Atlas Copco Stationary Air Compressors

GA55 - GA75 - GA55 W - GA75 W - GA90C - GA90C W

Instruction Book

Important
1. This book applies exclusively to compressors from serial number AII-471 000 onwards.
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 1428 00 www.atlascopco.com

Registration code: APC G55-90C/2000 / 38 / 998

2000-09

*2920142800*
 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 Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.7 Taking out of operation at end of compressor
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 3 service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.1.1 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1.3 Cooling and condensate drain systems . . . 6 4.1 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Unloading/loading system . . . . . . . . . . . . . . . . . . 6 4.2 Preventive maintenance schedule for the
1.2.1 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . 6 compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.2 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.3 Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Elektronikon regulator . . . . . . . . . . . . . . . . . . . . . 8 4.3.1 Atlas Copco Roto-injectfluid . . . . . . . . . 28
1.3.1 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.3.2 Mineral oil . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . 9 4.4 Oil and oil filter change . . . . . . . . . . . . . . . . . . . 28
1.3.3 Function keys . . . . . . . . . . . . . . . . . . . . . . 11 4.5 Storage after installation . . . . . . . . . . . . . . . . . . . 29
1.3.4 Menu-driven control programs . . . . . . . . 12 4.6 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Air dryer on GA Full-feature . . . . . . . . . . . . . . . 13
1.4.1 Compressed air circuit . . . . . . . . . . . . . . . 13 5 Adjustments and servicing procedures . . . . . . . . . . 29
1.4.2 Refrigerant circuit . . . . . . . . . . . . . . . . . . 13 5.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Installation proposal . . . . . . . . . . . . . . . . . . . . . . 15 6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.1 For GA55/GA55 W . . . . . . . . . . . . . . . . . 17 7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.2 For GA75/GA75 W . . . . . . . . . . . . . . . . . 17 7.1 Readings on display . . . . . . . . . . . . . . . . . . . . . . 31
2.3.3 For GA90C/GA90C W . . . . . . . . . . . . . . 18 7.2 Settings of safety valve . . . . . . . . . . . . . . . . . . . . 31
2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . 18 7.3 Maximum settings of overload relay, circuit
2.5 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 breaker and fuses . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Cooling water requirements . . . . . . . . . . . . . . . . 18 7.3.1 For GA55/GA55 W . . . . . . . . . . . . . . . . . 32
7.3.2 For GA75/GA75 W . . . . . . . . . . . . . . . . . 32
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . 20 7.3.3 For GA90C/GA90C W . . . . . . . . . . . . . . 33
3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.3.4 Setting maximum fuse . . . . . . . . . . . . . . . 33
3.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.4 Settings of dryer switches . . . . . . . . . . . . . . . . . . 33
3.1.2 User Manual . . . . . . . . . . . . . . . . . . . . . . 20 7.5 Compressor specifications . . . . . . . . . . . . . . . . . 33
3.1.3 Outdoor/altitude operation . . . . . . . . . . . 20 7.5.1 Reference conditions . . . . . . . . . . . . . . . . 33
3.1.4 Moving/lifting . . . . . . . . . . . . . . . . . . . . . 20 7.5.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.5 External compressor status indication . . . 20 7.5.3 GA55/GA55 W Pack . . . . . . . . . . . . . . . . 34
3.1.6 Compressor control modes . . . . . . . . . . . 20 7.5.4 GA55/GA55 W Full-feature . . . . . . . . . . 34
3.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.5.5 GA75/GA75 W Pack . . . . . . . . . . . . . . . . 35
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7.5.6 GA75/GA75 W Full-feature . . . . . . . . . . 35
3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . 23 7.5.7 GA90C/GA90C W Pack . . . . . . . . . . . . . 36
3.4.1 Checking the display . . . . . . . . . . . . . . . . 23 7.5.8 GA90C/GA90C W Full-feature . . . . . . . 36
3.5 Manual control . . . . . . . . . . . . . . . . . . . . . . . . . . 24 7.6 Conversion list of SI units into US/British units 37
3.6 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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1 LEADING PARTICULARS
1.1 General description

GA are stationary, single-stage, oil-injected screw compressors start, stop and emergency stop buttons. An electric cabinet
driven by an electric motor. GA55, GA75 and GA90C are comprising the motor starter is located behind this panel.
air-cooled, whereas GA55 W, GA75 W and GA90C W are
water-cooled. The compressors are provided with an automatic condensate
drain system.
GA Pack
GA Pack are enclosed in a sound-insulated bodywork. The GA Full-feature
compressors are controlled by the Atlas Copco Elektronikon® GA Full-feature are GA Pack compressors, additionally
regulator. This electronic control module is fitted to the door provided with an air dryer (3-Fig. 1.3) integrated in the
of the front panel. The Elektronikon regulator reduces the bodywork. The dryer removes moisture from the compressed
power consumption and it allows the operator to easily program air by cooling the air to near freezing point and automatically
and monitor the compressor. The control panel includes the draining the condensate. See section 1.4.

