GA500................49 ROGRAMMABLE SETTINGS FOR UP TO Installation........................54 ........................54 IMENSION DRAWING ........................61...
  • Page 6 Instruction book ............................93 IL CHANGE ..........................98 IL FILTER CHANGE ......................101 TORAGE AFTER INSTALLATION ..........................101 ERVICE KITS Adjustments and servicing procedures..............103 ..........................103 IR FILTERS .............................105 OOLERS ..........................106 AFETY VALVE Problem solving......................108 .........................108 ROBLEM SOLVING Technical data......................111 ........................111 EADINGS ON DISPLAY .........................112 EFERENCE CONDITIONS ............................112 IMITS...

  • Page 7: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions, general General precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
  • Page 8 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 9: Safety Precautions During Operation

    Instruction book 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 10: Safety Precautions During Maintenance Or Repair

    Instruction book Safety precautions during maintenance or repair 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 • Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid.

  • Page 12: General Description

    Instruction book General description Introduction General General view of GA90 up to GA160 2920 1475 06...
  • Page 13 Instruction book General view of GA90W up to GA160 W General view of GA200, GA250 and GA315 60 Hz 2920 1475 06...
  • Page 14 Elektronikon regulator. Energy recovery The compressor is provided with an Atlas Copco energy recovery system to recover the major part of the compression heat in the form of hot water without any influence on the compressor performance.
  • Page 15 This compressor can be equipped with: ISO connections for GA 90 up to GA 160, GA 315 50 Hz, GA 355 up to GA 500 and GR 110 up to GR200. NPT connections for GA 90 up to GA 160 and GR 110 up to GR200.

  • Page 16: Air And Oil System

    Instruction book Air and oil system Flow diagrams Flow diagram of GA90 up to GA160 2920 1475 06...
  • Page 17 Instruction book Flow diagram of GA200, GA250 and GA315 60 Hz 2920 1475 06...
  • Page 18 Instruction book Flow diagram of air dryer on GA Full-Feature compressors Air flow Air drawn through filters (AF) and unloaders (UA) is compressed in compressor elements (E). Compressed air and oil are discharged through check valves (CV) to air receiver/oil separators (AR) where oil is separated from the compressed air.

  • Page 19: Cooling And Condensate System

    In air receivers (AR) most of the oil is removed from the air centrifugally. Almost all of the remaining oil is removed by the separator elements. Cooling and condensate system Condensate drain system Condensate drains of GA 90 up to GA 160 2920 1475 06...
  • Page 20 Instruction book Condensate drains of GA 200, GA 250 and GA 315 60 Hz Automatic condensate drain, compressor Automatic condensate drain, dryer (Full-Feature compressors only) Automatic condensate drain, DD filter (option) Automatic condensate drain, OSD (option) Manual condensate drain Manual condensate drain, dryer (Full-Feature compressors only) Condensate traps are installed downstream of the air coolers to prevent condensate from entering the air outlet pipe.

  • Page 21: Regulating System

    Instruction book Regulating system Flow diagrams Flow diagram of GA 90 up to GA 160 2920 1475 06...
  • Page 22 Instruction book Flow diagram of GA 200 (W), GA 250 (W) and GA 315 (W) 60 Hz Reference Designation To air cooler To/from oil cooler Regulating system The compressor is controlled by Elektronikon® regulator The regulator keeps the net pressure within programmable pressure limits by automatically loading and unloading the compressor depending on the air consumption.
  • Page 23 (unloading pressure), solenoid valve (5) is de- energised. The plunger of the valve moves downwards by spring force: Description for GA 90 up to GA 250 and GA 315 60 Hz Phase...

  • Page 24: Elektronikon Regulator

    Instruction book Elektronikon regulator ® Elektronikon regulator Control panel Introduction In general, the Elektronikon regulator has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) •...
  • Page 25 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 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 within a programmed time period.

  • Page 26: Control Panel

    Instruction book Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Start button Button to start the compressor. LED (8) lights up indicating that the Elektronikon regulator is operative. Display Shows messages about the compressor operating condition, a service need or a fault. Scroll keys Keys to scroll upwards or downwards through the display.

  • Page 27: Function Keys

    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 “Load” To load the compressor manually “Mainscreen”...

