Atlas Copco Stationary Air Compressors

GA5 - GA7 - GA11C

Instruction book

Important 1. This book applies exclusively to GA5 - GA7 - GA11C from following serial number onwards: AII-130 000 2. This book must be used together with the "User manual for Elektronikon regulator for GA5 up to GA90C"

Copyright 2000, Atlas Copco Airpower n.v., Antwerp, Belgium. 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. This instruction book meets the requirements for instructions specified by the machinery directive 98/37/EC and is valid for CE as well as non-CE labelled machines.

No. 2920 1424 00 Registration code: APC G5-11C/2000 / 38 / 991 2000-09

www.atlascopco.com

*2920142400*

Instruction book

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life. Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the beginning. The maintenance schedule comprises measures for keeping the machine in good condition. 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 all operating data, maintenance performed, etc. in an operator's logbook available 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 Atlas Copco who can be contacted for any further information. In all correspondence always mention the type and the serial number, shown on the data plate. For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data". The company reserves the right to make changes without prior notice.

Contents
Page 1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.1 General description . . . . . . . . . . . . . . . . . . . . . . . 3 1.1.1 Compressor variants . . . . . . . . . . . . . . . . 3 1.1.2 Main options - special versions . . . . . . . . 5 1.1.3 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1.4 Oil system . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1.5 Cooling and condensate drain systems . . 5 1.2 Unloading/loading system . . . . . . . . . . . . . . . . . 5 1.2.1 Unloading . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2.2 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.3 Elektronikon regulator for GA Pack/ Full-feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3.1 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3.2 Control panel . . . . . . . . . . . . . . . . . . . . . 10 1.3.3 Function keys . . . . . . . . . . . . . . . . . . . . . 12 1.3.4 Menu-driven control programs . . . . . . . 12 1.4 Regulator for GA Standard Pack . . . . . . . . . . . 13 1.4.1 Regulator . . . . . . . . . . . . . . . . . . . . . . . . 13 1.4.2 Control panel . . . . . . . . . . . . . . . . . . . . . 16 1.5 Air dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.5.1 Compressed air circuit . . . . . . . . . . . . . . 16 1.5.2 Refrigerant circuit . . . . . . . . . . . . . . . . . 16 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . 2.2 Installation proposals . . . . . . . . . . . . . . . . . . . . 2.3 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . 2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . 2.5 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . 3.1 Before initial start-up . . . . . . . . . . . . . . . . . . . . 3.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 User manual . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Outdoor/altitude operation . . . . . . . . . . 3.1.4 External compressor status indication for GA Pack/Full-feature . . . . . . . . . . . . 3.1.5 Remote control for GA Pack/ Full-feature . . . . . . . . . . . . . . . . . . . . . . 3.1.6 Remote pressure sensing for GA Pack/Full-feature . . . . . . . . . . . . . . 3.2 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 For GA Pack/Full-feature . . . . . . . . . . . . . . . . . 3.4.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 During operation . . . . . . . . . . . . . . . . . . 3.4.3 Checking the display . . . . . . . . . . . . . . . 3.4.4 Manual control . . . . . . . . . . . . . . . . . . . 3.4.5 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 For GA Standard Pack . . . . . . . . . . . . . . . . . . . 3.5.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . 2 17 17 18 21 23 23 24 24 24 24 24 24 24 24 24 25 25 25 25 25 26 26 26 26 Page 3.5.2 During operation . . . . . . . . . . . . . . . . . . 26 3.5.3 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.6 Taking out of operation at end of compressor service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Preventive maintenance schedule for the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Oil specifications . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Atlas Copco Roto-injectfluid . . . . . . . . 4.3.2 Mineral oil . . . . . . . . . . . . . . . . . . . . . . . 4.4 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . 4.6 Storage after installation . . . . . . . . . . . . . . . . . . 4.7 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjustments and servicing procedures . . . . . . . . . 5.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Safety devices of dryer on GA Full-feature/ Standard Pack with dryer . . . . . . . . . . . . . . . . . 5.5 Load/unload pressure switch on GA Standard Pack . . . . . . . . . . . . . . . . . . . . . . 5.6 Temperature shut-down switch on GA Standard Pack . . . . . . . . . . . . . . . . . . . . . . 5.7 Belt set exchange . . . . . . . . . . . . . . . . . . . . . . . 27 27 28 29 29 29 29 29 30 30 31 31 31 31 31 31 32 32

6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Readings on display or gauges . . . . . . . . . . . . . 7.2 Settings of overload relay and fuses . . . . . . . . . 7.3 Settings of fan control switch (GA Full-feature/Standard Pack with dryer) . . 7.4 Compressor specifications . . . . . . . . . . . . . . . . 7.4.1 Reference conditions . . . . . . . . . . . . . . . 7.4.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . 7.4.3 GA5 Pack/Standard Pack . . . . . . . . . . . 7.4.4 GA5 Full-feature/Standard Pack with dryer . . . . . . . . . . . . . . . . . . . . . . . . 7.4.5 GA7 Pack/Standard Pack . . . . . . . . . . . 7.4.6 GA7 Full-feature/Standard Pack with dryer . . . . . . . . . . . . . . . . . . . . . . . . 7.4.7 GA11C Pack/Standard Pack . . . . . . . . . 7.4.8 GA11C Full-feature/Standard Pack with dryer . . . . . . . . . . . . . . . . . . . 7.5 Air receiver data . . . . . . . . . . . . . . . . . . . . . . . . 7.6 Conversion list of SI units into US/ British units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 35 35 36 36 36 36 36 37 37 38 38 39 39 39

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1 Leading particulars
1.1 General description
GA are stationary, single-stage, oil-injected screw compressors driven by an electric motor. The compressors are air-cooled. 1.1.1 Compressor variants GA Standard Pack GA Standard Pack are enclosed in a sound-insulated bodywork. The control panel is fitted to the door at the front side. It includes the start button and the stop/emergency stop button. The relay-controlled regulator and the motor starter are located in an electric cabinet behind the door.

GA Standard Pack with integrated dryer (Fig. 1.1) These GA Standard Pack compressors are 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 automatically draining the condensate. See section 1.5. The compressors are provided with an automatic condensate drain system. GA Pack (Fig. 1.2) GA Pack are enclosed in a sound-insulated bodywork. The compressors are controlled by the Atlas Copco Elektronikon regulator. This electronic control module (E1) is fitted to the door of the front panel. The Elektronikon regulator reduces the power consumption and it allows the operator to easily program and monitor the compressor. The control panel includes the start, stop and emergency stop buttons.

E1 2

AV

AV

1 1 Dm Da Dm Da
51014F

51062F

AV Da Dm 1 2

Air outlet valve Automatic condensate drain outlet Manual condensate drain valve Service panel Control panel, GA Standard Pack

AV Da Dm E1 1

Air outlet valve Automatic condensate drain outlet Manual condensate drain valve Elektronikon regulator, GA Pack/Full-feature Service panel

Fig. 1.1 GA7 Standard Pack with integrated dryer

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Fig. 1.2 GA5 Pack 3

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An electric cabinet comprising the motor starter is located behind this panel. The compressors are provided with an automatic condensate drain system.

GA Full-feature (Figs. 1.3 and 1.4) GA Full-feature are GA Pack compressors, 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 automatically draining the condensate. See section 1.5.

E1

AV

AV

UA E 1 1 Dm Da FN M1 Dm Da

51005F 51015F

Fig. 1.3 Front view GA11C Full-feature AV Da Dm E E1 FN M1 UA 1 2 3

Fig. 1.4 Rear view GA11C Full-feature

Air outlet valve Automatic condensate drain outlet Manual condensate drain valve Compressor element Elektronikon regulator, GA Pack/Full-feature Fan, coolers Drive motor Unloader Service panel Data plate Vibration damper

Figs. 1.3 and 1.4 GA11C Full-feature 4

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1.1.2 Main options - special versions Fullfeature Pack Standard Pack

passed. At approx. 80 degrees celsius for GA5-7 or approx. 55 degrees celsius for GA11C, all oil flows through the oil cooler. 1.1.5 Cooling and condensate drain systems (Figs. 1.5 and 1.6)

Integrated oil/water separator (OSD) . . . . . . . . . . High ambient version (up to 50 degrees celsius) . . . . . . . . Lifting device . . . . . . . . . . . . Bodywork heating . . . . . . . . Rain protection . . . . . . . . . . . Heavy-duty filter . . . . . . . . . Modulating control regulator 2) . . . . . . . . . . . . . . Integrated condensate separator (WSD) . . . . . . . . . . Integrated dryer . . . . . . . . . . Main power isolating switch . . . . . . . . . . . . . . . . . . Electronic drain . . . . . . . . . . Dryer by-pass . . . . . . . . . . . . Relay expansion box . . . . . . Unit on air receiver . . . . . . . . Tropical thermostat (75-90 degrees celsius) . . . . .