E1 1

3
51040F
4

E1 Control module
1 Air outlet valve
2 Electric cable entry
3 Automatic condensate drain outlet of optional oil separator kit (OSD)
4 Manual condensate drain valve

Fig. 1.1 General view of GA75 Full-feature

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1.1.1 Air flow (Fig. 1.5)

Air drawn through filter (AF) and open inlet valve (IV) into Check valve (CV) prevents blow-back of compressed air when
compressor element (E) is compressed. Compressed air and the compressor is stopped. Minimum pressure valve (Vp)
oil flow into air receiver/oil separator (AR) via check valve prevents the receiver pressure from dropping below a minimum
(CV). The air is discharged through the outlet valve via pressure. The minimum pressure valve includes a check valve
minimum pressure valve (Vp), air cooler (Ca) and condensate which prevents blow-back of compressed air from the air net.
trap (4).

1 3
2

E1

S3
11

10

51041F

9 6
7
8

E1 Control module 4 Drive motor 8 Air receiver

S3 Emergency stop button 5 Oil separator kit (OSD), optional 9 Oil level gauge
1 Fan 6 Air filter 10 Oil filters
2 Fan motor 7 Oil filler plug 11 Air cooler
3 Electric cabinet
Fig. 1.2 Front view of GA75 Full-feature

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1.1.2 Oil system (Fig. 1.5)

In air receiver/oil separator (AR), most of the oil is removed By-pass valve (BV) starts opening the oil supply from cooler
from the air/oil mixture centrifugally. The balance is removed (Co) when the oil temperature has increased to 40 degrees
by oil separator element (OS). The oil collects in the lower Celsius. At approx. 55 degrees Celsius 1) all the oil flows
part of air receiver/oil separator (AR), which serves as oil through the oil cooler.
tank.
Oil stop valve (Vs) prevents the compressor element from
The oil system is provided with a by-pass valve (BV). When flooding with oil when the compressor is stopped. The valve
the oil temperature is below 40 degrees Celsius 1), by-pass is opened by element outlet pressure when the compressor is
valve (BV) shuts off the oil supply from oil cooler (Co). Air started.
pressure forces the oil from air receiver/oil separator (AR)
through oil filters (OF) and oil stop valve (Vs) to compressor
element (E) and its lubrication points. Oil cooler (Co) is by-
passed.

2 3 4 5
1

16

10

51042F
15 11
12
13
14

1 Air outlet valve 7 Oil filters 12 Arrow, motor rotation direction

2 DD or PD filter (optional) 8 Unloader (depends on compressor type)
3 Air dryer (only on Full-feature) 9 Compressor element 13 Drive motor
4 Fan motor 10 Check valve 14 Automatic condensate drain outlet
5 Fan 11 Oil stop valve of optional OSD
6 Oil cooler 15 Manual condensate drain outlet
16 Condensate trap
Fig. 1.3 Rear view of GA75 Full-feature

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1 2 1.1.3 Cooling and condensate drain systems

(Fig. 1.5)

The cooling system comprises air cooler (Ca) and oil cooler
(Co). On air-cooled compressors, the cooling air is generated
by fan (FN). Water-cooled compressors have a cooling water
system. The water flows through the inlet pipe, the tubestacks
of the air cooler and oil cooler, and the outlet pipe.

51043F A condensate trap (4) is provided in the air outlet system.

4 3 The trap is equipped with a valve for automatic condensate
draining during operation (5) and a manually operated valve
for draining after stopping the compressor (6).
1 Pictograph, manual condensate drain valve
2 Pictograph, automatic condensate drain outlet
3 Automatic condensate drain outlet 1.2 Unloading/loading system (Fig. 1.5)
4 Manual condensate drain valve
1.2.1 Unloading
Fig. 1.4 Condensate drains
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 de-
energized. 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).

