Instruction book for compressors GAS -GA7-GA10 Fro Registration code Collection: APC GS-10 38 Sequence: 978 No. 292011950 00 1997-02 Important ‘This book applies exclusively o GAS - GA7 - GA10 rom serial number All-112 227 onwards equipped with = an electronic regulator as shown on the left above. For these compressors, this book must be used together with the “User manual for electronic reguator fr GAS up to GA7S compressors" ~ an elecro-preumatic regulator as shown on the lft beiow. ‘This instruction book meets the requirements for instructions specified by the machinery directive 89/992/EEC and is valid for CE as well as non-CE labelled machines — Aldax Copoo Industrial Air Division - 8-2610 Wilk - Belgium —a— Aldtas Copeo industrial Ar Division Instruction book — Tis instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service ie. Read ths bock belore puting the machine into operation to ensure correct handling, operation and proper maintenance from the begining. The maintenance schedule comprises measures for keeping the machine in good condition Keep the book available for the operator and make sure that the machine is operated and that maintenance is carried out according to the instructions. Record al operating data, maintenance performed, etc. in an operator's logbook availabe from Atlas Copco. Follow all relevant safety precautions, including those mentioned on the cover of this book. Repairs must be carried out by trained personnel from Allas Copco who can be contacted for any futher information Inall correspondence always mention the type and the serial number, shown on the data plate. For all data not mentioned inthe text, see sections ‘Preventive maintenance schedule" and "Principal data. ‘The company reserves the right to make changes without prior notice. CONTENTS Page Page 1. Leading particulars 3&5. Manual control for GA Pack FulHfeature .......... 22 4.1 General description 3 36. Stopping 2 14.1 Airflow 5 37 Taking out of operation at end of compressor 14.2 Oilsystem 5 serve ie 2 4.1.3 Gooling and condensate drain systems. 5 1.2. Unloadingfoading system 5 4 Maintenance 2 4.2.1 Unloading 5 4.1. Compressor motor 2 4.22 Loading 5 42 Preventive maintenance schedule forthe compressor 23, 4.3. Elecical system fr GA Pack Ful-eature 7 43. Oilend oi fit change interval me 41.4 Electronic contol module for GA Pack /Ful-feature... 7 4.4 Oil specications wn Bh 4.4.1 Electronic reguitor . 7 4.4.1 Alas Copco Roto-njectiid 24 4.42 Control panel cee 10 442 Mineral oil 24 1.5. Elecical system for GA Standard Pack 1145 Oilchange wn 4.5.1 Regulator . : 1348 Oilfiter change 25 1.52 Control panel : hiss 18 47. Storage ater instalation 25 1.8 Airdryer on GA Full-eature si 13 4B. Service kis. wn 4.6.1 Compressed air circuit. 13 1.62 Refrigerant circuit Liss 13 5 Adjustments and servicing procedures 25 2 Installation . ce BD Ae itor 7 2 Coolers... Fy 2.1 Dimension drawings eal cag taae A 22 Becta si egal veoedoyarmat 84 Beene os equating devices on GA Full-eature eas © J 58. Loadlunioad pressure switch on GA Standard Pack .. 26 25 Petographe : © J. 5:7. Temperature shut-down swich on GA Standard Pack. 27 3 Operating instructions 7 206 Problem solving . . a 3.1. Before intial star-up : 20 3.1.1 Safety precautions 20 7 Principal data 29 3.1.2 User manual (GA Pack//Fullfeature only) ... 20 7.1. Readings 29 3.13. Outdoorlatitude operation 20 7.11 Readings on display on GA Pack/Ful-eature 23 3.1.4 Handing 20 7.42 Readings on gauges on GA Standard Pack .. 29 3.1.5 Exiemal compressor status indication 72. Setting of safety valve... 29 (GA Pack /FulHfeature ony) sess. 2073. Fan contol switch on GA FulMeature 23 3.1.8 Compressor contol modes 7.4 Compressor specications we BD (GA Pack /Full-eature only) 20 7.44 Reference conditions 29 32 Inial star-up : 20 742. Limitations : 2 33. Starting a 743 Spectications of GAS 30 3.4 During operation 21 7.44 Specifications of GA7. . 30 3.4.1. Checking the display 7.45. Specifications of GA10. : 31 (GA Pack /FulHfeature only) 21 75. Conversion Ist of SI units into US/Biish units 31 2 2920 195000Instruction book — Industrial Ai Division tlax Copoo — 1 LEADING PARTICULARS 1.4 General description GAare siationary, single-stage, o-injected screw compressors driven by@an electric motor. GAS, GA7 and GAt0 are air-cooled GA Standard Pack (Figs. 2a and 9) ‘The compressors are enclosed in a sound-insulated bodywork, A ‘contro! panel including the starVstop switch is provided. An electric cabinet comprising the relay-coniroled regulator and motor starter is located behind this panel GA Pack (Figs. 2b and 62) The compressors are enclosed in a sound-insulated bodywork. The {ont panel comprises an electronic contol madule including the start ‘and stop buttons. An emergency stop button is also provided. An lectria cabinet comprising the motor starter is located behind this panel. An automatic condensate drain system is provided. GA Full-feature (Figs. 1 and 6a) GA Ful-feature compressor are additionally provided with an air dryer integrated in the bodywork. The dryer removes moisture from the compressed air by cooling the air to near freezing point and automaticaly craining the condensate. See section 1.8 FN AF F083 AF Airfiter FC. Olfiler plug 3. Hoe cip 8. Warring: votage AN. Airoutet valve FN, Fan 4. Hose 9. Automatic condensate Ca. Aircooler MT. Moisture rap 5. Condenser (ony Ful drain Co. Oilcooler M1. Compressor motor ‘eature) 10. Manual condensate drain Da, Automatic condensate OF. Oilfiter 6. Plug 11. Label, type of compressor drain outlet 8. Oil separator element ol m1. Manual condensate ‘SG. Oillevel sight glass Pictographs drain valve Vp. Minimum pressure vae 7, Switch off votlage and Dm2. Oil drain valve 1. Electric cabinet ‘opressurize compressor E.—Compressorelement 2.—=Belts before repairing Fig. 1. Side views, GA FulHfeature 28201380 00 3Altias Copco Industria Ar Division — Instruction book Fig. 2a. Side view, GA Standard Pack A. Ar filer N. Air outlet valve Ca, Aircooler Co. Oil cooler m2, Oildrain valve E Compressor element FC. Oilfile plug FN, Fan Mt Motor MT. Moisture trap OF, Oilfiter 0S. Oil separator PSR18. Load/unioad pressure switch SG, Oillovel sight glass SV. Safety valve Vp. Minimum pressure valve 1 Electric cabinet 2. Data pate 3 Hose cip 4 Hose 6. Regulator 6 Bets Figs.2. Side views Options and special versions Full: Pack Standard feature Pack Integrated oiwater separator(OSO). 1) 0 1) High ambient version (uptos0°C) .. NA 00 Ling device 0 0 0 Bodywork heating 0 o 0 Rein protection 0 o oO Heavy-duty fiter 0 0 0 Modulating controlreguator2).....0 9 0 Integrated condensate separator (wso) ss 0 Integrated cryer S 0 NA Main power isolating switch 0 a oO Electronic drain 0 a oO Dryer by-pass 0 0 NA Transformer kit for dryer voltage supply 0 0 NA Relgy expansion box 0 0 NA O=oplional —S= standard NA not available 41) fan ollwater separator is desired, a freestanding OSD22 must be applied 2) Notfor GAs. F082 Fig. 2b. Sie view, GA Pack 2900 1950 00|Instruction book Industral Air Division Addas Copeo — 1.1.1 Airflow (Fig. 3) ‘Ar drawn trough fiter (AF) and open inet valve (IV) into compressor element (E) is compressed. The compressed air fows through ol separator (OS), minimum pressure vaive (Vp) and air cooler (Ca) to ute valve (AV). 1.1.2 Oil system (Fig. 3) Ar pressure forees the oil from oi tank (OT) through ol cooler (Co) and fiter (OF) to compressor element (E) and the lubrication points. ‘The system comprises a by-pass valve (BV). When the oltemperature is below 75°C (167°F), there is no olf tothe ol cooler, At approx. ‘90°C (194°F}, the valve is closed so that llth oll passes through the cooler 1.1.3 Cooling and condensate drain systems (Fig. 1) The cooling system comprises ar cooler (Ca) andi cooler (Co). The cooing aris generated by fan (FN) ‘A moisture trap (MT) is provided inthe air outlet system of GA Pack and Fulleature compressors). The raps equipped witha vaive for ‘automatic condensate draining during operation (Oa) and a manually ‘operated valve for draining after stopping the compressor (Omt) 1.2 Unloading/loading system (Fig. 3) 1.2.1 Unloading the air consumption sess than the ai output of the compressor, the net pressure increases. When the net pressure reaches the unioadng pressure, solenoid vale (Y1) is de-energized. The plunger ofthe \aive returns by spring force: 1. The contol pressure present inthe chambers of loading plunger (LP) and unloading valve (UV) is vented to atmosphere via solenoid valve (Y1). 