0 NA 0 0 0 0 0 S S 0 0 0 0 0 0

0 0 0 0 0 0 0 S 0 0 0 NA 0 0 0

1) 0 0 0 0 0 0 0 NA 0 0 NA NA 0 0

The cooling system comprises air cooler (Ca) and oil cooler (Co). The cooling air is generated by fan (FN). A condensate trap (MT) is provided in the air outlet system 3). The trap is equipped with a valve for automatic condensate draining during operation (Da-Figs. 1.1 up to 1.4) and a manually operated valve for draining after stopping the compressor (Dm-Figs. 1.1 up to 1.4).

1.2 Unloading/loading system

1.2.1 Unloading (Fig. 1.6) If the air consumption is less than the air output of the compressor, the net pressure increases. When the net pressure reaches the unloading pressure, solenoid valve (Y1) is deenergized. The plunger of the valve returns by spring force: 1. The control pressure present in the chambers of loading plunger (LP) and unloading valve (UV) is vented to atmosphere via solenoid valve (Y1). 2. Loading plunger (LP) moves upwards and causes inlet valve (IV) to close the air inlet opening. 3. Unloading valve (UV) is opened by receiver pressure. The pressure from air receiver (AR) is released towards unloader (UA). 4. The pressure is stabilized at a low value. A small amount of air is kept drawn in through valve (BV1) and is blown to the unloader. Air output is stopped (0 %), the compressor runs unloaded.

0 = optional S = standard NA = not available

1.1.3 Air flow (Figs. 1.5 and 1.6) Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. Compressed air and oil flow into air receiver/oil separator (AR). The air is discharged through outlet valve (AV) via minimum pressure valve (Vp), air cooler (Ca) and condensate trap (MT).

1.1.4 Oil system (Figs. 1.5 and 1.6) In air receiver/oil separator (AR), most of the oil is removed from the air/oil mixture centrifugally. The balance is removed by oil separator element (OS). The oil collects in the lower part of air receiver/oil separator (AR), which serves as oil tank. The oil system is provided with a by-pass valve (BV). When the oil temperature is below 65 degrees celsius for GA5-7 or below 40 degrees celsius for GA11C, there is no oil flow to the oil cooler (Co). Air pressure forces the oil from air receiver/ oil separator (AR) through oil filter (OF) to compressor element (E) and the lubrication points. Oil cooler (Co) is by2920 1424 00

1.2.2 Loading (Fig. 1.5) When the net pressure decreases to the loading pressure, solenoid valve (Y1) is energized. The plunger of solenoid valve (Y1) moves against spring force: 1. Control pressure is fed from air receiver (AR) via solenoid valve (Y1) to loading plunger (LP) and unloading valve (UV). 2. Unloading valve (UV) closes the air blow-off opening. Loading plunger (LP) moves downwards and causes inlet valve (IV) to open fully. Air output is resumed (100 %), the compressor runs loaded.

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Fig. 1.5 GA Full-feature during loading

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Fig. 1.6 GA Pack during unloading AF AR AV BV BV1 CV Ca Co Da Dm DP E E1 FC FN Air filter Air receiver/oil separator Air outlet valve Oil cooler by-pass valve By-pass valve Check valve Air cooler Oil cooler Automatic condensate drain outlet Manual condensate drain valve Oil drain plug Compressor element Elektronikon regulator Oil filler plug Fan, coolers Gl IV LP MT M1 OF OS PT20 SV TT11 UA UV Vp Y1 1 Oil level gauge Inlet valve Loading plunger Air cooler moisture trap Drive motor Oil filter Oil separator element Pressure sensor, air outlet Safety valve Temperature sensor, compressor element outlet Unloader Unloading valve Minimum pressure valve Loading solenoid valve Flexible, oil scavenge 2 3 Flexible, blow-off air or control air Belts

On Full-feature also: M2 Refrigerant compressor M3 Motor, condenser fan S3 Condenser fan control switch TT90 Temperature sensor, dewpoint 5 Air/air heat exchanger 6 Filter 7 Capillary tube 8 Fan, condenser 9 Condenser 10 Hot gas by-pass valve 11 Air/refrigerant heat exchanger (evaporator)

Figs. 1.5 and 1.6 Air-oil and unloading-loading systems

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K11 T2 1X1

1.3 Elektronikon regulator for GA Pack/ Full-feature

The control system consists of an electronic regulator and a control panel. 1.3.1 Regulator (E1-Figs. 1.2 and 1.3) Automatic control of the compressor The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor. A number of programmable settings, e.g. the unloading and loading pressures, the minimum stop time and the maximum number of motor starts are taken into account. The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases. In case the expected stopping period is too short, the compressor is kept running to prevent too-short standstill periods. Warning A number of time-based automatic start/stop commands may be programmed. 5) Take into account that a start command will be executed (if programmed and activated), even after manually stopping the compressor.

T1

F4/5/6

F2 F1 K22 K23 F21

51008F

K21

F1/F6 F21 K11 Fig. 1.7

Fuses Overload relay, drive motor Auxiliary contactor for dryer 4)

K21 K22 K23 T1/T2 1X1

Line contactor Star contactor Delta contactor Transformers Terminal strip

Electric cabinet, GA Pack/Full-feature (typical example)

SENSORS/SOLENOID VALVES/ ELECTRONIC DRAIN B1 Electronically-controlled condensate drain 6) PT20 Pressure sensor, air outlet TT11 Temperature sensor, compressor element outlet TT90 Temperature sensor, dewpoint 4) Y1 Loading solenoid valve MOTORS M1 Drive motor

ELECTRIC CABINET F1/F8 Fuses F21 Overload relay, drive motor K11 Auxiliary contactor for dryer 4) K21 Line contactor K22 Star contactor K23 Delta contactor T1/T3 Transformers 1X1 Terminal strip CONTROL MODULE (E1) I Start button

K01 K02 K03 K04 K05 K10 O S3

Blocking relay Auxiliary relay, star contactor Auxiliary relay, delta contactor Auxiliary relay, loading/ unloading Auxiliary relay, high/low air pressure Auxiliary relay, dryer Stop button Emergency stop button

DRYER ON FULL-FEATURE (A1)

Fig. 1.8 Electrical diagram, GA Pack/Full-feature 50 Hz with star-delta starter 8

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Protecting the compressor Shut-down If the compressor element outlet temperature exceeds the programmed shut-down level, the compressor will be stopped. This will be indicated on display (4-Fig. 1.10). The compressor will also be stopped in case of overload of drive motor (M1). Shut-down warning If the compressor element outlet temperature exceeds a programmed value below the shut-down level, this will also be indicated to warn the operator before the shut-down level is reached. Service warning The regulator continuously monitors the oil, oil filter, oil separator and air filter. Each input is compared to programmed limits. If these limits are exceeded, a message will appear on display (4-Fig. 1.10) to warn the operator to 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 Atlas Copco. Warning If activated and provided the module 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. The power recovery time (the period within which the voltage must be restored to have an automatic restart) can be set between 1 and 254 seconds or to symbol 00!. If the power recovery time is set to 00!, the compressor will always restart after a voltage failure, no matter how long it takes to restore the voltage.

1.3.2 Control panel (Fig. 1.10) Ref Designation Function

Automatic operation LED

Indicates that the regulator is automatically controlling the compressor: the compressor is loaded, unloaded, stopped and restarted depending on the air consumption and the limitations programmed in the regulator. Indicates that the voltage is switched on.

Voltage on LED

General alarm LED Is normally out. Is alight if a warning or shut-down warning condition exists (see section 1.3.1) or if a sensor is out of order. General alarm LED Is normally out. Blinks if a shutdown condition exists (see section 1.3.1), if a sensor with shut-down function is out of order or after an emergency stop. Display Indicates the name of the sensor of which the actual reading is displayed. Indicates the unit and actual reading.

F0 M1 M2 S3

Fuses (customer's installation) Refrigerant compressor Motor, condenser fan Condenser fan control switch

Fig. 1.9 Electrical diagram, dryer on GA Full-feature 10

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Ref

Designation

Function

11 4

6 8

Display

Indicates messages concerning the compressor operating condition, a sensor error, a service need or a fault. Keys to control and program the compressor. See section 1.3.3. As long as an arrow is shown on the right side of the display, the key with the same symbol can be used to scroll through the display. Key to go to the next field of the display. Push button to start the compressor. LED (1) lights up indicating that the regulator is operative (in automatic operation). The LED goes out after unloading the compressor manually. Push button to stop the compressor. LED (1) goes out. The compressor will stop after running in unloaded condition for 30 seconds. Push button to stop the compressor immediately in case of emergency. Must be unlocked before starting by pulling it out.

10 3 12

7 9 5

Function keys

Scroll keys

Tabulator key

Start button

50418F

S3

Stop button

S3

Emergency stop button

S3 1 2 3 4 5 6 7 8 9 10 11 12

Emergency stop button LED, automatic operation LED, voltage on LED, general alarm Display Function keys Scroll keys Tabulator key Start button Stop button Pictograph, automatic operation Pictograph, voltage on Pictograph, alarm

Fig. 1.10 Control panel, GA Pack/Full-feature

Delivery air bar Auto loaded Menu F1

7.0 More F2 Unld F3

Status data Main F1 Slct F2 F3

Fig. 1.11 Example of the main display

Fig. 1.12 Example of a main menu

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1.3.3 Function keys (5-Fig. 1.10) The keys are used: - To manually load/unload the compressor - To call up or to program settings - To reset a motor overload, shut-down or service message, or an emergency stop - To have access to all data collected by the regulator The functions of the keys vary depending on the displayed menu. The actual function is abbreviated and indicated on the bottom line of the display just above the relevant key. The most common abbreviations are listed below.