  • Page 28: Scroll Keys

    Instruction book Scroll keys Control panel The keys (1) allow the operator to scroll through the display. As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll key with the same symbol can be used to see the next item. As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key with the same symbol can be used to see the previous item.

  • Page 29: Control Programs

    Instruction book 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 the manual condensate drain valves to depressurize the air system.
  • Page 30 Instruction book Menu flow for GA 90 up to GA 315 (simplified example) 2920 1475 06...
  • Page 31 Instruction book Menu flow for GA 90 W up to GA 315 W (simplified example) Program Function Main screen Shows in brief the operational status of the compressor. Is the gateway to all functions. “Status Data” Calls up the status of the compressor protection functions (shut-down, shut-down warning and service warning).

  • Page 32: Calling Up Menus

    Loads and unloads the compressor manually. Calling up menus Description Control panel When the voltage is switched on, the Main screen is shown automatically. Example of Main screen of GA 90 up to GA 500 “Compressor Outlet” 7.5 bar “Automatically Loaded” “Menu”...

  • Page 33: Main Screen Menu

    If the function or arrow keys (1, 2 and 3) are not used for some minutes, the regulator will automatically return to the Main screen. Whenever displayed on a submenu screen, press the “Mainscreen” (F1) key to return to the Main screen. Example of Main screen of GA 90 up to GA 500 “Compressor Outlet” 7.5 bar “Automatically Loaded”...

  • Page 34: Status Data Menu

    Instruction book • Messages regarding the compressor operating condition • Just above the function keys (3), the actual functions of these keys Status data menu Warning Before starting any maintenance or repairs, press the stop button (4), wait until the compressor has stopped, press the red emergency stop button and open the isolating switch (customer's installation) to switch off the voltage to the compressor.
  • Page 35 Instruction book “All Conditions Are OK” “Menu” “Help” A shut-down message exists • In case the compressor is shut down, LED (1) will blink. • In case of a shut-down due to too high a temperature at the outlet of the compressor element: “Element Outlet”...
  • Page 36 “Status Data” menu to “Inputs” and press the “Reset” key to reset the service message. • In case the service message was referring to “Plan”: carry out the service actions related to the indicated plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See Service menu.

  • Page 37: Measured Data Menu

    Instruction book 3.10 Measured data menu Control panel Function To call up information regarding the actually measured data and the status of some inputs such as the motor overload protection. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): •...

  • Page 38: Counters Menu

    Instruction book 3.11 Counters menu Control panel Function To call up: • The running hours • The loaded hours • The number of motor starts • The number of hours the regulator (module) has been under tension • The number of load cycles Procedure Starting from the Main screen (see Main screen...

  • Page 39: Test Menu

    Instruction book 3.12 Test menu Control panel 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 menu), press the “Menu” (F1) key. •...

  • Page 40: Modifying Parameters

    Instruction book 3.14 Modifying parameters Control panel Function To modify a number of parameters. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Modify Parameters” is followed by a horizontal arrow. •...

  • Page 41: Modifying Protection Settings

    Instruction book 3.15 Modifying protection settings Control panel Function To modify protection settings: • “Shutdown”, e.g. for the compressor element outlet temperature • “Shutdown warning”, e.g. for the compressor element outlet temperature • “Warning”, e.g. for the dew-point temperature • “Service warning”, e.g. for the maximum pressure drop over the air filter To check various compressor conditions, e.g.

  • Page 42: Modifying Service Plans

    Service plans are to be carried out. Always consult your Atlas Copco Customer Centre in case any timer should be changed. The intervals must not exceed the programmed nominal values.