2. Loacng plunge (LP] moves by spring force andcauses inlet valve (1) to close te air inlet opening 3. Unloading valve (UV) is opened by receiver pressure. The pressure from oil separator (OS) is released towards unloader (UA ‘Ar output is stopped (0%), the compressor runs unloaded. 1.22 Loading When the net pressure decreases to the loading pressure, solenoid valve (Y1) is energized. Theplunger othe valve moves against spring force: 1. Control pressure is fed from oil separator (OS) via solenoid valve (1) to loacng plunger (LP) and unioaing valve (UV) 2. Unioatng valve (UV) closes the air blow-off opening. Loading Plunger (LP) moves against spring force and causes inlet valve (IV) to open fully. Air output is resumed (100%), the compressor runs loaded. 41) Avaliable as option on GA Standard Pack AE Aicfiter LP. Loading plunger WY, Unloading valve 6. Manual condensate AV. Air outlet valve M1. Compressor motor Vp. Minimum pressure drain valve BV. Oilcooler by-pass valve MT. Moisture trap vave 7. Capitary tube BVI. Bypass valve OF Oilfiter Y1, Loading solenoid valve 8. Condenser cooling fan Ca. Aircooler OS, Oilseparatorelement 1. il scavenging line 9, Relrigerant condenser Co. Oilcooler OT. Oiltank 2 Flexible, controlar 10. Hot gas by-pass valve Da, Automatic condensate PS. Oil preseparator 3. Betts 11, Airetigerant heat rain outet PT20. Pressure sensor, at exchangerlevaporator Dm1. Manual condensate outet 12, Liquid refrigerant aryer! rain valve SG. Cillevel sight glass fier m2. Oil drain valve SV. Safety ae M2. Motor, condenserfan 13. Alrfir heat exchanger E Compressor element ‘TT11, ‘Temperaturesensor, $3. Contfol swith, con: 14, Pressure dewpoint Et. Control module ‘compressor element denser fan sensor FC. Giller plug uti 4. Condensate trap 18. Insulation block FN. Fan UA. Unloader 5. Automatic condensate 16. Condensate separator MV. Inlet valve drain hose Fig. 3. GA Pack /Fullfeature during lading (see next page) 2820 1380 00 5Instruction book D ARINLET (1) D> compressen ain OuT (2) ——> COMPRESSED AIR (3) ‘lL (4) [= REFRIGERANT LIQUID (5) ==» REFRIGERANT GAS (6) 220 1350.00Instruction book Industria Air Division ddas Copeo — i 2x4 m2 1 2223 K21 21 1X1 F3.-F2 FI CMSHI2 1x4 1.3 Electrical system for GA Pack / Full-feature The system comprises Compressor motor (Mig. 1) Electronic contol module (Fig. 63) Compressor start button () and stop button (0) (Fig. 6a) Emergency stop button ($3-Fig. 62) Etecric cabinet (Fig. 4) Sensors forthe compressor element outa temperature (TT11) and fr the air outet pressure (PT20) 7. Dewpoint temperature sensor (7780) forFul-eature compressors 1.4 Electronic control module for GA Pack / Full- feature The control module consists of an electonic regulator and a control panel 1.4.1. Electronic regulator (E1-Fig. 4) The regulator has folowing functons: Controting the compressor The regulator mainizins the net pressure between programmable its by automaticaly lading and unioading the compressor. A number of programmable setting, eg, the unloading and loading pressures, the minimum stop time andthe maximum numb of motor sats are taken into account ‘The regulator stops the compressor whenever possible to reduce the See legend of Figs. 5 fr denomination of components Fig. 4. Electic cabinet of GA Pack /Ful-feature (typical example) Power consumption and restarts itautomatically when the net pressure decreases. In case the expected unloading period is too shor, the ‘Compressor is kept running to prevent too-short standstill periods. Protecting the compressor Ifthe compressor element outlet temperature exceeds the programmed shut-down level, the compressor willbe stopped. This willbe indicated ‘onthe control panel (Fig. 6a). The compressor will also be stopped in cease of overioad of compressor motor (M1). tthe compressor element outlet temperature exceeds a programmed value below the shut-down level ths will also be indicated to wam the ‘operator befor the shut-down level is reached. Monitoring components subject to service ‘The regulator continuously monitor theo ol fite, oil separator and airfiter. Each inputis compared to programmed limits. these its are exceeded, a message wil appear on the display (Fig. 6a) to warn the operator o replace the indicated component. ‘Automatic restart after voltage failure For compressors leaving the factory, this function is made inactive, If desired, the function can be activated. Consult llas Copco. Waring I activated and provided the module was in the automate operation ‘mode, the compressor wil automaticaly restar if the supoly voltage to the module is restored within a programmed time peri (his time period is called the power recovery time. It the power recovery time is set to O01, the compressor will avays restart ater a voltage failure, no matter how long it takes to restore the voltage. 2820 150.00— Aithas Copeo. Industrial Air Division Instruction book — 2 Hl af Fig. 5a. Electrical diagram, GA Pack /Ful-feature (50 He / star-deta) 8 2820 1980 00Instruction book — Industrial Air Division Alas Copco — SENSORS/LOADING SOLENOID VALVE PT20. Pressure sensor, ar outlet Tit, Temperature sensor, compressor lament outlet ‘TT90. Temperature sensor, dewpoint 1) Y1. Loading solenoid valve ‘2, Solenoid valve, modulating contol MOTORS Mi. Compressor motor M3. Fanmotor2) ELECTRIC CABINET FYFE. Fuses F21. Overload relay, compressor motor 1) Only for Fullfeature compressors. Fig. 5b, Electrical diagram, dryer on GA Ful-feature Kit, Auxillary contactor for dryer 1) Ket, Line contactor K22, Star contactor 23, Delta contactor TiT2, —Translormers 1X1, Terminalstrip 1X2, Terminal strip. 1X4, Terminal strip. CONTROL MODULE (E1) (CMS1/2, Switches, selection of compres sor control mode I Start button Kot. Blocking relay 02, Auriiary relay, star contactor 2) Installed in electric cabinet of compressors designed for high-temperature conditions. 3) Customers insiallaton. Koa, Ko4, Kos, K10, 0. 83 ‘Auxiliary relay, deta contactor ‘Auxiliary relay, loading/unloading ‘Auxiliary rela, highow air pressure ‘Auniiary relay, dryer Stop button Emergency stop button 2X1/6. Connectors On GA Full-feature also: Fo. Mt wa, 83. Figs. 5. Electrical diagrams for GA Pack Fullfeature Fuses3) Refrigerant compressor/motor Motor, condenser cooling fan Control switch, condenser cooling fan 00 1350 00|Aldlas Copco \ndustial Air Division — Instruction book 1.4.2 Control panel (Fig. 6a) To control the compressor and to read and modify programmable parameters, the regulator is provided with a panel including: Indicators, keys and buttons 1 Automatic operation LED Indicates that the regulator is automatically controling the ‘compressor: the compressor is loaded, unloaded, stopped ‘and restarted depending on the air consumption and the limitations programmed in the regulator. 2 Votage on LED Hdaxtoper eS Indicates that the voltage is switched on. ~ 3 General alarm LED is normally ou, Is alight or binks incase of an abnormal condilon, See below. ~- & Dok x0 ase h $9. Emergency sip button 8. Start button the name ofthe sensor of wich he actual reading is 1+ LED. aulomatc operation 9. Stop bution sepayed 2. LED, votage on 10. Pictograph, emergency sop = hewetand actual racing 3. LED, general alarm 11, Pictograph, automatic 4. Display operation + messages regarding the operating staus, a sensor 5. Function keys 12, Pilogreph voltage on faut error, a service need ora faut 4 eee Setrceeaaany 5 Fincton keys 7. Tabuetorkey ee uum aal oe Fg, 62, Control panel of GA Pack Ful-eature line. The most common ones ae listed below. 