Abbreviation

Designation

Function

Slct

Select

To select a submenu or to read more details of a selection shown on the display To unload the compressor manually

Unld

Unload

Abbreviation

Designation

Function

1.3.4 Menu-driven control programs To facilitate programming and controlling the compressor, menu-driven programs are implemented in the electronic module. The User manual for Elektronikon regulator for GA5 up to GA90C deals elaborately with all regulator functions.

Add

Add

To add compressor start/stop commands (day/hour) To cancel a programmed setting when programming parameters To delete compressor start/stop commands To show limits for a programmable setting To list programmed start/stop commands (day/hour)

Canc

Cancel

Del

Delete

Program/ Function

Description

Lim

Limits

MAIN DISPLAY

List

List

Shows in short the operation status of the compressor. It is the gateway to all functions. See Fig. 1.11. Allows a quick look at the actual status of the compressor. See section 3.4. To manually load/unload the compressor See Fig. 1.12. It is the gateway to following menus: Calling up the status of the compressor protection functions (service warning, shut-down and shut-down warning). Resetting of a shut-down and motor overload. See section 1.3.1. Calling up actually measured values and the status of the motor overload protection. Calling up the running hours, loading hours, regulator hours and number of motor starts.
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More Load Main Load Main To load the compressor manually To return from a menu to the main display (Fig. 1.11) Starting from the main display (Fig. 1.11), to initiate the main menu (Fig. 1.12) which gives access to submenus Starting from a submenu, to return to the main menu (Fig. 1.12) To modify programmable settings To have a quick look at the compressor status Measured data

Load/Unld

Menu

Menu

MAIN MENU

Status data

Mod More

Modify More

Prog Rset Rtrn

Program To program modified settings Reset Return To reset a timer or message To return to a previously shown option or menu

Hours

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Program/ Function

Description

1.4 Regulator for GA Standard Pack

1.4.1 Regulator (Fig. 1.13)

Service

Calling up and resetting the service messages for the oil, oil filter, oil separator, air filter. Allows a display test. Modifying the settings for regulation (e.g. loading and unloading pressures), for protection (e.g. temperature shut-down level) and for service (e.g. for the oil). Programming automatic compressor start/stop commands. Programming the time, date, display language, units, motor start mode and date format. Calling up the saved data: last shutdown, last emergency stop, longest load, longest unload.

Test Modify settings

The regulator loads, unloads, stops and restarts the compressor according to the air consumption, and protects the compressor and motor from overloads. The unloading and loading pressures are the opening and closing pressures respectively of switch (PSR19-Fig. 5.2). See section 5.5. Star/delta switch-over / Delayed motor stopping A time relay (K24) is provided: - for delayed motor stopping: the frequency of automatic motor starts is limited by stopping the motor only after a set time of 5 minutes of uninterrupted unloaded operation; if the net pressure drops to the loading pressure within the set unloading time, the compressor will be loaded without stopping - to switch over from star to delta connection 10 seconds after starting Compressor temperature shut-down switch (TSHH11) The switch prevents damage resulting from too high a temperature at the outlet of the compressor element. See section 5.6. Motor overload relay (F21) The relay prevents damage resulting from too high a motor current.

Timer

Configuration

Saved data

Selecting a menu When the voltage is switched on, the MAIN DISPLAY (Fig. 1.11) is shown automatically. The other menus are selected by pressing one of function keys (5-Fig. 1.10). Pushing the key <<Menu>> initiates the MAIN MENU (Fig. 1.12), giving access to most other functions via submenus; the submenus can be selected by pressing the key <<Slct>> (select). Whenever displayed on the bottom line of the screen, press the key <<Menu>> to return from a submenu to the MAIN MENU. Whenever displayed, press the key <<Main>> to return from a menu to the MAIN DISPLAY.

1X1

T1 F2 F1 K24

F1/2 F21 K21 K22 K23 K24 T1 1X1

Fuses Overload relay, drive motor Line contactor Star contactor Delta contactor Time relay for star/delta switch-over (10 seconds) and for delayed motor stopping (5 min) Transformer Terminal strip

K22 K23 F21 K21

Fig. 1.13 Electric cabinet, GA Standard Pack (typical example)

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13

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Fig. 1.14 Standard Pack with integrated dryer (star-delta starter) F1/3 F21 H1 K1 K11 K21 K22 K23 K24 M1 PSR19 P1 14 Fuses Overload relay, drive motor Automatic operation lamp Blocking relay Auxiliary contactor for dryer 7) Line contactor Star contactor Delta contactor Time relay for star/delta switch-over (10 seconds) and for delayed motor stopping (5 min) Drive motor Load/unload pressure switch Hourmeter indicating total motor running time
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Fig. 1.15 Standard Pack without transformer S1 S3 S4 TSHH11 T1 Y1 Y2 1X1 Start button Button to stop the compressor after 30 seconds of unloading or to stop it immediately (emergency) Switch to load or unload the compressor Gauge, indicating temperature at outlet of compressor element combined with shut-down switch Transformer Loading solenoid valve Solenoid valve, modulating control 6) Terminal strip

Figs. 1.14 and 1.15 Electrical diagrams, GA Standard Pack/Standard Pack with dryer
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1.4.2 Control panel (Fig. 1.16)

1.5 Air dryer (Fig. 1.5)

GA Full-feature and GA Standard Pack with integrated dryer are provided with a dryer which removes moisture from compressed air.

Gp 1 P1 2 S4 3

TSHH11
1.5.1 Compressed air circuit

S1/H1

S3

Compressed air enters heat exchanger (5) and is cooled by the outgoing, dried air. Moisture in the incoming air starts to condense. The air then flows through heat exchanger (11) where the refrigerant evaporates withdrawing heat from the air. This cools the air to close to the evaporating temperature of the refrigerant. More water in the air condenses. The cold air then flows through moisture trap (MT) which separates condensate from the air. The condensate is automatically drained through outlet (Da). The cold, dried air then flows through heat exchanger (5), where it is warmed up by the incoming air. 1.5.2 Refrigerant circuit Compressor (M2) delivers high-pressure refrigerant gas which flows through condenser (9) where the refrigerant condenses. The liquid refrigerant flows through filter (6) to capillary tube (7). The refrigerant leaves the capillary tube at evaporating pressure. The refrigerant enters evaporator (11) where it withdraws heat from the compressed air by further evaporation. The heated refrigerant leaves the evaporator and is sucked in by compressor (M2). By-pass valve (10) regulates the refrigerant flow. Fan (8) is switched on or off by switch (S3) depending on the loading degree of the refrigerant circuit.

51028F

Gp H1 P1 S1 S3

Gauge indicating the working pressure Automatic operation lamp Hourmeter indicating the total motor running time Start button Button to stop the compressor after 30 seconds of unloading or to stop it immediately (emergency) S4 Switch to load or unload the compressor TSHH11 Gauge, indicating temperature at outlet of compressor element combined with shut-down switch Pictographs 1 Working pressure 2 Running hours 3 Unloaded operation 4 Unload compressor and wait 30 seconds before stopping 5 Outlet temperature of compressor element 6 Loaded operation Fig. 1.16 Control panel, GA Standard Pack

Footnotes chapter 1 1) If an oil/water separator is desired, an integrated condensate separator must be applied. 2) Not for GA5. 3) Available as an option for GA Standard Pack. 4) Only for Full-feature compressors 5) See User manual for Elektronikon regulator, section "Timer submenu". 6) Available as an option 7) Only for Standard Pack with integrated dryer

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2 Installation
2.1 Dimension drawings (Figs. 2.1 and 2.2)

Fig. 2.1 Dimension drawing, GA Pack/Full-feature

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Fig. 2.2 Dimension drawing, GA Standard Pack

2.2 Installation proposals (Figs. 2.3 and 2.4)

Ref. Description/recommendation Ref. Description/recommendation

Install the compressor on a solid, level floor suitable for taking the weight. Position of the compressed air outlet valve. The pressure drop over the delivery pipe can be calculated as follows: dp = (L x 450 x Qc1.85) / (d5 x P)

dp = L d P = = =

2 3

Qc =

pressure drop (recommended maximum = 0.1 bar) length of delivery pipe in m inner diameter of the delivery pipe in mm absolute pressure at the compressor outlet in bar(a) free air delivery of the compressor in l/s

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Fig. 2.3 Installation proposal, GA Pack/Full-feature

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Fig. 2.4. Installation proposal, GA Standard Pack

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Ref.

Description/recommendation

Ref.