  • Page 43: Programming Clock Function

    Instruction book 3.17 Programming clock function Control panel Function To program: • Time-based start/stop commands for the compressor • Time-based change-over commands for the net pressure band Programming start, stop and pressure band commands In this example, the compressor will be programmed as follows: •...
  • Page 44 Instruction book “Monday” “Tuesday” “Wednesday” “Menu” “Delete” • Use the scroll keys (1) until the day on which a command must be programmed is followed by a horizontal arrow. Press the tabulator key (2); following screen appears: --:-- ---------------------- --:-- ---------------------- --:-- ----------------------...
  • Page 45 Instruction book “Clock Function” “Not Activated” “Menu” “Modify” “Delete” • Press the key “Modify”, “Not Activated” starts blinking. • Press the arrow down key (1) “Not Activated” changes to “Activated”. • Press the key “Program”. It is necessary to program the start/stop commands in successive order timewise. Program the commands from Monday till Sunday, e.g.: •...
  • Page 46 Instruction book arrow. Press the key “Modify”, the first two digits of the command start blinking. Modify as required using the scroll keys, i.e. in the example above change “18” into “17” using the arrow up key (1). • If necessary, press the tabulator key (2) to go to the next field to be modified, the minutes indication and the start/stop/pressure band indication.

  • Page 47: Modifying Configuration Settings

    Instruction book Press the arrow down key and add the last command of the list (in the example above “18:00 Stop Compressor” and press the key “Program”. Deleting a command • Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the option “Modify Parameters”...
  • Page 48 Instruction book Function To modify a number of parameters. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to the right. •...

  • Page 49: Service Menu

    Instruction book 3.19 Service menu Control panel Function • To reset the service plans which are carried out. • To check when the next service plans are to be carried out. • To find out which service plans were carried out previously. Service plans A number of service operations are grouped (called Level A, Level B, etc...).
  • Page 50 Instruction book Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Service” is followed by a horizontal arrow. • Activate the menu by pressing tabulator key (2). •...

  • Page 51: Saved Data Menu

    Instruction book 3.20 Saved data menu Control panel Function To call up some data saved by the regulator. These data are: • Last shut-down data • Last emergency stop data Procedure Starting from the Main screen (see Main screen menu): •...
  • Page 52 Instruction book Minimum Factory Maximum setting setting setting Motor running time in star Load delay time (star-delta) Load delay time (no star-delta) Number of motor starts (star-delta) starts/day Number of motor starts (no star-delta) starts/day Minimum stop time (for compressors with a maximum working pressure lower than 13 bar (188 psi) Minimum stop time (for compressors with a...
  • Page 53 Instruction book Minimum Factory Maximum setting setting setting Loading pressure, 8.6 bar compressor bar(e) 9.105 Loading pressure, 125 psi compressor psig 65.3 91.4 132.1 Loading pressure, 10.4 bar compressor bar(e) 10.805 Loading pressure, 150 psi compressor psig 65.3 140.7 156.7 Loading pressure, 13.8 bar compressor bar(e) 12.7...
  • Page 54 Instruction book Minimum Factory Maximum setting setting setting Compressor element outlet temperature ˚F (shut-down warning level) (without energy recovery) Compressor element outlet temperature ˚C (shut-down level) (without energy recovery) Compressor element outlet temperature ˚F (shut-down level)(without energy recovery) Compressor element outlet temperature ˚C (shut-down warning level) (with energy recovery)
  • Page 55 Is the time for which the signal must exist before the compressor is shut down. If it is down signal required to program this setting to another value, consult Atlas Copco. Permissive start The compressor will not start if this level is exceeded at the moment of starting. If the level level remains too high for 30 seconds, the message “Start failure”...

  • Page 56: Installation

    Instruction book Installation Dimension drawing Compressor dimensions Dimension drawing of GA90/110 air-cooled 2920 1475 06...
  • Page 57 Instruction book Dimension drawing of GA90/110 water-cooled 2920 1475 06...
  • Page 58 Instruction book Dimension drawing of GA132/160 and GR110 up to GR200, air-cooled 2920 1475 06...
  • Page 59 Instruction book Dimension drawing of GA132/160 and GR110 up to GR200, water-cooled 2920 1475 06...
  • Page 60 Instruction book Dimension drawing of GA200/250 and GA315 60 Hz, air-cooled 2920 1475 06...
  • Page 61 Instruction book Dimension drawing of GA200/250 and GA315 60 Hz, water-cooled Text on drawing Reference Designation Compressed air outlet Cooling air outlet Air inlet Cooling air inlet Water in 2920 1475 06...
  • Page 62 Instruction book Reference Designation Water out Voltage supply entrance Centre of gravity With door fully open (10) Manual drain (11) Automatic drain (18) Centre of gravity (with energy recovery) (19) Energy recovery, water in (20) Energy recovery, water out (21) Automatic drain, only for units with OSD (22) Only for energy recovery...