8 Scroll keys ‘As long as an arrow s shown on the right side ofthe display, the key withthe same symiol can be used to scroll through ~ the display ee 7 Tabulatorkey ee a Key to got the next feof the display. ve _ one Menu More Unis Push button to start the compressor. LED (1) lights up Ft Fo F3 indicating that the regulator is operative (in automatic operation) The LED goes ot alr unloacing the compressor Fig, 6b. Example ofthe main display manually 8 Stop button Push button to stop the compressor. LED (1) goes out. The compressor wil stop after running in unioaded condition for 30 seconds en $83 Emergency stp buton Main rH v Push button to stop the compressor immediately in case of : emergency. Mus! be unlocked belore restarting A Fe F3 Fig. 6c. Example ofa main menu 10 2220 195000Instruction book — Industrial Air Division Atlas Copco — General alarm LED (3-Fig. 6a) 1) ‘The LED blinks in case ofa shutdown (due o ether to high a compressor element outlet temperature or overioad of the ‘compressor motor); at the same time the shut-down screen appears. See section. After eliminating the cause of the trouble ‘and when the abnormal concition has disappeared, press key < (5) = The LED biinks and the compressor is shut down ithe sensor of the compressor element (TT11-Fig, 15) is out of order; atthe same time the dispay will show a ful message. Switch off the voltage, depressurize and check the sensor and its wing ‘The LED is alight in case of a shut-down waming, at the same time a warning message appears. Remedy, see section 6 ~The LEDis aigtifthe dewpoint sensor (TT30) is out of order (on Fullfeature compressors); atthe same time a fault message is shown. Stop the compressor, switch of the voltage, depressurize ‘and check the sensor and its wiring Selecting a menu To faciltate controling the compressor, menu-criven programs are implemented inthe electronic module. Use the function keys (6) to selec the menus in order to program and monitor the compressor, The “User manual for electronic regulator for GAS up to GA7S compressors’ deals elaborately wit all regulator functions. Function keys Abbre- Desig: Viation nation ‘Add Add To add compressor staristop commands (day/ hour) Cane Cancel Tocancel a programmed setting when programming parameters Del Delete To delete compressor starvstop commands Lim Limits To show limits for a programmable setting List List Tolist programmed start/stop commands (day/ hour) Load Load Toload the compressor manually Main Main Toretum from a menu to the main display (Fig. 6b) Menu Menu Starting trom the main display (Fig. 6b), to initiate the main menu (Fig. 6c) which gives access to submenus Starting from a submenu, to return tothe main menu (Fig. 60) Mod — Modify To modiy programmable settings More More To have a quick lok atthe compressor status Prog Program To program modified settings 1.5 Electrical system for GA Standard Pack The system comprises: 1. Compressor motor (Mt-Fig. 1) 2. Regulator enclosed in a cabinet (Fig. 7) 3. Control panel with starvstop switch (St-Fig. 9) 4, Temperature shut-down switch (TSHH11-Fig 9) 5. Loadlunload pressure switch (PSR1S-Fig. 2a) fll ]Ie1 ‘See legend of Fig. for denomination of components Reet Rese! To eset timer or message Rtn Retum To return toa previously shown option ormenu Fig. 7. Electric eabnet of GA Standard Pack (typical exampe) Slet Select To select a submenu orto read more detais of a selection shown on display Unid Unload To unload the compressor manually eee 41) Const the User manval or he eletonic regulator, secon ‘Status daa submenu" 220 135000 1"— ‘Aldias Copco \ndustial Ait Division Instruction book — wow {| cies 96 A aoe ‘SWITCHES /LOADING SOLENOID VALVE F21. Overload relay, compressor motor PSR19. —Loadlunioad pressure switch K21, Line contactor TSHH11. Temperature shut-down switch 22. Star contactor Yi Loading solenoid valve K23. Dea contactor v2 Solenoid valve, modulating control K26. Timer, delayed mator stopping (5 minutes) T Transformer (t provided) MOTORS 4X18. Terminal strips Mt Compressor motor M2. Fan motor (provided on compressors designed for high CONTROL PANEL temperature conditions) Pt Hourmeter, motor runing ime Si. Satstop switch ELECTRIC CABINET FAS. Fuses Fig. 8. Electrical diagram for GA Standard Pack with star-deta starter 2920 1950 00Instruction book — Industrial Air Division Atlas opeo — 1.5.1 Regulator (Fig. 8) ‘Tho regulator loads, unloads, stops and restarts the compressor according to the air consumption, and protects the compressor and ‘motor rom overloads. The unloading and loading pressures are the opening and closing pressures respectively of switch (PSRI9). See section 56 Delayed motor stopping ‘The time relay for delayed motor stopping (K26) limits the frequency of automatic motor starts by stopping the motor only afteraset ime of 5 minutes of uninterupted unloaded operation. If the net pressure ‘drops to the loading pressure within th set unloading time, the ‘compressor willbe loaded without stopping Compressor temperature shut-down switch (TSHH11) ‘The switch prevents damage resulting from too high @ temperature at the outlet of the compressor element Motor overload relay (F21) ‘The relay prevents damage resuting from too high a motor curent. 1.5.2 Control panel (Fig. 9) Gp, Gauge indicating the working pressure PI Hourmeter indicating the total motor running time st ‘Switch to start or stop the compressor TSHH11. Gaugelswitch, indicating the temperature atthe outet of the compressor element as wel as the shut-down ‘temperature; the regulator then stops the compressor Pictograph, working pressure Pictograph, outlet temperature of compressor element Pictograph, running hours. Pictograph, compressor stop Pictograph, compressor stat 1.6 Air dryer on GA Full-feature (Fig. 3) GA FulHteature are provided with a dryer which removes moisture from the compressed air. See Fig. Sb for the electrical diagram. 1.6.1 Air circuit Compressed air enters heat exchanger (13) and is cooled by the ‘outgoing, cold, dried air. Water inthe incoming a starts to condense. ‘The air then flows through heat exchanger/evaporator (11) where the TSHHIt ! | Froet Fig. 9. Control panel o GA Standard Pack refrigerant evaporates causing te arto be further cooled to close to the evaporating temperature ofthe retigerant. More water inthe ar condenses. The cod ar then flows through separator (16) where condensate is separated from the air, The condensate collects in condensate trap (4) andis automaticaly drained. The col, cried ai flows through heat exchanger (13) where it is warmed up by the incoming ar 1.6.2 Refrigerant circuit Compressor (Mt) delivers hot, high-pressure refrigerant gas which flows through condenser (9) where most ofthe refrigerant condenses. ‘The liquid flows through dryerfter (12) to capilary tube (7). The ‘refrigerant leaves the capilary tube at evaporating pressure. ‘The refrigerant enters evaporator (11) where it withdraws heat from the compressed air by urther evaporation at constant pressure. The ‘heated refrigerant leaves the evaporator and is sucked in by the ‘compressor. 320 1950 00| 13— Aitias Copco Industrial Air Division Instruction book — 2 INSTALLATION 2.1. Dimension drawings (Figs. 10) ome. ae = = NEE, ar cer ong ORE, nia Gone 8 ms, Tawa Pe a “ a HD lcowes zeae] | ae | salar ———? Lose [ae 2 se ri ioe ois ea Lei Fig. 10a. Dimension drawing for GA Pack and Ful-feature <> “ has 91.5 | SI verses oe" 0 Ero leo, 7 as [eer [i= [pm [Dm] as] = [=| @] ss | ar | ~ [=] | ae] a [2s | | se | 1 aane te Fig. 10, Dimension drawing for GA Standard Pack 14 2320 195000Instruction book Industrial Ai Division Atlas Copeo — 22 Electric cable size, settings of overload relay (F21) and main fuses Attention Local reguatons remain applcabie i they ae stricter than he values proposed below. ‘Te voltage drop must not exceed 5% of the nominal votage. itmay be necessary to use cabes witha larger section than those stated to comply with this requirement 25 m, max. ambient temperature = + On GA Full-teature, the current to the air dryeris 2.4 A (50 Hz) or2.7 A (60 H2). Max. cable leng °C, cables in ree ar orn raceway, copper conductors. Compressor type Supply voltage Line current Cable section Overload relay Fuses ™ a) {mmAWG size) (A) (a) 50 Hz compressors with star-delta starter Gas 230 2 4 2 35 Gas 400 2 25 7 20 GAS 500 10 25 6 20 Gar 230 29 6 7 35 GAT 400 7 4 10 6 GAT 500 13 25 8 20 Gato 230 39 10 2 50 Gato 400 2 6 13 35 Gato 500 18 4 10 5 60 Hz compressors with star-delta starter Gas 220290 23 4 13 5 GAS 380 13 25 8 Py Gas 4401460 " 25 7 20 Gav 2201280 30 6 17 35 Gav 380 18 4 10 6 Gar 440v460 5 25 9 20 Gato 2201230 40 10 23 50 GAIO 380 23 6 13 35 Gato 4401460 20 4 2 5 60 Hz compressors with direct-on-line starter CSAHRC — ULClass K5 GAS 200 Awas 6 60 60 GAS 220!290 : AwGs 23 60 60 Gas 4401460 AwG12 1 30 30 Gas 515 Awa12 9 30 30 Gar 200 AWGS 34 Cy) 70 Gar 2201280 ws 30 60 6 Gav 440/460 AWG10 18 60 60 Gav 515 AWG12 5 30 30 Gato 200 AWG 4 100 100 Gato 2201280 AWG 40 80 70 Gato 440i460 AWGB 20 60 6 Gato 575 : Awa10 8 60 0 2320 1350 00| 8— Sielax Copco Industria Ait Division Instruction book — 2.3 Installation proposal (Fig. 11) a Cae In. 600 — vexnnonrneda sa |) Se LT one DI ri Pee ee A Fig. 11 Installation proposal, typical example fr GA Standard Pack (installation of GA Pack /FulHeatur is similar) 2920 1350 00Instruction book Indust ir vision Atlas Copco — Ret. Description/recommendation Ret. Description/recommendation 1, Install the compressor on a level floor suitabe for taking the 4 ‘weight of the compressor and with a minimum clearance of 41.2 m above the unit (except for ventilation proposals 2 and 4 2 Position of compressed air outlet valve. 