Description/recommendation

It is recommended that the connection of the compressor air delivery pipe is made on top of the main air net pipe to minimize carry-over of possible remainder of condensate. 4 Ventilation: the inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor or dryer is avoided. The air velocity to the grids must be limited to 5 m/s. The maximum allowable pressure drop over the cooling air ducts is 30 Pa. If exceeding this value, a fan is needed at the outlet of the ducts. Consult Atlas Copco. For alternatives 1 and 3, the required ventilation capacity to limit the compressor room temperature can be calculated as follows: Qv = Qv = Qv = N = dT = 1.16 N / dT for GA Pack (1.16 N + 0.6) / dT for GA Full-feature required ventilation capacity in m3/s nominal motor power of compressor in kW temperature increase in compressor room

The air receiver (optional) should be installed in a frostfree room on a solid, level floor. For normal air consumption, the volume of the air net (receiver and piping) can be calculated as follows: V V Qc P1 fmax dP T1 To = (0.25 x Qc x P1 x To) / (fmax x dP x T1) = = = = = = = volume of air net in l free air delivery of compressor in l/s compressor air inlet pressure in bar absolute cycle frequency = 1 cycle/30 s Punload - Pload in bar compressor air inlet temperature in K air receiver temperature in K

10-Fig. 2.4

For GA Standard Pack, a condensate trap is available as option.

By-pass system for compressors with dryer (optional): 10-Fig. 2.3 Dryer by-pass pipe. 11-Fig. 2.3 Condensate trap.

For alternatives 2 and 4: the fan capacity should match the compressor fan capacity at a pressure head equal to the pressure drop over the air ducts.

The drain pipes to the drain collector must not dip into the water of the drain collector. Atlas Copco has oil/ water separators (type OSD) to separate the major part of the oil from the condensate to ensure that the condensate meets the requirements of the environmental codes. Position of the control panel. Position of the mains cable. Filter, type DD, for general purpose filtration (optional). The filter traps solid particles down to 1 micron with a max. oil carry-over of 0.5 mg/m3. A high-efficiency filter, type PD (optional), may be installed downstream of a DD filter. This filter traps solid particles down to 0.01 micron with a max. oil carry-over of 0.01 mg/m3. If oil vapour and odours are undesirable, a filter of the QD type (optional) should be installed downstream of the PD filter. It is recommended to provide by-pass pipes and valves over the filters to isolate the filters during maintenance without disturbing the compressor.

2.3 Electric cable size

Attention - Local regulations remain applicable if they are stricter than the values proposed below. - The voltage drop must not exceed 5% of the nominal voltage. It may be necessary to use cables with a larger section than those stated to comply with this requirement. - The values on the next page apply to Full-feature compressors

6 7 8

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Compressor type

Voltage (V)

Frequency (Hz)

Cable section (mm2)

With star-delta starter GA5 GA5 GA5 GA5 GA7 GA7 GA7 GA7 GA11C GA11C GA11C GA11C With star-delta starter GA5 GA5 GA5 GA5 GA7 GA7 GA7 GA7 GA11C GA11C GA11C GA11C

200 230 400 500 200 230 400 500 200 230 400 500

50 50 50 50 50 50 50 50 50 50 50 50

6 6 2.5 2.5 10 10 4 2.5 16 16 6 6

200/220 220/230 380 440/460 200/220 220/230 380 440/460 200/220 220/230 380 440/460

60 60 60 60 60 60 60 60 60 60 60 60

6 6 2.5 2.5 10 10 4 4 16 16 10 6

Note: The size is valid for cable PVC 70 degrees celsius at ambient temperature 40 degrees celsius according to EN60204

Compressor type

Voltage (V)

Frequency (Hz)

Cable section (AWG size)

With direct-on-line starter GA5 GA5 GA5 GA5 GA7 GA7 GA7 GA7 GA11C GA11C GA11C GA11C

200 220/230 440/460 575 200 220/230 440/460 575 200 220/230 440/460 575

60 60 60 60 60 60 60 60 60 60 60 60

AWG8 AWG8 AWG12 AWG12 AWG6 AWG6 AWG10 AWG10 AWG4 AWG4 AWG8 AWG8

Note: The size is valid for cable PVC 90 degrees celsius at ambient temperature 40 degrees celsius according to EN60204

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2.4 Electrical connections

General 1. Provide an isolating switch nearby the compressor. 2. Check the fuses and the setting of the overload relay. See section 7.2. 3. If provided, check transformer (T1-Figs. 1.7 and 1.13) for correct connection. Check the setting of drive motor overload relay (F21) and that overload relay (F21) is set for automatic resetting. On GA Standard Pack with voltage transformer 1. Connect the power supply cables to terminals 1, 3 and 5 of contactor K21 (see Figs. 1.13 and 1.14). 2. Connect the earth conductor to earth bolt (PE). On GA Standard Pack without voltage transformer 1. Connect the power supply cables to terminals 1, 3 and 5 of contactor K21 (see Figs. 1.13 and 1.15). 2. Connect the earth conductor to earth bolt (PE) and the neutral conductor to terminal (N) of strip 1X1. 3. Check the connection of wire (2-Fig. 1.15): - either towards the neutral terminal (N) in case of a 3 x 400 V plus neutral mains - or towards terminal (2) of fuse F2 in case of a 3 x 230 V mains On GA Standard Pack with integrated dryer 1. Connect the power supply to terminals 1, 3 and 5 of contactor K21 (see Fig. 1.14). 2. Connect the earth conductor to the earthing terminal and the neutral conductor to terminal (N) of strip 1X1.

3. The voltage supply to the dryer must be 230 V singlephase. The voltage to the dryer is supplied over the contacts of relay (K11), which close when the compressor is started. For compressor supply voltages different from 3 x 400 V plus neutral or 3 x 230 V, the power to the dryer is supplied by a transformer. On GA Pack 1. Connect the power supply to terminals 1, 3 and 5 of contactor K21 (see Figs. 1.7 and 1.8). 2. Connect the earth conductor to the earthing terminal and the neutral conductor to terminal (N) of strip 1X1. On GA Full-feature 1. Connect the power supply to terminals 1, 3 and 5 of contactor K21 (see Figs. 1.7 and 1.8). 2. Connect the earth conductor to the earthing terminal and the neutral conductor to terminal (N) of strip 1X1. 3. The voltage supply to the dryer must be 230 V singlephase. The voltage to the dryer is supplied over the contacts of relay (K11), which close when the compressor is started. For compressor supply voltages different from 3 x 400 V plus neutral or 3 x 230 V, the power to the dryer is supplied by a transformer.

2.5 Pictographs (Fig. 2.5)

Read the warnings attentively and act accordingly.

1 2 3 4

Manual condensate drain Automatic condensate drain Warning: switch off voltage and depressurize compressor before repairing Warning: before connecting compressor electrically, consult Instruction book for motor rotation direction

5 6 7 8 9

Do not adjust switch if it is depressurized Consult Instruction book before greasing Lightly oil gasket of oil filter, screw it on and tighten by hand (approx. half a turn) Warning: voltage Torques for steel (Fe) or brass (CuZn) bolts

Fig. 2.5 Pictographs (typical examples)

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3 Operating instructions
3.1 Before initial start-up
3.1.1 Safety The operator must apply all relevant safety precautions, including those mentioned in this book.

Bridge terminals 30 and 34 of strip (1X1): the outlet pressure is still sensed by pressure transducer (PT20), resulting in loading and unloading of the compressor at the pressures programmed in the electronic regulator (if terminals 30 and 34 are not bridged, the compressor is switched out of automatic load/unload operation and remains running unloaded). 3.1.6 Remote pressure sensing for GA Pack/Fullfeature

3.1.2 User manual Warning Read the "User manual for Elektronikon regulator for GA5 up to GA90C compressors" to familiarize yourself with all regulator functions. Stop the compressor and switch off the voltage before connecting external equipment. Have the modifications checked by Atlas Copco.

3.1.3 Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below 0 degrees celsius, precautions must be taken. In this case, and also if operating at high altitude, consult Atlas Copco.

1. Bridge terminals 30 and 35 of strip (1X1-Fig. 1.8). 2. Connect a pressure switch between terminals 30 and 34 of strip (1X1): this results in loading and unloading of the compressor at the closing and opening pressures of the external pressure switch respectively.

3.2 Initial start-up

1. Following transport fixations, painted red, are provided: - two spacers (1-Fig. 3.1) underneath the compressor element support: unscrew the bolts underneath the frame and remove the spacers - support (2-Fig. 3.1) underneath the drive motor: unscrew bolts (5) underneath the frame, loosen nut (3), remove the support and retighten nut (3) 2. Check that the electrical connections correspond to the local codes and that all wires are clamped tight to their terminals. The installation must be earthed and protected against short circuits by fuses of the inert type in all phases. An isolating switch must be installed near the compressor. 3. Fit air outlet valve (AV-Figs. 1.1 up to 1.4). Close the valve. Connect the air net to the valve. 4. Connect the manual condensate drain valve (Dm-Figs. 1.1 up to 1.4). Close the valve. Connect the valve to a drain collector. See Figs. 2.3 and 2.4. 5. Connect the automatic drain outlet (Da-Figs. 1.1 up to 1.4) to a drain collector. See Figs. 2.3 and 2.4. 7. Check the oil level. The pointer of level gauge (Gl-Fig. 5.1) should register in the green or orange range. 8. A label dealing in short with the operating instructions and explaining the pictographs is delivered with the literature set. Affix it next to the control panel. Make yourself familiar with the instructions and pictographs explained, as well as with those mentioned in section 2.5. 9. Provide labels, warning the operator that: - the compressor may be restarted automatically after voltage failure (GA Pack/Full-feature, see section 1.3.1) - the compressor is automatically controlled and may be restarted (for GA Pack/Full-feature even after manually stopping, see section 1.3.1) - the compressor may be remotely controlled (see section 3.1.5)

3.1.4 External compressor status indication for GA Pack/Full-feature Warning Stop the compressor and switch off the voltage before connecting external equipment. Have the modifications checked by Atlas Copco.