AF Air filter M2 Fan motor Y1 Loading solenoid valve

AO Air outlet M3 Refrigerant compressor 1 Fan, condenser
AR Air receiver/oil separator M4 Motor, condenser fan 2 Condenser
BV Oil cooler by-pass valve OF Oil filters 3 Condensate separator
Ca Air cooler OS Oil separator element 4 Condensate trap
CM Control module PDT1 Pressure sensor, oil separator 5 Automatic condensate drain
Co Oil cooler pressure difference outlet
CV Check valve PT20 Pressure sensor, air outlet 6 Manual condensate drain valve
DP1 Oil drain plug, air receiver SV Safety valve 7 Capillary tube
DP2 Oil drain plug, oil stop valve S2 Condenser fan control switch 8 Flexible, control or blow-off air
DP3 Oil drain plug, check valve S3 High pressure shut-down switch 9 Insulating block
E Compressor element TT11 Temperature sensor, compressor 10 Accumulator
FC Oil filler plug element outlet 11 Hot gas by-pass valve
FN Fan UA Unloader 12 Filter
Gl Oil level gauge UV Unloading valve 13 Air/air heat exchanger
IV Inlet valve VI Air filter service indicator 14 Oil scavenging flexible
LP Loading plunger Vp Minimum pressure valve 15 Air/refrigerant heat exchanger
M1 Drive motor Vs Oil stop valve (evaporator)
Fig. 1.5 Flow diagram (typical example of GA Full-feature)

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2. Loading plunger (LP) moves upwards and causes inlet 1.3 Elektronikon regulator
valve (IV) to close the air inlet opening.
3. Unloading valve (UV) is opened by receiver pressure. The The control system consists of an electronic regulator and a
pressure from air receiver (AR) is released towards control panel.
unloader (UA).
4. The pressure is stabilized at a low value. A small amount
of air is kept drawn in and is blown to the unloader. 1.3.1 Regulator (E1-Fig. 1.1)

Air output is stopped (0 %), the compressor runs unloaded. The regulator has following functions:

1.2.2 Loading 1.3.1.1 Automatic control of the compressor

When the net pressure decreases to the loading pressure, The regulator maintains the net pressure between
solenoid valve (Y1) is energized. The plunger of solenoid programmable limits by automatically loading and unloading
valve (Y1) moves upwards against spring force: the compressor. A number of programmable settings, e.g. the
unloading and loading pressures, the minimum stop time and
1. Control pressure is fed from air receiver (AR) via solenoid the maximum number of motor starts are taken into account.
valve (Y1) to loading plunger (LP) and unloading valve
(UV). The regulator stops the compressor whenever possible to
2. Unloading valve (UV) closes the air blow-off opening. reduce the power consumption and restarts it automatically
Loading plunger (LP) moves downwards and causes inlet when the net pressure decreases. In case the expected
valve (IV) to open fully. unloading period is too short, the compressor is kept running
to prevent too-short standstill periods.
Air output is resumed (100 %), the compressor runs loaded.

CMS1/2. Switches, compressor control

module
F1/5. Fuses
F21. Overload relay, drive motor
K21. Line contactor
K22. Star contactor
K23. Delta contactor
L1/L2/L3 Terminals, mains
PE Earth terminal
Q15. Circuit breaker, fan motor 3)
T1/T2. Transformers
1X1. Terminal strip
On Full-feature also:
F6/7/8. Fuses
K11. Contactor, refrigerant
compressor
K12. Contactor, condenser fan
1X4. Terminal strip

Fig. 1.6 Electric cubicle of 50 Hz

compressors (typical example)

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Warning A number of time-based automatic start/stop 1.3.2 Control panel (Fig. 1.8)
commands may be programmed. 2) Take into
account that a start command will be executed
(if programmed and activated), even after
Ref. Designation Function
manually stopping the compressor.

1 Automatic Indicates that the regulator is

operation LED automatically controlling the
compressor: the compressor is
1.3.1.2 Protecting the compressor loaded, unloaded, stopped and
restarted depending on the air
Shut-down consumption and the limitations
If the compressor element outlet temperature exceeds the programmed in the regulator.
programmed shut-down level, the compressor will be stopped.
This will be indicated on display (4-Fig. 1.8). The compressor 2 Voltage on LED Indicates that the voltage is
will also be stopped in case of overload of drive motor (13- switched on.
Fig. 1.3) or fan motor (4-Fig. 1.3). 3)
3 General alarm Is alight if a warning, service
Shut-down warning LED warning or shut-down warning
If the compressor element outlet temperature exceeds a condition exists or if a sensor is
programmed value below the shut-down level, this will also out of order.
be indicated to warn the operator before the shut-down level Blinks in case of shut-down, if a
is reached. sensor with shut-down function
(e.g. TT11) is out of order or after
Service warning an emergency stop.
The regulator continuously monitors the oil, oil filters, oil Consult the User manual for
separator and air filter. Each input is compared to programmed Elektronikon regulator, section
limits (temperatures, pressures and/or running hours). If these "Status data submenu".
limits are exceeded, a message will appear on display (4-Fig.
1.8) to warn the operator to replace the indicated component. 4 Display Indicates messages concerning
the compressor operating
Warning condition, a service need or a
A warning message also appears if: fault. Consult the User manual
On water-cooled compressors the cooling water outlet for Elektronikon regulator,
temperature exceeds the warning level. sections "Status data submenu"
On Full-feature compressors the dewpoint temperature exceeds and "Service submenu".
the warning level.
5 Function keys Keys to control and program the
compressor. See below.