3 The maximum total pipe length (including interconnecting pining between compressor and receiver) can be calculated as follows: APxOxXP, if Z 450 x Qc'# L_ = pipe length in m AP = _ maximum allowable pressure drop (cecommended 0.1 bar) inner diameter of pipe in mm ‘compressor outiet pressure in bar absolute {ee air delivery of compressor in is Venilaton: the inlet grids and ventlation fan should be installed in sucha way that any recculaton of cooling ai to the compressor or dryer i avoided. The air vlocty tothe grids must be limited to § mis. The maximum allowable pressure drop over the cooing ar ducts is 30 Pa. I this pressure drop is excooded, a fan is needed at he outlet of the cooling ar ducts. The maximum air temperature at the compressor inlake opening is 40°C (minimum 0°C) The required ventilation to limit the compressor room temperature can be calculated as follows: For alternatives 1 and 3: Qv = 0.92 NAT Qy = required ventilation capacity in ms N shalt input of compressor in kW AT = _ temperature increase in compressor room For altematives 2 and 4, 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. 1. Transport bott 2. Transport spacer Fig. 12, Transport fixations 20 1350 00|Alttas Copeo Industrial Air Division — Instruction book Description/recommendation 5 Position of condensate drain tlexibles. The flexibies towards the drain collector must not dip into the water of the drain collector. Atlas Copco has oil separators (OSD) to separate the major part of oil rom condensate to ensure that the condensate meets the requirements of the environmental codes. Position of contrl pane! Position of mains cables entry. See section 2.2 for the recommended electric cables. See section24 for connecting the power supply. ‘Accondensate trap is integrated in the bodywork of GA Pack/ FulMfeature, tis available as option for GA Standard Pack, Optional filters can be installed in the pressure line Sownsream ofthe ott ve ADD filter for general-purpose titration (iter raps solid Particles down to 1 micron with max. ol cary-over of 0.5 maim’), Ahigh-etficiency PD filter (traps solid particles down to 0.0% micron with max. ol carry-over af 0.01 mg/m), A PD fiter must be installed downstream of a DD fier Ifo vapour and odours are undesirable a filler of the QD type should be installed downstream of the PD fie. ‘The air receiver (optional) should be installed in a frost-tree room and on a level concrete foundation. For normal ir consumption, the volume ofthe air net (receiver ‘and piping) can be calculated as follows: 75xQxP volume of air netin | free air delivery of compressor in Vs compressor ar inlet pressure in bar absolute unload - Pload in bar 2.4 Electrical connections General ‘The installation mustinclude an isolating switch near to and visible {tom the compressor. Make sure that this switch is open to ‘isolate the compressor from the mains before carrying out any connection ‘See section 2.2 forthe size of the electric cables, The installation must be earthed and protected against short circuits by fuses ofthe inet ype in each phase. See section 2.2. To DRYER (1) Fig, 19. Suppl tom hase condutrnewel conductor TO DRYER (1) TO DRYER (1) ob tt eee Fig. 134, Supply trom optional volage transformer Figs. 13. Dryer connections on GA Ful-feature The electrical connections must correspond tothe local codes. The indications on the data plate of the drive motor must correspond tothe mains supply votage and frequency Check the fuses andthe seting ofthe oveoad relay. Seo secon 22. 18 2820 195000Instruction book — Industrial Air Division Atlas Copoo — ‘On GA Standard Pack Connect the power supply to terminals (L1, L2 and 1.) of terminal sttip (1X2-Fig. 7) and the earth conductor to terminal (PE) For compressors with votage transformer, check thatthe connections atthe primary side o the transformer correspond tothe mains voage. For compressors without voltage transformer, check the connection, of wire (2-Fig. 8): either towards the neutral terminal (N) incase of a 3x 400 V plus neutral mains; connect the neutral conductor to terminal (N) 0 towards terminal (2) of fuse F2 in case ofa 3x 230 V mains (On GA Pack Connect the power supply to terminals (L1, L2 and L3) of terminal strip (1X2-Fig. 4). Connect the earth conductor to terminal (PE) of terminal strip (1X2) and the neutral conductor to terminal (N}. Consult section 2.2 (On GA Fullfeature = Connect the power supply to terminals (Lt, L2and 3) of terminal sttip (1X2-Fig, 4). Connect the earth conductor to terminal (PE) of terminal strip (1X2) and the neutral conductor to terminal (N), Consult section 2.2, The electrical diagram ofthe dryers stuck on the dryer module. ‘The voltage tothe dryer is supplied over the contacts of relay (K11-Fig. 4), which close when the compressor is started. ‘The voltage supply tothe dryer must be single-phase 230 V. ‘The voltage may be branched off directy trom the mains supply or via‘an optional voltage transformer Be ot 1. The dryer voltage supply is branched off from the mains ‘supply ~ Fora compressor supply voltage of 3x 400 V plus neutr ‘conductor (Fig. 132) ‘The dryer supply voltage is branched off between a phase conductor andthe neutral conductor. For a compressor supply voltage of 3 x 230 V (Fig. 13b} The dryer supply voltage is branched off between two phase conductors For all other supply voltages (Fig. 13c} A separate single-phase 230 V voltage supply must be provided. Use wiring of minimum 1.5 mm. The dryer must be protected by fuses. Consult section 2.2 2. The dryer voltage is branched off from the optional voltage transformer ‘The correct connections are shown on Fig. 136, 25 Pictographs Fig. 14 shows typical examples of pictographs used for GA ‘compressors. See also Figs. 6a and 9 Water outlet Water inlet Manual condensate drain ‘Automatic condensate drain Before connecting compressor electrical, consult instruction book for motor rotation direction Torques for ste! (Fe) or brass (CuZn) bots Consult Instruction book before greasing Switch off voltage before removing protecting cover inside electric cubicle 8. Switch off votage and depressurize compressor belore repairing Fig. 14. Pictographs 2920 198000, 9— Aldlas Copeo Industrial Ar Division — Instruction book 3 OPERATING INSTRUCTIONS 3.1. Before initial start-up 3.4.1. Safety precautions The operator must apply alrlevant safety precautons, including those mentioned in tis book. 3.1.2. User manual (GA Pack/Full-feature only) Read the "User manual for electronic regulator for GAS up to GA75 compressors ofamilaize yourself wit all regulator functions. 3.1.3 Outdoorlaltitude operation if the compressors installed outdoors or # the ai inlet temperature can be below 0°C (32°F), precautions must be taken. In this case, and aso i operating at high aude, consult Alas Copco 3.1.4 Handling ‘The bottom frame ofthe compressor is designed for easy handling with a pallet truck 3.1.5. External compressor status indication (GA Pack / Full-feature only) ‘A relay box for extemal compressor status indication (E2-Fig. Sa) is avaliable as option. Itcanbe connectedto the electronic contol module (1). The relay box has relays for indication of: ‘manual load/unload or automatic operation (KO8) warning condition (K07) = shut-down condition (KO8) ‘Maximum load for hese contacts: 1 A/240V AC. Stop the compressor ‘and switch off the votage before connecting external equipment 3.1.6 Compressor control modes (GA Pack / Full- feature only) ‘The electronic regulator has two switches (CMS1/2-Fig. 4) to select folowing compressor control mades (0 = open 1 = cased) (MS1 CMS2 Compressor mode ‘Compressor in local control mode (remote control is made inactive). 