A relay box for remote compressor status indication is available as option. It can be connected to the electronic control module (see Fig. 1.8). The following indications can be indicated by means of builtin relays: - Manual load/unload or automatic operation - Warning condition - Shut-down condition Contact rating: 1 A / 250V AC

3.1.5 Remote control for GA Pack/Full-feature Warning Stop the compressor and switch off the voltage before connecting external equipment. Have the modifications checked by Atlas Copco.

1. To switch the compressor to remote control mode, bridge terminals 2 and 4 of connector (2X4) located at the back side of the electronic module (E1-Figs. 1.2 and 1.3). 2. For remote starting and stopping, connect a start/stop switch between terminals 30 and 31 of terminal strip (1X1Fig. 1.8). 24

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10. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of the motor (M1-Fig. 1.4): the correct rotation direction is indicated by an arrow provided on the fan housing. If the rotation direction is wrong, switch off the voltage and reverse two incoming electric lines. 11. Check the programmed settings. 1) 12. Start and run the compressor for a few minutes. Check that the compressor operates normally.

3.3 Before starting

Check the oil level (Gl-Fig. 5.1). The pointer should register in the upper field of the green range or in the orange range. If the pointer registers in the red range (low range), depressurize the oil system by unscrewing oil filler plug (FC) one turn. Remove the plug and add oil until the level reaches the filler opening. Fit and tighten the plug.

3.4 For GA Pack/Full-feature

3.4.1 Starting (Fig. 1.10) 1. Switch on the voltage. Check that voltage on LED (2) lights up. The message <<Compressor off>> appears. 2. Open air outlet valve (AV-Figs. 1.2 up to 1.4). 3. Close condensate drain valve (Dm- Figs. 1.2 up to 1.4). 4. Press start button (8). The compressor starts running and automatic operation LED (1) lights up. Ten seconds 2) after starting, the drive motor switches over from star to delta. At the same time 2) the compressor starts running loaded. The message on display (4) changes from <<Auto unloaded>> to <<Auto loaded>>. 3.4.2 During operation 1. Check the oil level during unloaded operation: the pointer of level gauge (Gl-Fig. 5.1) must register in the green range; if not, press stop button (9-Fig. 1.10), wait until the compressor has stopped, depressurize the oil system (by unscrewing oil filler plug FC-Fig. 5.1 one turn) and wait a few minutes. Remove the plug and add oil until the level reaches the filler opening. Fit and tighten the plug. 2. When automatic operation LED (1-Fig. 1.10) is alight, the regulator is automatically controlling the compressor, i.e. loading, unloading, stopping of the motors and restarting. 3.4.3 Checking the display (Fig. 1.10) 1. Regularly check display (4) for readings and messages. Normally, the main display (Fig. 1.11) is shown, indicating the compressor outlet pressure, the status of the compressor and the abbreviations of the functions of the keys below the display. 2. Always check display (4) and remedy the trouble if alarm LED (3) is alight or blinks. Consult section 1.3.2. 3. The display (4) will show a service message if one of the monitored components is to be serviced; stop the compressor, replace the component and reset the relevant timer. 3) Warning Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop button (S3), switch off the voltage and depressurize the compressor.

AF

FN

M1

3
51006F

2 4 5

AF E FN M1 1 2 3 4 5

Air filter Compressor element Cooling fan Drive motor Transport bolt and spacer, to be removed Transport support, to be removed Nut Vibration damper Transport bolts, to be removed

Fig. 3.1 Compressor element/transport fixations

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Notes - Whenever a warning, service request, sensor error or motor overload message is displayed, the free spaces on the display between function keys (5) are filled with blinking indicators (**). - When more than one message needs to be displayed (e.g. both warning and service), the messages will be displayed one after the other for 3 seconds. 4. Regularly press key <<More>> (5) 4) to call up information about the actual compressor condition: - the status of controlling the compressor (automatic or manual, local or remote) - the status of the compressor start/stop timer (on or off) 5) - the maximum allowable unloading pressure - the outlet pressure - the compressor element outlet temperature - the dewpoint temperature 6) - the status of the overload protection of the drive motor (normal or not) - the total running and loading hours

3.4.5 Stopping (Fig. 1.10) 1. Press stop button (9). LED (1) goes out. The message <<Programmed stop>> appears. The compressor runs unloaded for 30 seconds and then stops. 2. To stop the compressor in case of emergency, press button (S3). Alarm LED (3) blinks. After remedying the fault, unlock the button by pulling it out and press key <<Rset>> (5) before restarting. The message <<All conditions are OK>> appears. Press keys <<Menu>> and <<Main>>. 3. Close air outlet valve (AV-Fig. 1.2 up to 1.4) and switch off the voltage. 4. Open condensate drain valve (Dm-Fig. 1.2 up to 1.4).

3.5 For GA Standard Pack

3.5.1 Starting (Fig. 1.16) 1. Switch on the voltage. 2. Open the air outlet valve. 3. If installed, close condensate drain valve (Dm-Fig. 1.1). 8) 4. Check that push button (S3) is unlocked (pulled out) and that toggle switch (S4) is moved to the left (unloaded) position. 5. Press start button (S1). The compressor starts running and lamp (H1) lights up. 6. Move switch (S4) to the right to load the compressor.

3.4.4 Manual control (Fig. 1.10) 7) Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and restarts the compressor automatically. LED (1) is then alight. If required, the compressor can be unloaded manually. In this case, the compressor is switched out of automatic operation: the compressor remains running unloaded unless it is loaded again manually.

3.5.2 During operation Manually unloading Press the key <<Unld>> (unload) (5). LED (1) goes out. The message <<Manual Unloaded>> appears on the display. 1. Check the oil level during unloaded operation: the pointer of level gauge (Gl-Fig. 5.1) must register in the green range; if not, move switch (S4) to the left, wait 30 seconds and then press stop button (S3). Depressurize the oil system by unscrewing oil filler plug (FC-Fig. 5.1) one turn and wait a few minutes. Remove the plug and add oil until the level reaches the filler opening. Fit and tighten the plug. Pull out button (S3). 2. When automatic operation lamp (H1) is alight, the regulator is automatically controlling the compressor, i.e. loading, unloading, stopping of the motor and restarting. 3. Regularly check the readings on the gauges.

Manually loading Press the key <<Load>> (5). LED (1) lights up. The command <<Load>> does not force the compressor in loaded condition, but it will switch the compressor to automatic operation again: the compressor will be loaded if the air net pressure drops below the programmed level.

Manually starting In automatic operation, the regulator limits the number of motor starts. If the compressor is stopped manually, it must not be restarted manually within 5 minutes after the last stop. This corresponds with maximum 12 starts per hour.

3.5.3 Stopping (Fig. 1.16) 1. Move switch (S4) to the left to unload the compressor and wait 30 seconds.

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2. Press stop button (S3). After stopping, unlock the button by pulling it out. 3. To stop the compressor in case of emergency, press button (S3). Before restarting, unlock the button by pulling it out. 4. Close the air outlet valve and switch off the voltage. 5. If installed, open the condensate drain valve. 8)

4 Maintenance
Attention 1. Apply all relevant safety precautions, including those mentioned in this book. 2. Read section 2.5 to familiarize yourself with all warning labels and pictographs. 3. Before carrying out any maintenance or repair on the compressor: - For GA Pack/Full-feature, press stop button (9-Fig. 1.10), wait until the compressor has stopped (approx. 30 seconds), press emergency stop button (S3) and switch off the voltage. - For GA Standard Pack/Standard Pack with dryer, move switch (S4-Fig. 1.16) to the left, wait 30 seconds, press stop button (S3) and switch off the voltage. - Close air outlet valve (AV-Figs. 1.1 up to 1.4) and depressurize by opening plug (FC-Fig. 5.1) one turn and by opening valve (Dm-Figs. 1.1 up to 1.4). 4. The air outlet valve (AV-Figs. 1.1 up to 1.4) can be locked during maintenance or repair as follows: - Close the valve. - Remove the bolt fixing the handle. - Lift the handle and turn it until the slot of the handle fits over the blocking edge on the valve body. - Lock the handle using the special bolt and wrench delivered loose with the compressor.

3.6 Taking out of operation at end of compressor service life

At the end of the service life of the compressor, proceed as follows: 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. 5.1) one turn and by opening valve (Dm-Fig. 1.1). 4. 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. 5. Drain the oil and condensate circuits. 6. Disconnect the condensate piping from the condensate net.

4.1 Drive motor (M1-Fig. 1.4)

The motor bearings are greased for life.