  • Page 63: Installation Proposal

    Instruction book Installation proposal Compressor room example Compressor room example of GA 90 up to GA 160 air-cooled 2920 1475 06...
  • Page 64 Instruction book Compressor room example of GA 90 up to GA 160 water-cooled 2920 1475 06...
  • Page 65 Instruction book Compressor room example of GA 200, GA 250 and GA 315 60 Hz air-cooled 2920 1475 06...
  • Page 66 Instruction book Compressor room example of GA 200, GA 250 and GA 315 60 Hz water-cooled Text on drawing Reference Designation Minimum free area Ventilation proposals Cooling systems 2920 1475 06...
  • Page 67 Instruction book Description Phase Description Install the compressor on a level floor suitable for taking its weight. For ventilation alternative 1 (indicated as Alt. 1), the minimum distance between the top of the bodywork and the ceiling is 1200 mm (47 in). Remove the plastic plug (if provided) from the compressor air outlet pipe and fit the air outlet valve (to be provided by the customer) to the pipe.
  • Page 68 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. A water shut-off valve and water drain valve in the compressor water inlet pipe and outlet pipe can be installed by the customer.

  • Page 69: Electric Cable Size

    Electric cable size Electrical connections Electrical connections of GR 110 up to GR 200, GA 90 up to GA 250 and GA 315 60 Hz compressors Cable size GA 90 up to GA 250 50 Hz and GR 50 Hz compressors...
  • Page 70 2x (3x240 mm +120 mm GA 250 500 V 2x (3x150 mm +70 mm GA 90 up to GA 315 60 Hz and GR 60 Hz IEC compressors Compressor Supply voltage Cable size GA 90 220 - 230 V 2x (3x150 mm...

  • Page 71: Pictographs

    Instruction book Compressor Supply voltage Cable size GA 200 575 V 2x (3xMCM300+AWG2) GA 250 440 - 460V 4x (3xAWG3/0+AWG3) GA 250 575 V 2x (3xMCM350+AWG0) GA 315 440 - 460V 4x (3xAWG4/0+AWG3) GA 315 575 V 4x (3xAWG2/0+AWG4) Pictographs Control panel Pictographs of control panel Reference...

  • Page 72: Cooling Water Requirements

    Instruction book Other locations Reference Description Automatic condensate drain Automatic condensate drain for optional oil/water separator (type OSD) Manual condensate drain Stop the compressor before maintenance or repair 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...
  • Page 73 Instruction book This recommendation is a general guide line for acceptable coolant quality. Type of system First, it is important to consider whether you are dealing with a closed system or an open system. In a closed system, the same cooling water circulates through a system without contact with air. An open system is a pass-through system, or a circulating system with a cooling tower.
  • Page 74 Instruction book Total dissolved Temperature Ca-hardness (ppm M-alkalinity (mval/l) D solids (mg/l) (˚C) CaCO 28 - 31 44 - 55 0.90 - 1.10 32 - 37 56 - 69 1.12 - 1.38 38 - 44 70 - 87 1.40 - 1.76 45 - 50 88 - 110 1.78 - 2.20...
  • Page 75 Instruction book Total dissolved solids (TDS) This is the sum of all the ions in the water. It can be derived from the dry residue after evaporation (but not including suspended solids), or it can be estimated from the electrical conductivity. In a closed system, the following limits apply : TDS <...
  • Page 76 Instruction book Suspended solids Non-soluble particles, size < 1 mm. < 10 ppm 2920 1475 06...