0 tor ‘Compressor in remote contro! mode (focal control ‘is made inactive) For remote starting and stopping: Connect one side of a remote start button (normally open contact} to. terminal 3 of connector (2Xé) 1). Connect one side of a remote stop button (normally closed contact) to terminal 4 of connector (2X4)1). Bridge the other sides ofthese buttons. Connect tis comman joint to terminal 2 of connector (2X4). Bridge terminal 28 of strip (1X1-Fig. 4) and terminal 6 of connector (2Xé) 1). In this mode, the outlet pressure is stil sensed by pressure transducer (PT20), resulting in loading and Unloading of the compressor at the pressures programmed in the electronic regulator. If terminals 26 and 6 are not bridged, the compressor is switched out of automatic load! tnioad operation and remains running unloaded. For remote loading/unloading (via external Pressure switch): Bridge terminal 28 of strip (1Xt-Fig. 4) and terminal 7 of connector (2X4) 1) and connect a loadfunioad switch between terminal 28 of strip (1Xt-Fig. 4) and terminal 6 ‘of connector (2X4) 1). This results in loading ‘and unloading ofthe compressor atthe closing ‘and opening pressures ofthe extemal pressure switch respectively. Have the modifications checked by Atlas Copco. Stop the compressor and swith ofthe voltage before connecting extemal equigment. Only Voltage-free contacts are alowed. 3.2 Initial start-up 1. Remove the transport bots and spacers. See Fig, 12. ‘Check hat ne electrical connectans correspon the local codes ‘and that allwres are camped tghto their terminals. See section 24. 3. Check the voltage selecting wires at the primary side of transformer (T1-Fig. 4) 2), the setting of compressor motor overload relay (F21), and that overoad relay (F21) is set for CMS CMS2 Compressor mode automate reseting 1) tthe back ofthe electronic module (se Fig. 4. © 0 Compressor off 2) For GA Standard Pack i transiormers provided 20 2820 1360 00Instruction book Industria Ai Division Medas Copco — 4, Fitair outlet valve (AV-Figs 1 and 2). Close the vaive. Connect the ainet to te vave, 5. Fitvalve (Om1-Fig. 1). Close the valve. Connect the valve to a rain colectr.1) 6. Connect the automatic drain outlet (Da-Fig. 1} to drain collector. D) 7. The drain pipes tothe drain collector must not dip ito the water. For draining of pure condensate water, install an ollwater ‘separator (OSD) which is available from Atlas Copco as option ithe pipes have been led down ouside the room where freezing is possible, they must be insuiated 8. Check the oil level. The evel in sight-glass (SG-Fig. 15) should be clearly visible. 9. A sticker dealing in short with the operating instructions and explaining the pictographs is delvered with he iterature set. Ato the sticker next othe control panel. Make yourself familiar with the instructions and pitographs explained, as well as with those mentoned in section 2.5. 10. Check he motor (Mt-Figs 1 and2)forcorrect cretion of rotation An arrow is provided onthe motor cooling air duct Totaciltate tis check, folow the instructions on the sheet attached to the ventilation oullet grating on the roof of the compressor: ‘Switch on the voliage, With the doors ofthe bodywork closed, look at the sheet atte pressing button (8-Fig. 6a) ormoving switch (S'-Fig. 9) to: if the sheet is not blown away, stop the compressor immediately by pressing button (9-Fig. 6a) or ‘moving switch (S1-ig. 8) 100", switch of the votage and reverse ‘wo ofthe votage suppiy ines. Repeat the procedure: the sheet is blown away, the direction of rotation is corect. Remove the sheet 11, On GA Pack /FulHeature, check the programmed settings. 2) 12. Sta and run the compressor fora few minutes. Check thatthe ‘compressor operates normally. 33 Starting For GA Pack/Full-feature Fig. 63) 4. Check the oi level: the level should be cleary visible in sight- glass (SG-Fig. 15) 2. Switch on the voltage. Check that voltage on LED (2) lights up. ‘The message > appears. 3, Clase condensate drain valve (Omt-Fig. 1). ‘Open air outlet valve (AV-Fig, 1) 5. Press start button | (8). The compressor starts running and ‘automatic operation LED (1) lights up. Ten seconds 3) after starting the compressor motor switches over from star to delta At the same time 3) the compressor starts running loaded. The message on display (4) changes from <> to <>. For GA Standard Pack 1. Check the ol lev: the level should be clearly visible in sight- ass (SG-Fig, 15). 2. Switch on the votage. 3. installed, close the condensate drain valve. 4) 4. Open air outlet valve (AV-Fig. 2). 5. Move switch (81-Fig. 9) t0" 3.4 During operation 1. Check he oil evel during loaded operation: the sight-gass (SG- Fig. 15] must be between 1/4 and 3/4 ful For GA Pack/ Full-feature Fig. 6a) 2. If automatic operation LED (1) is alight, the regulator is automaticaly controling the compressor, i. loading, unioading, stopping of the motors and restating 3.4.1. Checking the display (GA Pack / Full-feature only) 5) 1. Regula check he display frreadings andmessages. Normaly the main dispay (Fig. 60) is shown, indicating the compressor cute pressure, he satus othe compressor and he abbrevitons of te functions of the keys below he display. See section 1.4 2. Aways check he cispay (4) and remedy the rouble falar LED {8)is aight orbirks. See section 1.4 ‘3. The display (4) will show a service message if one of the monitored componens iso be serviced; replace the component and reset the relevant mer. Notes: = Whenevera shut-down, shutdown warring, service request, sensor error moto overoacimessageis islayed the ree ‘spaces on the display between the function keys (5) are filled with binking indeators (*) When mare than one message needs o be displayed (09 both waming and sence), tne messages will be displayed one after the other for 3 seconds. 4. Regularly press the key <> (5) 6) to call up information ‘about the actual compressor condition: the status of controling the compressor (automatic or manual, local or remote) + the status ofthe compressor start/stop timer (on or off) 7) + the maximum allowable unloading pressure = the outlet pressure = the compressor element outlet temperature = the dewpoint temperature (on Ful-eature compressors) ~ the status ofthe motor overload protection (normal or not) = the otal running and foading hours 1). Anautomate cain system for GA Standard Pack is avalabe as option. 2) Consultne User manual forthe electronic regulator, sections regarding the submenus ‘Measured data’, “Service, "Modify setings', Timer" ‘and "Programmable settings 3) Prograrmable. See the User manual forthe electronic regulator, section Programmable settings. 4) An automatic condensate drain system is available a option 5) Consult te User manual fo the electronic regulator, sections "Status data submenu’ and Service submens 6) Ifthe > function isnot indicated on the bottom ne of dsplay (4-Fig. 6a), press key <> (6) unt function appears above key (F), then pros the key <