Footnotes chapter 3 1) Consult the User manual for Elektronikon regulator. 2) Programmable. 3) Using key <<Rset>>: see User manual for Elektronikon regulator, section "Service submenu". 4) If the function <<More>> is not indicated on the bottom line of display (4-Fig. 1.10), press key <<Menu>> (5) until function <<Main>> appears above key (F1), then press the key <<Main>>. 5) The compressor is automatically started and stopped if these start/stop commands are programmed and activated; consult section 1.3.1. 6) For Full-feature compressors. 7) If the <<Load>> or <<Unld>> (unload) function is not indicated on the bottom line of display (4), press key <<Menu>> (5) until the function <<Main>> appears above key (F1), then press the key <<Main>>. 8) A condensate drain system is available as option for GA Standard Pack.

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4.2 Preventive maintenance schedule for the compressor 1)

Attention For overhauling or carrying out preventive maintenance, service kits are available. See section 4.7. Atlas Copco offers several types of Service contracts, relieving you of all preventive maintenance work. For more details, consult your nearest Atlas Copco representative. The schedule comprises a 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, replace all disengaged packings, e.g. gaskets, O-rings, washers.

Period 2)

Running hours 2)

See section

See notes Operation below table Before starting Check oil level (Gl) During operation Check readings on display or gauges Check that condensate is discharged during loading (Da) Check oil level (Gl) After stopping Drain condensate (Dm) Operate safety valve (SV) Carry out a LED/display test (Pack/Full-feature) Check for possible leaks Inspect coolers (Ca/Co); clean if necessary Inspect condensor of dryer (Full-feature); clean if necessary Remove air filter element (AF), replace if necessary Remove, dismantle and clean float valve of moisture trap (MT) Check belt tension and condition. Adjust, if necessary Have safety valve (SV) tested Have operation of electrical interlockings, motor breakers, etc. tested Test temperature shut-down protection Replace air filter element (AF) If Atlas Copco Roto-injectfluid is used, change oil and oil filter (OF) For 13 bar and 175 psi If oil as specified in section 4.3.2 is used, change oil and oil filter For 7.5-8-10 bar and 100-125-150 psi If oil as specified in section 4.3.2 is used, change oil and oil filter Have all flexibles inspected Clean compressor Have oil separator (OS) replaced; inspect valve (CV) for cleanness

Daily "

--

3.3

--

" " "

----

3.4/3.5/7.1 -3.4/3.5

----

" 3-monthly " " " " " " -Yearly " " " "

----1000 1000 1000 -1000 ---4000 4000

3.4/3.5 5.3 --5.2 -4.7 -5.7 5.3 --4.7/5.1 4.4/4.5/4.7

--4 6 1 1 1/8 ----5 1 2/3

"

500

4.4/4.5/4.7

" " " 2-Yearly

1000 --8000

4.4/4.5/4.7 --4.7

2 7 ---

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Notes 1. More frequently when operating in a dusty atmosphere. 2. Use genuine Atlas Copco filters. 3. Recommended oil: Atlas Copco Roto-injectfluid. For the change interval in extreme conditions of temperature, humidity or cooling air, consult Atlas Copco. 4. Consult the User Manual for Elektronikon regulator, section "Test submenu". 5. For GA Pack/Full-feature: Consult the User Manual for Elektronikon regulator before modifying the temperature protection settings, section "Modify settings submenu". Decrease the shut-down warning level and shut-down level for the compressor element outlet temperature to the minimum. Run the compressor: when reaching the setting, the unit must shut down. Attention: reset the shut-down level and warning level to their original values. For GA Standard Pack: consult Atlas Copco. 6. Any leak should be attended to immediately. 7. Damaged flexibles must be replaced immediately. 8. Replace the air filter element if damaged or heavily contaminated.

4.3 Oil specifications

Attention Never mix oils of different brands or types. Use only nontoxic oils. 4.3.1 Atlas Copco Roto-injectfluid It is strongly recommended to use Atlas Copco Rotoinjectfluid. This is special oil for screw compressors which keeps the compressor in excellent condition. Roto-injectfluid can be used for compressors operating in ambient temperatures between 0 and 40 degrees celsius. See also section 4.7. Although Roto-injectfluid is recommended, mineral oil can be used after taking following precautions: - the previously used oil should first be drained and the system flushed - the oil filter and oil separator should be replaced - the oil must meet the requirements as specified below 4.3.2 Mineral oil Properties: high-quality, mineral oil with oxidation inhibitors and anti-foam and anti-wear properties. The viscosity grade must correspond to the ambient temperature and ISO 3448, as follows: Ambient temperature Viscosity grade Viscosity index

4.4 Oil change (Fig. 5.1)

1. Run the compressor until warm. Stop the compressor and depressurize by unscrewing filler plug (FC) one turn to permit any pressure in the system to escape. 2. Drain the oil by removing drain plug (DP). Fit and tighten plug (DP) after draining. Deliver the oil to the local oil collection service. 3. Fill receiver (AR) with oil until the level reaches the filler neck. Take care that no dirt drops into the system. Fit and tighten plug (FC). 4. Run the compressor for a few minutes. Stop the compressor and wait a few minutes to allow the oil to settle. Depressurize the system by unscrewing filler plug (FC) one turn to permit any pressure in the system to escape. Fill the receiver with oil until the level reaches the filler neck. Tighten plug (FC). 5. Reset the oil service warning. 3)

4.5 Oil filter change (Fig. 5.1)

1. Stop the compressor and depressurize by unscrewing filler plug (FC) one turn to permit any pressure in the system to escape. Wait a few minutes. 4. Remove oil filter (OF). 5. Clean the filter seat on the manifold. Oil the gasket of the new element. Screw the element into place and tighten firmly by hand. 6. Remove plug (FC) and fill with oil until the level reaches the filler opening. 7. Tighten plug (FC). 8. Reset the oil filter service warning. 3) 29

Consistently above 25 degrees celsius . . . . . . . . . . . . . . . . . . . . ISO VG 68 Between 25 and 0 degrees celsius . . . . . . . . . . . . . . . . . . . . ISO VG 46

Minimum 95 Minimum 95

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4.6 Storage after installation

Run the compressor twice a week until warm. Load and unload the compressor a few times. If the compressor is stored without running from time to time, protective measures must be taken. Consult Atlas Copco.

4.7 Service kits

Service kits are available offering the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. The kits comprise all parts needed for servicing. Service kits For oil filter and air filter For oil separator Ordering number 2901 0559 00 2901 0523 00

Atlas Copco Roto-injectfluid Roto-injectfluid (see section 4.3) can be ordered in following quantities: Quantity 5-litre can 20-litre can Ordering number 2901 0245 01 2901 0522 00

Footnotes chapter 4 1) Use only authorized parts. Any damage or malfunction 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, especially the service intervals, depending on the environmental and working conditions of the compressor. 3) For GA Pack/Full-feature: using key <<Rset>>: see User manual for Elektronikon regulator, section "Service submenu".

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5 Adjustments procedures

and

servicing

5.2 Coolers
Keep the coolers clean to maintain the cooling efficiency. Remove any dirt from the coolers with a fibre brush. Never use a wire brush or metal objects. Then clean by air jet in reverse direction of normal flow while covering all compressor parts under the coolers. If it is necessary to wash the coolers with a cleansing agent, consult Atlas Copco.

5.1 Air filter (AF-Fig. 5.1)

1. Stop the compressor. Switch off the voltage. Remove the filter cover and the filter element. Discard the air filter element. 2. Fit the new element and the cover. 3. For GA Pack/Full-feature, reset the air filter service warning using key <<Rset>>. 1)

5.3 Safety valve (SV-Fig. 5.1)

Operate the safety valve, depending on the type of valve: - by unscrewing the cap one or two turns and retightening it - or by pulling the valve lifting lever

AF

OF

SV
Testing The valve can be tested on a separate compressed air line. If the valve does not open at the set pressure stamped on the valve, consult Atlas Copco. Warning No adjustments are allowed. Never run the compressor without safety valve.

AR

5.4 Safety devices of dryer on GA Fullfeature/Standard Pack with dryer

The regulating and safety devices are factory-adjusted to obtain optimum performance of the dryer. Do not alter the setting of any of the devices.

FC GL

51003F

DP

5.5 Load/unload pressure switch on GA Standard Pack

The switch (PSR19-Fig. 5.2) allows the operator to select the unloading pressure and the pressure difference between the unloading and loading pressures. The unloading and loading pressures are the opening and closing pressures of the air pressure switch. Adjustment can only be carried out when the pressure switch is pressurized. Remove blocking device (1) before adjusting knob (2). The unloading pressure is controlled by adjusting knob (2). Turn the knob clockwise to raise the unloading pressure, anticlockwise to lower it.

AF AR DP FC Gl OF SV

Air filter Air receiver/oil separator Oil drain plug Oil filler plug Oil level gauge Oil filter Safety valve

Fig. 5.1 Air receiver

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1 2

5.6 Temperature shut-down switch on GA Standard Pack

Switch (TSHH11-Fig. 1.16) has an adjusting screw in the centre at the back of the housing of the switch.
3

The reset screw is located in the centre of the indicator scale and is protected by a cap. To reset the switch after tripping, unscrew the cap and turn the reset screw with a screwdriver anti-clockwise.