  • Page 77: Operating Instructions

    Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below freezing point, precautions must be taken. In this case, and also if operating at high altitude, consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude from the other side of the frame.
  • Page 78 General preparations Plugs to fill compressor elements of GA 90 up to GA 160 and GR 110 up to GR 200 at initial start-up Plugs to fill compressor elements of GA 200, GA 250 and GA3 15 60 Hz at initial start-up...
  • Page 79 Check that the compressor is filled with oil; the pointer of the oil level indicator should be in the green range (see the section Oil change). Protection during transport Transport fixtures for GA 90 up to GA 160 2920 1475 06...
  • Page 80 Instruction book Transport fixtures for GA 200, GA 250 and GA 315 60 Hz Step Action The gear casing supports, motor support and air receiver supports are secured to the frame, immobilising the vibration dampers during transport. Remove the bushes (1) from the gear casing supports and the motor support. Remove the brackets fitted next to the air receiver supports.
  • Page 81 Instruction book Electric cabinet Example of a cubicle with starter Example of a cubicle without starter 2920 1475 06...
  • Page 82 Instruction book Step Action Check that the electrical connections correspond to the local codes.The installation must be earthed and protected by fuses in all phases. An isolating switch must be fitted. Check the wires on transformers (T1/T2) for correct connection. Check the setting of the circuit breakers (see the section Settings of circuit breakers).

  • Page 83: Before Starting

    Instruction book Oil separating device Step Action Remove the cover and fill vessel (1) with water to the level of water outlet (2). Refit the cover. Start up Step Action Close the drain valves (see the section Cooling and condensate system).

  • Page 84: Starting

    Instruction book Control panel Step Action Switch on the voltage. Voltage on LED (6) lights up. Close the condensate drain valves (see the section Cooling and condensate system). Open the air outlet valve. Check the oil level indicator (see the section change).
  • Page 85 Instruction book Control panel Control panel of MkIV regulator Step Action Press start button (1). The compressor starts running in unloaded condition. Automatic operation LED (8) lights up. Approx. 10 seconds later (programmable), the compressor starts running loaded. The message on display (2) changes from “Automatically unloaded” to “Automatically loaded”. On water-cooled compressors, regulate the cooling water flow with the compressor running loaded.

  • Page 86: During Operation

    Instruction book Reference Name Air inlet temperature in ˚C Condensation temperature in ˚C Effective working pressure in bar Relative air humidity in % During operation Warning The operator must apply all relevant Safety precautions. The operator should immediately stop the machine in case of oil leaks internally in the machine as wel as externally and consult a competent technician to resolve the cause.

  • Page 87: Checking The Display

    Instruction book If the compressor is stopped, it may start automatically. Checking the display Warning Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the emergency stop button and switch off the voltage. Close the air outlet valve and open the manual condensate drain valve.

  • Page 88: Manual Loading/Unloading

    Instruction book Example of the main menu “Status data” “Measured Data” “Counters” “Mainscreen” Example of the main display Main display of GA compressors “Compressor outlet” 7.5 bar “Automatically loaded” “Menu” “Unload” Manual loading/unloading Control panel Control panel of Elektronikon MkIV regulator Example of the main display Main display of GA compressors 2920 1475 06...

  • Page 89: Stopping

    Instruction book “Compressor outlet” 7.5 bar (109 psi) “Automatically loaded” “Menu” “Unload” Automatic operation Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and restarts the compressor automatically. LED (8) is then lit. Manually unloading Press “Unload”...

  • Page 90: Taking Out Of Operation

    Instruction book Control panel Control panel of Elektronikon MkIV regulator Reference Name Press stop button (9). LED (8) goes out. The message “Programmed stop” appears. The compressor runs unloaded for 30 seconds and then stops. To stop the compressor in the event of an emergency, press button (S2). Alarm LED (7) blinks.

  • Page 91: Use Of Air Receiver

    Instruction book Step Action 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. Drain the oil and condensate circuits. On water cooled compressors, drain the water circuits. Disconnect the compressor condensate piping from the condensate drain net.

  • Page 92: Maintenance

    Instruction book Maintenance Preventive maintenance schedule Warning Before carrying out any maintenance, repair work or adjustment, proceed as follows: Stop the compressor. • • Press emergency stop button (S2). • Close the air outlet valve and open the manual condensate drain valves. •...

  • Page 93: Motors

    Elektronikon regulator. When a level is reached, a message will appear on the screen. After carrying out all service actions, the interval timers must be reset using the “Reset” key in the “Service” menu. Consult your Atlas Copco Service Centre. Motors Warning Stop the compressor and switch off the voltage.