>. 7). The compressors automaticaly started and stopped if these siastop commands ave programmed and activated; consult the User manual for ‘he electronic regulator, section “Timer submenu’ 2320 135000, a— ‘Aidan Copeo Indust ir Diision — Instruction book 3.5 Manual control for GA Pack /Full-feature (Fig. 6a) 1) "Normal, the compressor runsin automat operation i. the electronic regulator loads, unloads, stops and restarts the compressor aulomatically. LED (1) is then aight If required, the compressor can be unloaded manually. In this case, the compressor is switched out of automatic operation, ie. the ‘compressor remains running unloaded unless itis loaded again manual. Manually unloading Pross the key <> (unload) (65). LED (1) goes out. The message -<> appears onthe display. ‘Manually loading Press the key > (6). LED (1) lights up. The command «> does not force the compressor in loaded condition, but i Will switch the compressor to automatic operation again, ie. the ‘compressor willbe loaded i required by the air net pressure Manually startinginumber of motor starts Inautomatic operation, the regulator limits the numberof motor stars. tthe compressor is stopped manually, it must not be restarted within 6 minutes after the last stop. 3.6 Stopping For GA Pack /Full-feature (Fig. 63) 1, Press stop button O (9). LED (1) goes out. The message <> appears. The compressor runs unloaded {or 30 seconds and then stops. 2, To stop the compressor in case of emergency, press button (S3). Alarm LED (3) binks. After remedying the fait, uniock the ‘button by tuning it anticlockwise and press key > (5) before restarting. The message <> appears. Press keys <> and <. 3. Close air outlet valve (AV-Fig. 1) and switch off the voltage, 4. Open condensate drain valve (Omt-Fig, 1). For GA Standard Pack 1. Move switch (S1-Fig. 9) to postion °O" 2. Close air outlet valve (AV-Fig. 2a) and switch off the voltage, 3. If installed, open the condensate drain valve, 2) 3.7 Taking out of operation at end of compressor service life 1. Stop the compressor and close the air outlet valve, 2. Switch off the voltage and disconnect the compressor from the mains. 3. Depressurize the compressor by opening plug (FC-Fig. 16) one tum and opening valve (Omt-Fig. 1). 2) ‘4. Shutoff and depressurize the pat ofthe air net whichis connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net. Drainthe oil (Om2-Fig. 15) and condensate cuits (Omt-Fig. 1) 2) 6. Disconnect the compressor condensate piping (Da/Dm-Fig. 1) from the local condensate dain system. 2) 4 MAINTENANCE Attention Before starting any maintenance: 41. Stop the compressor: = OnGA Siandard Pack, move switch (S1-Fig. 9) to "0" ~ On GA Pack /Fullfeature, press button O (@-Fig. 6a), wait until the compressor has stopped (approx. 80 seconds) and press bution ($3-Fig, 6a). 2. Switch off the voltage. Ifa separate voltage supply is provided forthe dryer of GA Ful-feature (see section 2.4), make sure that te voltage tothe dryer is also switched otf 3. Close air outlet valve (AV-Figs. 1 and2) and depressurize th systom. 4, Apply all relevant safety precautions, including those mentioned in this book ‘The air outlet valve can be locked during maintenance or repair as follows: + Close the vaive. Remove the bol fixing the handle, ~ Lift the handle and turn until the slat of the handle fis over the blocking edge on the valve body. = Lock the handle using the special bolt and wrench delivered loose with the compressor. 4.1 Compressor motor (M1-Figs. 1 and 2) ‘The motor bearings are greased fo it, 41) Ifthe or < (unload) function isnot indicated on the bottom tne of display (4), press key <> (5) until the function < appea's above key (F1), then poss the Key <

> 2) Acondersate drain systemis availabe as opion for GA Standard Pack, 2 2320 185000Instruction book Industrial Ai Division Meda Capoo — 4.2 Preventive maintenance schedule for the compressor 1) Attention, For overhauling or carrying out preventive maintenance, service kts are available. See section 48, Allas Copco offers several types of Service Contracts, relieving you of all preventive maintenance work. For more deta, consult your nearest Atas Copco representative The schedule comprises @ summary of the maintenance instructions, Read the respective section before taking maintenance measures. The “longer interval" checks must also include the "shorter interval" checks. When servicing, repace all disengaged packings, e.g gaskets, O-rings, washers. Period2) Running See ‘See Operation hours 2) section note Daily Before starting ° - 33 ~ ‘heck ol evel During operation : 8 aan - CCheck readings on csplay or gauges : 8 - 113 Check that condensate is cischarged during loading (Da) g 8 34 - Check ci evel ($6) [ter stopping : - 36 13 Drain condensate (Omt) Monthly = - Check condition of belts monthly = 53 - Operate salty valve (SV) o - ~ 9 Carry out a LEDicisplay test (not on GA Standard Pack) : - - 8 ‘Check fr possible leaks 500 52 8 Inspect coolers (Ca/Ca); clean if necessary 0 500 - 117 Remove airfiter element (AF, inspect a - - 1 Clean compressor &monthly ~ - 1 (On GA FulHeature, brush or blow off the finned surlace of condenser Yeary = 53 Have safely valve tested . - Have operation of electrical components tested - - 10 Testtemperature shutdown protection 2000 444s 2/816 If Atlas Copco Rotoinjectiid is used, replace ol fiter (OF) 2 4000 - 13 Remove, ismantie and clean fat valve of moisture trap (MT) p 4000 448s 56 tas Copco Roto inject is used, change of _ 4000 - 6/12 Have ll separator (0S) replaced 000 51 6 Replace ar iter element (AF) 6000 - - Replace bets For 13 bar and 175 psi compressors 500 44145146 216 —__HKollas speced in section 442 is used, change ol ano fiter (OF) For7 ber, 10 ber, 100 psi, 125 psi and 150 psi compressors ‘ 1000 44145146 216 oll as specited in section 4.4.2 is used, change ol and ol fiter (OF) - - 4 Have all fexibes inspected : - 25 - Switch of votage. Check terminas in electric cabinet or tightness 1) Use only authorized parts. Any damage or matfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. 2) Whichever interval comes first. The local Sales Company may overrule the maintenance schedule, especialy the service intervals, depending on the environmental and working conditions ofthe compressor. 2920 195000 23— Aidlas Copco. Industial Ait Division Instruction book — Notes More frequently when operating in a dusty atmosphere. Use an oi fiter as specified inthe Parts list. The part number is marked onthe fir. Special Alas Copco oil for screw compressors keeping the compressor in excelent condition Damaged texibles must be replaced immediately. its strongly recommended to use Atlas Copco Roto:njectuid. Forte change nteval in extreme conditions of temperature, humid or cooing ai, consult Atias Copco, 6. Consult the User manual forthe electronic regulator for reseting the sence timer (not for GA Standard Pack) 7. Replace the fiter i damaged. 8 Any leak shouldbe attended to immediately. 9. 1 Consul the User Manual forthe electronic reguator, section ‘Display test” (nt for GA Standard Pack 0. For GA Pack /Ful- feature: Consul the User Manual forthe electronic reguatr, section "Modi setings submenu, before modifying the temperature protection settings Decrease the shut-down warning evel and shut-down level forthe compressor element outlet temperature othe minimum settings. Run the compressor: when reaching the setting the unit must shut down. Atterwards, reset the waming and shut-down levels to their orginal values. For GA Standard Pack, consult Atlas Copco for testing. 11. Alas Copco has ol separators (OSD) to separate the major part of ol rom condensate to ensure tha the condensate meets the requirements of the environmental codes 12. Install the new separator element with the mark TOP upwards. 18, An automatic condensate drain system is avaliable as option on GA Standard Pack. Tt 4.3 Oil and oil filter change interval Consult section 4.2 for the change intervals and section 4.4 forthe oi specifications. 2 44 Oil specitications 3 Never mix oils of different brands or types. Consult Atlas Copco for the recommended os. Use oni non-toxic ol. \p 4.4.1 Atlas Copco Roto-injectfluid E Itis strongly recommended to use Atlas Copco Roto-njectuid. This FC. is special ol for screw compressors which keeps the compressor in excellent condition, See also section 4.8 os 4.4.2 Mineral oil ‘Although Roto-injectui is recommended, a high-quality mineral oi with oxidation inhibitors and antioam and ant-wear properties can also be used after taking some precautions. The previously used oil shoul first be crained and the system flushed. The oil fier should be Fiore repiaced. The viscosity grade must correspond to the ambient temperature and ISO 3448, as flows: SG Dm2 1 oF rr. drain vate TT11, Temperature sensor, Ambient temperature Viscosity Viscosity Compressor element compressor element outet grade index FC. Oiler plug Vp. Minimum pressure valve OF, Oilfiter 1. Plug 0S. Oilseparator 2 Bush Consistently above 25°C (77°F) 1SOVG 68 Minimum 95 SG. Cillevalsight-glass 3. Nut Between 25°C (77°F) and 0°C (32°F). ISO VG 48 Minimum 95 Fig. 15. Oi system components 24 220 198000Instruction book Industrial Air Division Addas Copeo — 4.5 Oil change (Fig. 15) 1. Run the compressor until warm, ‘Stop it and close valve (AV- Figs. 1 and 2). Waita few minutes. Depressutize the ol system by opening oi filer plug (FC) one tur to permit any pressure to escape. 