50390F

5.7 Belt set exchange (Fig. 5.6)

The belts must be replaced as a set, even if one of them seems worn. Use Atlas Copco belts only. 1. Remove panel (1-Figs. 1.1/1.4). 2. Loosen hose clip (1) and retract hose (2) from fan housing (3). 3. Untighten fixation bolts (4). 4. Screw locking nut (6) upwards. Screw bush (7) and threaded rod (8) downwards; the compressor element will move downwards loosening the belt tension. 5. Remove cover (9) from housing (3) by turning it anticlockwise. 6. Unscrew the fixation bolt in the centre of the fan and remove the latter whereafter the belts can be removed without disconnecting the fan housing from support (5).

1 2 3

Blocking device, to be removed before turning knob 2 Adjusting knob Switch

Fig. 5.2 Load/unload pressure switch (Standard Pack)

The pressure difference between unloading and loading is adjusted by means of the same knob. The adjustment range is given in Figs. 5.3 and 5.4. Push down the knob and turn it clockwise to reduce the pressure difference, anti-clockwise to increase it.

Fig. 5.3 Switch MDR 53/16

Fig. 5.4 Switch MDR 53/11

Example (Fig. 5.4): for 8 bar(e) unloading pressure, the loading pressure is adjustable between 5 and 7.6 bar(e) Figs. 5.3 and 5.4 Adjustment ranges for load/unload pressure switch (Standard Pack) 32
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4 4 7

2 6 5 1 8

50444F

Fig. 5.5 Belt drive 1 2 3 4 5 6 7 8 9 Hose clip Hose Fan housing Fixation bolts Compressor element support Locking nut Bush Threaded rod Figs. 5.5 and 5.6 Belt drive Cover

Fig. 5.6 Belt drive

7. Install a new set of Atlas Copco belts. 8. Install and fix the fan. Mount inlet cover (9) on fan housing (3). 9. Screw locking nut (6) against bush (7); by turning the nut further, the compressor element is moved upwards tensioning the belts. The belt tension is correct if the deflection is between 5 and 6 mm when exerting a force of 25 N on the belt midway between both pulleys. 10. Mount hose (2) on fan housing (3) and tighten hose clip (1). 11. Tighten fixation bolts (4) and run the compressor for about 15 minutes. 12. Stop the compressor, check the belt tension and, if necessary, retension the belts (see steps 3 and 9). 13. Tighten fixation bolts (4) and screw locking nut (6) downwards against support (5). 14. Install panel (1-Figs. 1.1/1.4).

6 Problem solving
Attention 1. Apply all relevant safety precautions, including those mentioned in this book. 2. Read section 2.5 to familiarize yourself with all warning labels and pictographs. 3. Before carrying out any maintenance or repair on the compressor: - For GA Pack/Full-feature, press stop button (9-Fig. 1.10), wait until the compressor has stopped (approx. 30 seconds), press emergency stop button (S3) and switch off the voltage. - For GA Standard Pack/Standard Pack with dryer, move switch (S4-Fig. 1.16) to the left, wait 30 seconds, press stop button (S3) and switch off the voltage. - Close air outlet valve (AV-Figs. 1.1 up to 1.4) and depressurize by opening plug (FC-Fig. 5.1) one turn and by opening valve (Dm-Figs. 1.1 up to 1.4).

Footnote chapter 5 1) See User manual for Elektronikon regulator, section "Service submenu".
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4. The air outlet valve (AV-Figs. 1.1 up to 1.4) can be locked during maintenance or repair as follows: - Close the valve. - Remove the bolt fixing the handle. - Lift the handle and turn it until the slot of the handle fits over the blocking edge on the valve body. - Lock the handle using the special bolt and wrench delivered loose with the compressor. 5. Consult the User manual for Elektronikon regulator (section "Status data submenu") if a service message or fault message appears on display (4-Fig. 1.10) or when alarm LED (3-Fig. 1.10) is alight or blinks.

h h. i i

Safety valve (SV) leaking Replace valve Compressor element (E) out of order Consult Atlas Copco

5 Excessive oil flow through air inlet filter after stopping a Inlet valve (IV) stuck in open position a Have valve checked. Replace filter 6 a a b b c c d d e Safety valve (SV) blows after loading Inlet valve (IV) malfunctioning See 1b Minimum pressure valve (Vp) malfunctioning See 1d Oil separator element (OS) clogged See 4f Safety valve (SV) out of order See 4h On GA Full-feature, dryer piping clogged because of ice formation e Have refrigerant system checked by Atlas Copco 7 Element outlet 1) or air outlet temperature above normal a Insufficient cooling air or cooling air temperature too high a Check for cooling air restriction or improve ventilation of compressor room. Avoid recirculation of cooling air. If installed, check capacity of compressor room fan. b Oil level too low b Check and correct as necessary c Oil cooler (Co) clogged c Clean cooler d By-pass valve (BV) malfunctioning d Have valve tested e Air cooler (Ca) clogged e Clean cooler f Compressor element (E) out of order f See 4i 8 High oil consumption a Oil level (Gl) too high a Check for overfilling. Release pressure and drain oil to correct level b Incorrect oil causing foam b Change to correct oil c Oil separator element (OS) defective c Have element checked. Replace, if necessary.

Mechanical faults and suggested remedies (Figs. 1.5 and 1.6)

1 Compressor starts running, but does not load after a delay time a Solenoid valve (Y1) out of order a Replace valve b Inlet valve (IV) stuck in closed position b Have valve checked c Leak in control air flexibles c Replace leaking flexible d Minimum pressure valve (Vp) leaking (when net is depressurized) d Have valve checked 2 a a b b Compressor does not unload, safety valve blows Solenoid valve (Y1) out of order See 1a Inlet valve (IV) does not close See 1b

3 Condensate is not discharged from condensate trap during loading a Discharge flexible clogged a Check and correct as necessary b Float valve malfunctioning b Remove float valve assembly, clean and check 4 a a b b c c d d e e f f g g Compressor air output or pressure below normal Air consumption exceeds air output of compressor Check equipment connected Choked air inlet filter element (AF) Replace filter element Solenoid valve (Y1) malfunctioning See 1a Leak in control air flexibles See 1c Inlet valve (IV) does not fully open See 1b Oil separator element (OS) clogged Have element replaced Air leakage See 1c

Footnote chapter 6 1) For GA Pack/Full-feature, a warning message will appear on display (4-Fig. 1.10).

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7 Principal data
7.1 Readings on display (Fig. 1.10) or gauges (Fig. 1.16) 1)
Ref.: Reading: Shown: Ref.: Reading: Shown: Air outlet pressure Modulates between programmed unloading and loading pressures On gauge Gp (Fig. 1.16) or main display (Fig. 1.11) Compressor element outlet temperature Approx. 60 degrees celsius above cooling air temperature On gauge TSHH11 (Fig. 1.16) or when using key <<More>> (5-Fig. 1.10)

On Full-feature also: Ref.: Reading: Shown: Dewpoint temperature Approx. 3 degrees celsius at reference conditions When using key <<More>> (5-Fig. 1.10)

7.2 Settings of overload relay and fuses

Compressor type Supply voltage (V) Frequency (Hz) Max. setting of relay F21 (A) Fuses IEC (A) Fuses CSA HRC (A) Fuses UL K5 (A)

With star-delta starter GA5 GA5 GA5 GA7 GA7 GA7 GA11C GA11C GA11C With star-delta starter GA5 GA5 GA5 GA7 GA7 GA7 GA11C GA11C GA11C

230 400 500 230 400 500 230 400 500 220/230 380 440/460 220/230 380 440/460 220/230 380 440/460

50 50 50 50 50 50 50 50 50 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60

12.4 7.1 5.7 17.4 9.8 8 25.8 14.9 11.9 12.8 7.4 6.4 18.9 11 9.5 27 15.7 13.5 22.3 11.1 8.5 32.8 16.4 12.5 46.8 23.4 17.9

32 20 20 50 25 20 63 32 32 32 20 20 50 25 25 63 50 32 -

40 25 20 60 30 25 80 40 30

40 25 20 60 30 25 80 40 30

With direct-on-line starter GA5 220/230 GA5 440/460 GA5 575 GA7 220/230 GA7 440/460 GA7 575 GA11C 220/230 GA11C 440/460 GA11C 575

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7.3 Settings of fan control switch (GA Full-feature/Standard Pack with dryer)
Cut-out pressure Switch-on pressure Unit

Dryer fan control switch (50 Hz) Dryer fan control switch (60 Hz)

7.9 9.9

9 11

bar(e) bar(e)

7.4 Compressor specifications

7.4.1 Reference conditions Air inlet pressure (absolute) . . . . . . . . . . . . . . . . . . . . . . . . . . . Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relative humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar C % bar(e) 1 20 0 See nominal values below

7.4.2 Limitations Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . Minimum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) bar(e) C C See maximum values below 4 40 0

7.4.3 GA5 Pack/Standard Pack 2) Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum (unloading) pressure . . . . . . . . . . Nominal working pressure . . . . . . . . . . . . . . Temperature of air leaving outlet valve, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive motor, LEROY SOMER . . . . . . . . . . Motor shaft speed . . . . . . . . . . . . . . . . . . . . . Power input, GA . . . . . . . . . . . . . . . . . . . . . . Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . Mean sound pressure level 3) . . . . . . . . . . . .