  • Page 94: Oil Specifications

    GA 315 4000 h 60 gr (2.1 oz) 4000 h 45 gr (3.15 oz) Oil specifications Atlas Copco Roto-Inject Fluid Roto-Inject Fluid is a high-quality lubricant for single-stage, oil-injected rotary screw compressors. See the section Service kits. 2920 1475 06...

  • Page 95: Oil Change

    Instruction book Atlas Copco Roto-Xtend Duty Fluid Atlas Copco Roto-Xtend Duty Fluid is a high-quality synthetic lubricant for oil-injected scroll and screw compressors which keeps the compressor in excellent condition. Roto-Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F) (see section Service kits).
  • Page 96 Vent, filler and drain plugs Oil drain plugs on GA 90 up to GA 250, GA 315 60 Hz and GA 132 VSD up to GA 315 VSD compressor elements Vent, filler and drain plugs on air-cooled GA 90 up to GA 160 and GA 132 VSD up to GA 315 VSD compressors...
  • Page 97 Instruction book Vent, filler and drain plugs on air-cooled GA 200 up to GA 315 compressors Filler and drain plugs on water-cooled GA 90 up to GA 160 and GA 132 VSD up to GA 315 VSD compressors 2920 1475 06...
  • Page 98 Instruction book Filler and drain plugs on GA 200 up to GA 500 compressors 2920 1475 06...
  • Page 99 Instruction book Vent plug on water-cooled GA 90 up to GA 250, GA 315 60 Hz and GA 132 VSD up to GA 315 VSD compressors Procedure Step Action Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage.

  • Page 100: Oil Filter Change

    Instruction book Step Action After carrying out all service actions in the relevant “Service Plan”, reset the service warning as follows: • Press the “Menu” key (3). • Press key (1) until “Service” is followed by an arrow pointing to the right. Activate the menu by pressing key (2).
  • Page 101 Instruction book Position of oil filters Position of oil filter on GA 90 up to GA 160, GA 132 VSD up to GA 315 VSD and GR 110 up to 200 2920 1475 06...
  • Page 102 Instruction book Position of oil filter on GA 200 up to GA 500 2920 1475 06...

  • Page 103: Storage After Installation

    Service kits General 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 indicated in the relevant Parts Lists. Atlas Copco Roto-Inject Fluid Roto-Inject Fluid can be ordered in the following quantities: •...
  • Page 104 Instruction book Atlas Copco Roto-Xtend Duty Fluid Roto-Xtend Duty Fluid can be ordered in the following quantities: • 5-litre can: 2901 1700 00 • 20-litre can: 2901 1701 00 • 209-litre drum: 2901 1702 00 Oil specifications. 2920 1475 06...

  • Page 105: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filters Warning Stop the compressor, close the air outlet valve, press the emergency stop button and switch off the voltage. The operator must apply all relevant Safety precautions. Position of air filters Air filters, GA90 up to GA160 and GR110 up to GR200 2920 1475 06...
  • Page 106 Instruction book Air filters, GA200, GA250 and GA315 60 Hz Control panel of MkIII regulator Control panel of MkIV regulator 2920 1475 06...

  • Page 107: Coolers

    Stop the compressor, press the emergency stop button and switch off the voltage. The operator must apply all relevant Safety precautions. Procedure Cooler block of air-cooled GA 90 up to GA 250, GA 315 60 Hz and GR compressors 2920 1475 06...

  • Page 108: Safety Valve

    Instruction book Cooler block of water-cooled GA 90 up to GA 255, GA 315 60 Hz and GA 132 VSD up to GA 315 VSD compressors Keep the cooler block clean to maintain the cooling efficiency. On air-cooled compressors proceed as follows:...
  • Page 109 Location of safety valve on air-cooled GA 90 up to GA 250 and GA 315 60 Hz and GR compressors Location of safety valve on water-cooled GA 90 up to GA 250, GA 315 60 Hz, and GA 132 VSD up to GA 315 VSD compressors The valve can be tested on a separate compressed air line.