2. Remove plug (1). Drain the oi by opening valve (Om2}. Ciose the valve and reinstall the plug. Collect the ol ina collector and deliver ito the local ol collection serves. 3. Remove filer pug (FC) and pour 5 | of oil into the compressor element. Reinstall and tighten plug (FC). Open valve (AV-Figs. 2).2) 4. Reset the ol service warning. 1) 46 Oil filter change (Fig. 15) 1. Stop the compressor and close valve (AV-Figs. 1 and 2), Depressurize by unscrewing oi filer plug (FC) one turn to permit, ‘any pressure in the system to escape, 2. Remove oilfiter (OF). 3. Ciean the fier seat on the manifold. Oil the gasket of the new element. Sorew the element ino place and tighten firmly by hand. Check thatthe oil evel is clearly visible. ‘Tighten plug (FC) and open valve (AV-Figs. 1 and 2), 6, Reset the ol iter service warning. 1) 4.7 Storage after installation FRun the compressor twice a week until warm. Load and unioad the Compressor afew times. tthe compressors stored without running from tme to time, protective measures must be taken. Consutt Atas Copco. 4.8 Service kits ‘Service kits are available ofering the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. The kis comprise allparts needed for servicing. Consul the Parts ist forall service kis. 5 ADJUSTMENTS AND SERVICING PROCEDURES 5.1 Airfilter (AF-Fig. 1) 1. Stop the compressor. Remove the ar fiter element, Discard damaged elements 2, Fitthe new element 3. Reset the airfiter service warning, 1) 5.2 Coolers (ColCa- ig. 1) Keep the coolers clean to mainain the cooing efciency Remove any dt from the coolers wth a fibre brush, Never use a wire brush or metal objects. Then clean by air jet in reverse direction of rormal flow. ft should be necessary to wash the coolers with a cleansing agent, consult Alas Copco. 5.3 Safety valve (SV-Fig. 2b) (Operate the safety valve by unscrewing the cap one or two turns and retightening it or by pling the vale iting lever. Testing The valve can be tested on a separate compressed air ine. If the valve does not open atthe pressure marked on the valve, consult ‘tas Copco, Warning No adjustments are alowed. Never run the compressor without safety valve 5.4 Belt set exchange ‘The belts must be replaced as a set, even if only one of them seems worn. Use Atlas Copco belts ony. 1. Loosen clip (3-Fig. 1) and retract hose (4-Fig. 1) from the fan housing 2. Unscrew nut (3-Figs. 15/16) to fully loosen the spring force on Service kit for ol fie, Ordering number aa il separator and ir fiter ane 3. Take the bets out ofthe pulley grooves. The belts can be pulled over the fan housing without disconnecting the later. GAS-GA7-GAI0 201 0099 02 4: Install new bes. 1) Consut ne User manual forthe electronic regulator, section “Service Roto-injectuid submenu" (ot for GA Standard Pack Atlas Copco Roto-njectuid (see section 4.4.1) can be ordered in following quantities: 2) ‘Ifthe filer pug (F) is fited on a Teo betwoen the compressor element and sight-lass: = Remove plug (FC) and fil with il unt the level reaches the pug Quantity Ordering number ‘Tighten pug (FC). Open vaive (AV) ‘Siitrecan 2901 0086 01 ~ Rum the compressor for a few minutes. Stop it and close valve 25rlire can 201 0001 01 (AV). Open plug (FC) one tum to permit any pressure to escape. Fil with oi uni the levels inthe mide of sight-gass (SG). Tighten lug (FC), Open va (AV) 2820 1380 00 5— Sltlas Copco industial Ait Division Instruction book —. Hl qipb-—_1 F at ‘ A aikae—* lle Ls Va —s | _| Nut Bush Nut Motor plate ‘Spacer Fig. 16. Bel tensioning equipment 5. Screw on nut (3-Figs. 15/16) unl the spacer (6-Fig. 16) above the nuttouches bush 2-Fgs. 15/16). Make sure thatthe threaded rod remains perpendicular to the motor bottom plate. The bet tension is now correc. 6. Tighten nut (1-Fig. 16) to block the motor bottom plate (4-Fig 16) 7. Refit hose (4-Fig. 1) 5.5 Regulating devices on GA Full-eature (Fig. 3) ‘The fan control switch ($3) stops and starts the condenser fan to keep the condenser pressure as constant as possible. The hot gas by- pass valve (10) opens and hot, high-pressure gas is fed to the ‘evaporator in case the evaporator pressure should drop below a given value during partial or no load. Both the switch and the valve are factory-adjusted to obtain optimum performance ofthe dryer. Do not alter the factory aojustments, 5.6 Load/unload pressure switch on GA Standard Pack The switch allows the operator fo select the unloading pressure and the pressure ciference between the unloading and loading pressures, The unloading and loading pressures are the opening and closing pressures ofthe ar pressure switch, ‘Adjustment can only be carried out when the air pressure switch is pressurized. Remove blocking device (1-Fig. 17) before adjusting knob (2) ‘The unloading pressure is controled by adjusting knob 2). Turn the kx0b clockwise to raise the unloading pressure, ani-cockwise flower it ‘The pressure difference between unioading and loading is aojusted by means ofthe same knob. The adjustment range is given in Figs. 18, Push down the knob and turn it clockwise to reduce the pressure difference, anticlockwise to increase it Blocking device (10 be removed before turing knob 2) Adjusting knob Switch Spring housing Fig. 17. Air pressure switch (PSR19) 6 2820 135000,Instruction book Industrial Air Division Atlas Copco 6 4 =u ¥ ¥ 22 5 g g g 0 A 2 26 3 S 8 g é E sLk 545676900 2 LOADING PRESSURE —br(e) (2) Fig. 18a, Switch MDR 53/11 Example (see Fig, 18a): = unloading pressure(e): 8 bar eC aU twas UMLOKDNG PRESSURE —bar(o) (2) Fig. 180. Switch MDR 53/16 + loading pressure(e): adjustable between 5 bar and 7.6 bar Figs, 18. Pressure difference adjustment ranges 5.7 Temperature shut-down switch on GA Standard Pack Switch (TSHH11-Fg. 9) has an adjusting screw in the centre atthe back ofthe housing ofthe swith, ‘The reset screw is located inthe centre of the indicator scale and is protected by acap. To eset the switch ater tripping, unscrew the cap and tun the reset screw with a screw driver anti-clockwise, 6 PROBLEM SOLVING Attention, Betore stating any maintenance: ‘Stop the compressor: (On GA Standard Pack, move switch (S1-Fig. 9) 0 “O°. (On GA Pack / Ful-feature, press button 0 (9-Fig. 6a), wait Luni the compressor has stopped (approx. 30 seconds) and ‘press button (S3-Fig. 6a). ~ Switch off the voltage, Ita separate vottage suppl is provided for the dryer of GA Full-feature (see section 2.4), make sure thatthe vottage tothe dryer s also switched off = Giose the air outlet valve and depressurize the air system. ‘The outlet valve can be locked in closed positon. See section 4 = Apply all relevant safety precautions, including those mentioned inthis book. ‘The chart helps to solve mecranical problems. An electrical faut ‘must be traced by an electrician. Check that the wires are not ‘damaged and that they are clamped tight to thei terminals. 