Hz bar(e) bar(e) C

50 7.5 7 31 LS 132S 2920 6.3 4.8 65

50 8 8 31 LS 132S 2920 6.2 4.8 65

50 10 9.5 31 LS 132S 2920 6.2 4.8 65

50 13 12.5 31 LS 132S 2920 6.2 4.8 65

60 7.4 6.9 31 LS 132S 3515 6.4 4.8 66

60 9.1 8.6 31 LS 132S 3515 6.4 4.8 66

60 10.8 10.3 31 LS 132S 3515 6.5 4.8 66

60 12.5 12 31 LS 132S 3515 6.5 4.8 66

r/min kW l dB

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7.4.4 GA5 Full-feature/Standard Pack with dryer 2) Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum (unloading) pressure . . . . . . . . . . Nominal working pressure . . . . . . . . . . . . . . Temperature of air leaving outlet valve, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive motor, LEROY SOMER . . . . . . . . . . Motor shaft speed . . . . . . . . . . . . . . . . . . . . . Power input, GA . . . . . . . . . . . . . . . . . . . . . . Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . Mean sound pressure level 3) . . . . . . . . . . . . Refrigerant type . . . . . . . . . . . . . . . . . . . . . . Refrigerant charge . . . . . . . . . . . . . . . . . . . . Pressure dewpoint, approx. 4) . . . . . . . . . . .

Hz bar(e) bar(e) C

50 7.25 7 24 LS 132S 2920 6.4 4.8 65 R134a 0.39 3

50 7.75 7.75 24 LS 132S 2920 6.1 4.8 65 R134a 0.39 3

50 9.75 9.5 24 LS 132S 2920 6.3 4.8 65 R134a 0.39 3

50 12.75 12.5 24 LS 132S 2920 6.3 4.8 65 R134a 0.39 3

60 7.15 6.9 24 LS 132S 3515 6.5 4.8 66 R134a 0.39 3

60 8.85 8.6 24 LS 132S 3515 6.5 4.8 66 R134a 0.39 3

60 10.55 10.3 24 LS 132S 3515 6.6 4.8 66 R134a 0.39 3

60 12.25 12 24 LS 132S 3515 6.6 4.8 66 R134a 0.39 3

r/min kW l dB kg C

7.4.5 GA7 Pack/Standard Pack 2) Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum (unloading) pressure . . . . . . . . . . Nominal working pressure . . . . . . . . . . . . . . Temperature of air leaving outlet valve, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive motor, LEROY SOMER . . . . . . . . . . Motor shaft speed . . . . . . . . . . . . . . . . . . . . . Power input, GA . . . . . . . . . . . . . . . . . . . . . . Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . Mean sound pressure level 3) . . . . . . . . . . . .

Hz bar(e) bar(e) C

50 7.5 7 34 LS 132M 2930 8.7 4.8 66

50 8 8 34 LS 132M 2930 8.8 4.8 66

50 10 9.5 34 LS 132M 2930 8.7 4.8 66

50 13 12.5 34 LS 132M 2930 8.7 4.8 66

60 7.4 6.9 34 LS 132M 3530 8.9 4.8 67

60 9.1 8.6 34 LS 132M 3530 8.9 4.8 67

60 10.8 10.3 34 LS 132M 3530 8.9 4.8 67

60 12.5 12 34 LS 132M 3530 8.8 4.8 67

r/min kW l dB

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7.4.6 GA7 Full-feature/Standard Pack with dryer 2) Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum (unloading) pressure . . . . . . . . . . Nominal working pressure . . . . . . . . . . . . . . Temperature of air leaving outlet valve, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive motor, LEROY SOMER . . . . . . . . . . Motor shaft speed . . . . . . . . . . . . . . . . . . . . . Power input, GA . . . . . . . . . . . . . . . . . . . . . . Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . Mean sound pressure level 3) . . . . . . . . . . . . Refrigerant type . . . . . . . . . . . . . . . . . . . . . . Refrigerant charge . . . . . . . . . . . . . . . . . . . . Pressure dewpoint, approx. 4) . . . . . . . . . . .

Hz bar(e) bar(e) C

50 7.25 7 27 LS 132M 2930 8.8 4.8 66 R134a 0.39 3

50 7.75 7.75 27 LS 132M 2930 8.7 4.8 66 R134a 0.39 3

50 9.75 9.5 27 LS 132M 2930 8.8 4.8 66 R134a 0.39 3

50 12.75 12.5 27 LS 132M 2930 8.8 4.8 66 R134a 0.39 3

60 7.15 6.9 27 LS 132M 3530 9.0 4.8 67 R134a 0.39 3

60 8.85 8.6 27 LS 132M 3530 9.0 4.8 67 R134a 0.39 3

60 10.55 10.3 27 LS 132M 3530 9.0 4.8 67 R134a 0.39 3

60 12.25 12 27 LS 132M 3530 8.9 4.8 67 R134a 0.39 3

r/min kW l dB kg C

7.4.7 GA11C Pack/Standard Pack 2) Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum (unloading) pressure . . . . . . . . . . Nominal working pressure . . . . . . . . . . . . . . Temperature of air leaving outlet valve, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive motor, LEROY SOMER . . . . . . . . . . Motor shaft speed . . . . . . . . . . . . . . . . . . . . . Power input, GA . . . . . . . . . . . . . . . . . . . . . . Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . Mean sound pressure level 3) . . . . . . . . . . . .

Hz bar(e) bar(e) C

50 7.5 7 37 LS 132M 2940 12.5 4.8 67

50 8 8 37 LS 132M 2940 12.2 4.8 67

50 10 9.5 37 LS 132M 2940 12.6 4.8 67

50 13 12.5 37 LS 132M 2940 12.8 4.8 67

60 7.4 6.9 37 LS 132M 3560 12.8 4.8 68

60 9.1 8.6 37 LS 132M 3560 12.9 4.8 68

60 10.8 10.3 37 LS 132M 3560 13.1 4.8 68

60 12.5 12 37 LS 132M 3560 13.3 4.8 68

r/min kW l dB

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7.4.8 GA11C Full-feature/Standard Pack with dryer 2) Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum (unloading) pressure . . . . . . . . . . Nominal working pressure . . . . . . . . . . . . . . Temperature of air leaving outlet valve, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive motor, LEROY SOMER . . . . . . . . . . Motor shaft speed . . . . . . . . . . . . . . . . . . . . . Power input, GA . . . . . . . . . . . . . . . . . . . . . . Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . Mean sound pressure level 3) . . . . . . . . . . . . Refrigerant type . . . . . . . . . . . . . . . . . . . . . . Refrigerant charge . . . . . . . . . . . . . . . . . . . . Pressure dewpoint, approx. 4) . . . . . . . . . . .

Hz bar(e) bar(e) C

50 7.25 7 30 LS 132M 2940 12.7 4.8 67 R134a 0.4 3

50 7.75 7.75 30 LS 132M 2940 12.2 4.8 67 R134a 0.4 3

50 9.75 9.5 30 LS 132M 2940 12.8 4.8 67 R134a 0.4 3

50 12.75 12.5 30 LS 132M 2940 13.0 4.8 67 R134a 0.4 3

60 7.15 6.9 30 LS 132M 3560 12.9 4.8 68 R134a 0.4 3

60 8.85 8.6 30 LS 132M 3560 13.0 4.8 68 R134a 0.4 3

60 10.55 10.3 30 LS 132M 3560 13.2 4.8 68 R134a 0.4 3

60 12.25 12 30 LS 132M 3560 13.4 4.8 68 R134a 0.4 3

r/min kW l dB kg C

7.5 Air receiver data

Design pressure: . . . . . . . . 15 bar(e) Volume: . . . . . . . . . . . . . . . 8 l Test pressure: . . . . . . . . . . 22.5 bar(e)

7.6 Conversion list of SI units into US/British units

1 bar = 14.504 psi 1 g = 0.035 oz 1 kW = 1.341 hp (UK and US) 1 l = 0.264 US gal 1 l = 0.220 Imp gal (UK) 1 l = 0.035 cu.ft 1 l/s = 2.117 cfm 1 mm = 0.039 in 1 mbar = 0.401 in water column 1 N = 0.225 lbf 1 Nm = 0.738 lbf.ft x degrees celsius = (32 + 1.8 x) degrees fahrenheit 5)

Footnotes chapter 7 1) For GA Pack and Full-feature, see section 3.4 and the User manual for Elektronikon regulator, sections "Main display" and "More function". 2) At reference conditions 3) According to PNEUROP PN8NTC2.2 4) At 20 degrees celsius / 100% relative humidity 5) A temperature difference of 1 degree celsius = a temperature difference of 1.8 degrees fahrenheit

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Notes: ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ................................................................................................... ...................................................................................................

40

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