  • Page 110: Problem Solving

    Instruction book Problem solving Problem solving Warning Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the emergency stop button and switch off the voltage. Close the air outlet valve and open the manual condensate drain valves. Open and lock the isolating switch.
  • Page 111 Remedy the problem. It may be necessary to reset the display after remedying the fault: press the “Reset” key (2), the message “All protection functions are OK” will appear, after which the compressor can be restarted. Excessive oil consumption Have the compressor inspected by the Atlas Copco Customer Centre. Condition Fault Remedy...
  • Page 112 Instruction book Condition Fault Remedy Condensate is not discharged Strainer/restrictors at the inlets of Clean the strainer/restrictors. through OSD outlets. the separator vessels clogged. Consult Atlas Copco. Flexibles between condensate Replace flexibles. traps and OSD clogged. 2920 1475 06...

  • Page 113: Technical Data

    Instruction book Technical data Readings on display Important The readings are valid when operating under reference conditions. See the section Reference conditions Normally the main display is shown (see the section Function keys), indicating the actual air outlet pressure and the actual compressor status. The arrow down key allows the operator to call up other information such as actually measured pressures and temperatures.

  • Page 114: Reference Conditions

    Instruction book Cooling water temperature, GA90 up to GA250 and GA315 60 ˚C Below 50 Hz and GR compressors Cooling water temperature, GA90 up to GA250 and GA315 60 ˚F Below 122 Hz and GR compressors Pressure dew-point ˚C Approx. 3 Pressure dew-point ˚F Approx.

  • Page 115: Settings Of Safety Valve

    For GA compressors with a maximum working pressure of 100, 125, 145, 150, 188 217 psig or 200 psi Settings for overload relay and fuses 50 Hz IEC compressors with ABB motors GA 90 up to GA 250 and GR 110 up to GR 200 Compressor Supply Overload relay Fuses Class gL/...
  • Page 116 GA 250 2x (3x355) GA 250 2x (3x300) 60Hz IEC compressors with ABB motors GA 90 up to GA 315 and GR 110 up to GR 200 Compressor Supply Overload relay Fuses Class gL/ Fuses Class gL/ Fuses Class gL/...

  • Page 117: Settings Of Circuit Breakers

    3 fuses 3 fuses 2x3 cables to 2x3 cables to 3 cables to contactor contactor contactor (bridges to be installed by customer) GA 90 440-460 2x (3x125) 3x200 GA 90 2x (3x100) 3x150 GA/GR 110 440-460 2x (3x150) 3x250 GA/GR 110...
  • Page 118 Supply voltage (V) Circuit breakers Setting (A) GA 250 Q25/Q26 For cooler cooling fan (air-cooled 60 Hz) Compressor type Supply voltage (V) Circuit breakers Setting (A) GA 90 220-230 Q25/Q26 14.3 GA 90 Q25/Q26 GA 90 440-460 Q25/Q26 GA 90...
  • Page 119 GA/GR 200 GA 250 GA 250 GA 250 For bodywork ventilation fan (water-cooled 60 Hz) Compressor type Supply voltage (V) Circuit breakers Setting (A) GA 90 220-230 GA 90 GA 90 440-460 GA 90 GA/GR 110 220-230 GA/GR 110 GA/GR 110...
  • Page 120 Instruction book For dryer motor (50 Hz) Compressor type Supply voltage (V) Circuit breakers Setting (A) GA 90 GA 90 GA 90 GA/GR 110 GA/GR 110 GA/GR 110 GA/GR 132 GA/GR 132 GA/GR 132 GA/GR 160 GA/GR 160 GA/GR 160...
  • Page 121 Circuit breakers Setting (A) GA 315 For dryer cooling fan motor (50 Hz) Compressor type Supply voltage (V) Circuit breakers Setting (A) GA 90 GA 90 GA 90 GA/GR 110 GA/GR 110 GA/GR 110 GA/GR 132 GA/GR 132 GA/GR 132...
  • Page 122 (V) breakers r T1 r T1 r T1 r T1 250 VA 400 VA 630 VA 800 VA GA 90 GA 90 GA 90 GA/GR 110 GA/GR 110 GA/GR 110 GA/GR 132 GA/GR 132 GA/GR 132 GA/GR 160 GA/GR 160...