2320 1350 00| 7— Aithas Copco. Industrial ir Division — Instruction book For GA Pack/ Fullfeature also: = Tofaxiltate solving some problems, a number of messages may ‘appear on the contro! panel. Examples: Action Switch off the voltage. Check the terminals on connector (2X1) and emergency stop button ($3) for correct connection. Message System failure 10 or 106 System failure 11 Switch off the voltage. Check for Possible connection with the ground of one ofthe digital inputs at connector (2x4), System failure 104 Switch ofthe voltage. Check that the contacts to the digital inputs at the connectors of the module are votage- free, Connector (2X5) must only be used for connecting the Atlas Copco Relay expansion box (optional) which allows indication of manual automatic operation, waming condition or shut-down condition, = Consul the User manual for the electronic reguiator ita service ‘message or fault message appears on the display (4-Fig. 6a) or when alarm LED (3-Fig, 6a) is alight or bins. Mechanical faults and suggested remedies (Fig, 3) 1. Compressor starts running, but does not load after a delay time a. Solenoid vave (1) out of oder Have valve inspected Inlet vave (1) stuckin closed poston Consult las Copco Leak in contol air tlexibles Have leak repaired Minimum pressure valve (Vp) leaking (when net is ‘opressurized) 4. Consult Atlas Copco 2. Compressor does not unioad, safety valve blows 2. Solenoid valve (Y1) out of order a See ta . Inlet valve (V) does not close b. See tb 3. Condensate is not discharged from moisture trap 1) during loading a, Discharge flexible clogged ‘a, Check and correct as necessary ». Float valve matfunctioning ». Consult tas Copco 4, Compressor air output or pressure below normal 2. ‘Air consumption exceeds air ouput of compressor Check equipment connected . Choked airinet fier element (AF) 5. Replace fier element Solenoid valve (Y1) malfunctioning See 1a Leak in controlar flexiles See 16 Inlet vave (V) does not fully open See 1b il separator element (0S) clogged Have element replaced. Consult Atlas Copco Air leakage Check and correct as necessary Satety valve (SV) leaking Have valve replaced. Consul Atlas Copco ‘Compressor element (E) out of order Consult Atlas Copco Excessive oil consumption; ol carry-over through discharge tine i level (SB) 100 high ‘a. Checkforovertling. Release pressure and drain oto corect level Incorrect oi causing foam Change to correct oil Oi separator element (0S) detective Have element checked. Replace, if necessary. Install the element with the mark TOP at the top and the seam atthe bottom Safety vaive (SV) blows after loading Init valve (IV) malfunctioning See 1b Minimum pressure valve (Vp) malfunctioning See id il separator element (0S) clogged See 4i Safety valve (SV) out of order See 4h For Ful-leature: dryer pipes clogged by formation of ice Have refrigerant system checked, Consult Atlas Copco Element outlet 2) or air outlet temperature above normal ‘Insufficient cooing air or coating air temperature too high {Check for cooling air restriction or improve ventilation of compressor room. Avoid recirculation of cooling air. If installed, check capacity of compressor room fan Oil evel too ow (SG) Check and correct as necessary il cooler (Co) clogged Clean cooler By-pass valve (BV) malfunctioning Have valve replaced Air eooier (Ca) clogged Clean cooler Compressor element (E) out of order See 4i ‘Available as an option on GA Standard Pac. ‘A warning message will appear on display (Fig. a) (not for GA Standard Pack 8 2820 195000Instruction book Industrial Air Division Atlas Copco — 7 PRINCIPAL DATA 7.3 Fan control switch on GA Full-feature Cutout ‘Switeh-on Unit 7.1 Readings pressure pressure 7.1.1 Readings on display on GA Pack/Fullfeature — Fancontrolswitc (50 Hz) .. 7.9 9 bare) 4-Fig. 6a) 1 (+Fig. 6a) 1) Fan control switch (60 Hz) .. 9.9 " bar(e) Air outlet pressure Reading: Modulates between programmed unloading and loading prossures. ‘Shown: — On main display (Fig. 6b), when: ‘ficatic on nihing onveye 7.4 Compressor specifications selecting main cisplay with Keys > and ‘<

> (5-Fig. 6a) . - _ keys of module are not used for four minutes 7.4.1 Reference conditions Sensor PT20 Nominal working pressure as stated below Ret: Compressor element outlet temperature Arinlet pressure (absoute) bart Reading: Approx. 60°C above cooling air temperature Air inlet temperature °c 20 Shown: When using the key > (S-Fig. 62) on the main Relate hurt, % 0 display (Fig, 66) Sensor TT 7.4.2 Limitations On Fullfeatue also: Maximum working pressure as slated below Ref Dewpoint temperature Minimum working pressure barle) 4 Reading: Approx. 3°C Maximum inlet temperature 2)............ 40 ‘Shown: — When using the key <> (5-Fig. 6a) on the main ‘Minimum ambient temperature *c 0 display (Fig. 6b) Sensor: 790 7.1.2. Readings on gauges on GA Standard Pack (Fig. 9) Ret: Air outlet pressure (Gp) Reading: Modulates between preset unloading and loading pressures Ret.: Compressor element outlet temperature (TSHH11) Reading: For GASI7 approx. 60°C above cooling air temperature For GA10 approx. 65°C above cooling air temperature Setting: 110°C 72 Setting of safety valve The part number and sot pressure are stamped on the valve. Also consult the Pars lst. Ifthe valve is malfunctioning, replace itby one with the same number. No adjustments are allowed. 41). See User manual for electronic regulator, sections “Modty settings submenu" and “More functon', 2) Pack and Standard Pack compressors are also avaiable as High ambient version (HAV) designed for operation in ambient temperatures upto 50°C. 220 1950 00| 29— Aldlas Copeo Industrial Ai Division —_ Instruction book 7.4.3 Specifications of GAS 1) Compressor ype GA575 GAS GAS-10 GAS-19GAS-100 GA5-125 GAS-150 GAS.175 Frequency Ce ee ee Moor stat speed ‘min 2655 2855 2855 2855 «34758478475 TB Oi capacty 6 5 § § 5 5 5 §& GA Pack and GA Standard Pack Maximum (unloading) pressure bare) 7.5 8 10 13, 14 94 10.8 12.5 Nominal working pressure ba) 7 8 95 125 69 86 103 12 ‘Temperature of air at outlet valve °c 32 2 2 2 xB 3 3B xB Power input kW ud 72 72 72 70 72 72 72 ‘Sound pressure level (Pack) 2). dB(A) 68 68 68 68 69 69 69 69 ‘Sound pressure level (Standard Pack) 2) dB(A) 70 70 70 70 1 n n n GAFullesture Maximum (unloading) pressure bare) 7.25 75 975 12.75 7.15 8.85 1055 = 12.25 Nominal working pressure vba) 7 775 95 128 69 86 103 1 Temperature of rat outet vai 2% 2H Power input 7 78 770-7778 787878 ‘Sound pressure level 2) oB(A) 68 68 6B 68 69 69 69 69 Dryer type 01818818 DIB O18 =e OT Retrgerant type Rita RIGe RI4e AIM AIM RIM SMa RIE Retrgerant charge fg 025025025025 02502505025 7.4.4 Specifications of GA7 1) Compressor type GA7-75 GAT-8 GAT-10 GA7-13 GA7-100 GA7-125 GA7-150 GA7-175 Frequency ee ee ee) Motor shat speed rimin 2685 2885 «288528853505 95053505 3505 Oi capacity 6 6 § § 5 5 5 § GA Pack and GA Standard Pack ‘Maximum (unloading) pressure bare) 7.5 8 10 13 74 ot 10.8 125 Nominal working pressure bare) 7 8 «= 85 B BS BHC Temperature ofairatouletvane...... C2 HHH Power input w 98 96 98 98 987 98 98 98 Sound pressure level Pack) 2) a) 7 7 MOTH Sound pressure level (Standard Pack)2) BIA) 71 71h OO GAFull-feature Maximum (unloading) pressure bare) 725 775 «9751278 «7158851051225 Nominal working pressure. ba) 7 7759525 «BSH Temperature ofairatoutetvave...... °C 25 HBB BB Power input kW 103-98 103103103 tod td 104 Sound pressure level2) aa) 70 701TH rye ype Die 18 1B IBIBO DI Refrigerant type 7 Ri34a-R134a_R1S4a_AYS4aR1B4aA1S4aAISda AISA Refrigerant charge ko 025025025 025050250885 1) Atttorence coniions 2} Ascrdng to CAGI PNEUAOP PNANTC22 % 2920195000Instruction book Industrial Air Division tlas Capoo — 7.45 Specifications of GA10 1) Compressor type GAIO75 GAI0-8 GAI0-10 GA10-13 GA10-100 GAt0-125 GA10-150 GA10-175 Frequency Hz 50 so 50 50 60 6 = 60 80 Motor shatt speed rimin 2865 288528852885 «3490» 349034908400 Oil capacity 18 5 5 5 5 5 5 5 GA Pack and GA Standard Pack Maximum (unloading) pressure... bar(e) 75 8 10 13 74 91 108125 Nominal working pressure bare) 7 8 95 «1259 Temperature ofairatoutet vane. °C 92 32 2 2 5 3% 9585 Power input (Pack) kW 116 0 14115112 Powerinput (Standard Pack) ..... KN 131 126 128—=S«« 20st 1821308 ‘Sound pressure level Pack) 2).... dB(A) 72 m n n 7m n 2 n ‘Sound pressure level (Standard Pack) 2) BIA) 72 nm nm n 3 a 7 7B GAFul-feature Maximum (unloading) pressure... bare) 725 7.75 «9751275715 BBS 1055.12.25 Nominal working pressure bare) 7 TH 95) = 125 69s BHD Temperature ofairatoulletvave.. °C 25255 % 2B 2% BB Power input kw 1200-118 = 19120291811 ‘Sound pressure level 2) BA) 7227 nm 7 7m Rm 72 Dryer type rr Refrigerant type Riga R134a RIG RIGa | RIGMa | RISMaRAaIGHa Refrigerant charge hg 0.25025 025025025 0.250825 7.5 Conversion list of SI units into US/British units 14504 psi (095 oz 205 Ib 11min = 0.624 milan 41 KW =1.341 hp (UKand US) 11= 0.264 US gal 11= 0.220 Imp gal (UK) 11= 0.035 eutt 281 tt 225 lot 1mm = 0.039 in 11Nm = 0.738 tt 1 mifmin = 36.315 cfm XC = (32 +1.8x) °F +1 mbar = 0.401 in we. ANT°C=A11.8°F 41) Atreterence conditions. 2), According to CAG! PNEUROP PNENTC2.2, 2820 1960 00 3t— Atlas Copco. industrial Ar Division Instruction book — Notes: 2 2320 135000