  • Page 123: Compressor Data

    Instruction book Compressor type Supply Circuit Transforme Transforme Transforme Transforme voltage (V) breakers r T1 r T1 r T1 r T1 250 VA 400 VA 630 VA 800 VA GA/GR 160 220-230 GA/GR 160 GA/GR 160 440-460 GA/GR 160 GA/GR 200 GA/GR 200 440-460 GA/GR 200...
  • Page 124 Instruction book Units GA90 GA110 GA132 GA160 GA200 GA250 Power input, GA W Full-Feature Power input, GA W Full-Feature Oil capacity, GA Oil capacity, GA US gal 18.2 19.8 24.6 26.4 34.3 34.3 Oil capacity, GA Imp gal 15.2 16.5 20.5 28.6 28.6...
  • Page 125 Instruction book Units GA90 GA110 GA132 GA160 GA200 GA250 Oil capacity, GA W US gal 16.6 16.6 22.4 22.4 29.8 29.8 Oil capacity, GA W Imp gal 13.9 13.9 18.7 18.7 24.9 24.9 Oil capacity, GA W cu.ft 2.21 2.21 2.98 2.98 3.96...
  • Page 126 Instruction book Units GA90 GA110 GA132 GA160 GA200 GA250 Minimum cooling water flow Minimum cooling water flow Data for GA 13 bar (189 psi) 50 Hz compressors Units GA90 GA110 GA132 GA160 GA200 GA250 Maximum working pressure, GA Pack bar(e) Maximum working pressure, GA Pack psig Maximum working pressure, GA Full-...
  • Page 127 Instruction book Units GA90 GA110 GA160 GA200 GA250 GA315 Maximum working pressure, GA Pack psig Maximum working pressure, GA Full- bar(e) 7.15 7.15 7.15 7.15 7.15 7.15 Feature Maximum working pressure, GA Full- psig Feature Nominal working pressure bar(e) Nominal working pressure psig Motor shaft speed r/min...
  • Page 128 Instruction book Units GA90 GA110 GA160 GA200 GA250 GA315 Motor shaft speed r/min 1790 1790 1790 1790 1790 1790 Power input, GA Pack Power input, GA Pack Power input, GA Full-Feature Power input, GA Full-Feature Power input, GA W Pack Power input, GA W Pack Power input, GA W Full-Feature Power input, GA W Full-Feature...
  • Page 129 Instruction book Units GA90 GA110 GA160 GA200 GA250 GA315 Power input, GA W Full-Feature Power input, GA W Full-Feature Oil capacity, GA Oil capacity, GA US gal 18.2 19.8 26.4 34.3 34.3 34.3 Oil capacity, GA Imp gal 15.2 16.5 28.6 28.6 28.6...
  • Page 130 Instruction book Units GA90 GA110 GA160 GA250 GA315 Oil capacity, GA cu.ft 2.42 2.63 4.55 4.55 Oil capacity, GA W Oil capacity, GA W US gal 16.6 16.6 22.4 29.8 29.8 Oil capacity, GA W Imp gal 13.9 13.9 18.7 24.9 24.9 Oil capacity, GA W...

  • Page 131: Pressure Equipment Directives

    The following pressure bearing parts are of category higher than I : Oil separator vessel : Cat III For GA 90 and GA 110: design pressure 15 bar(e), content 147 l For GA 132 and GA 160: design pressure 15 bar(e), content 189 l Design standard : ASME section VIII div.

  • Page 132: Documentation

    Instruction book Documentation Declaration of conformity Typical example of a Declaration of Conformity document Declaration of incorporation Typical example of a Declaration of Incorporation document 2920 1475 06...
  • Page 133 Instruction book 2920 1475 06...
  • Page 136 Not for the sake of technology, but for the sake of our customer’s bottom line and peace-of-mind. That is how Atlas Copco will strive to remain the first choice, to succeed in attracting new business and to maintain our position as the industry leader.
  • Page 137 THIS DOCUMENT DOWNLOAD FROM www.repair-manuals.com THE LARGEST PDF MANUALS COMPLEX FOR HEAVY MECHANICAL TECHNICIANS MEMBERSHIP ACCOUNT HOLDERS CAN DOWNLOAD ALL MANUALS WITHOUT ANY ADDITIONAL COST EXPLORE AVAILABLE PLANS...

This manual is also suitable for:

Ga 110Ga 132Ga 160Ga 200Ga 250Ga 315

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