6 Scroll keys Keys to scroll through the display.

1.3.1.3 Automatic restart after voltage failure
7 Tabulator key Key to go to the next field of the
For compressors leaving the factory, this function is made display.
inactive. If desired, the function can be activated. Consult
Atlas Copco. 8 Start button Push button to start the
compressor. LED (1) lights up
Warning If activated and provided the module was in the indicating that the regulator is
automatic operation mode, the compressor will operative (in automatic
automatically restart if the supply voltage to the operation). The LED goes out
module is restored within a programmed time after unloading the compressor
period. manually.
The power recovery time (the period within which the 9 Stop button Push button to stop the
voltage must be restored to have an automatic restart) compressor. LED (1) goes out.
can be set between 1 and 254 seconds or to symbol The compressor will stop after
00!. If the power recovery time is set to 00!, the running in unloaded condition for
compressor will always restart after a voltage failure, 30 seconds.
no matter how long it takes to restore the voltage.

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SENSORS/LOADING SOLENOID K01 Blocking relay OPTIONAL EQUIPMENT

VALVE K02 Auxiliary relay, star A1 Dryer
PDT1 Pressure sensor, pressure contactor B1 Electronic water drain
difference over oil separator K03 Auxiliary relay, delta (EWD)
PT20 Pressure sensor, air outlet contactor E4 Communication module
TT11 Temperature sensor, K04 Auxiliary relay, loading- K04' Auxiliary relay Load/Unload
compressor element outlet unloading for ES100
TT51 Temperature sensor, cooling K05 Auxiliary relay, high/low K25 Phase sequence protection
water outlet 4) pressure R1, K34 Drive motor thermistor
Y1 Loading solenoid valve K06 Auxiliary relay, manual/ protection, shutdown
automatic operation R2, K35 Drive motor thermistor
CUBICLE K07 Auxiliary relay, general protection, warning
F1/5 Fuses warning R3/R4/R7 Freeze protection
F21 Overload relay, drive motor K08 Auxiliary relay, general R5 Heater Electronic Water
K21 Line contactor shut-down Drain (EWD)
K22 Star contactor K10 Auxiliary relay, dryer R6 Heater Oil Separator Kit
K23 Delta contactor control (OSD)
Q15 Circuit breaker, fan motor 3) 0 Programmed stop button R96 Anti-condensation heater
T1/T2 Transformers S3 Emergency stop button S5 Key switch
1X1/2 Terminal strips S10 Main power isolating switch
MOTORS TSLL91 Thermostat freeze protection
CONTROL MODULE (E1) M1 Drive motor Y2 Solenoid valve, modulating
I Start button M2 Fan motor 3) control
Y51 Water shut-off valve (water-
cooled versions)

Fig. 1.7 Electrical diagram of 50 Hz compressors with star-delta starter (typical example)

Ref. Designation Function Abbre- Desig- Function

viation nation

S3-Fig. 1.2 Emergency Push button to stop the compres-

stop button sor immediately in case of Add Add To add compressor start/stop commands
emergency. After remedying the (day/hour)
trouble, unlock the button by
pulling it out. Canc Cancel To cancel a programmed setting when
programming parameters

Pictographs
10 Alarm
11 Automatic operation
12 Voltage on

11 1 2 12 4 6
1.3.3 Function keys

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, 3 8
or an emergency stop
10 9
- To have access to all data collected by the regulator
7
The functions of the keys vary depending on the displayed 5
menu. The actual function is abbreviated and indicated on
the bottom line of the display just above the relevant key. The 51046F
most common abbreviations are listed below.
Fig. 1.8 Control panel

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Abbre- Desig- Function Program/ Description

viation nation Function

Del Delete To delete compressor start/stop More Allows a quick look at the actual status
commands of the compressor. See section 3.4.

Lim Limits To show limits for a programmable Load/Unld To manually load/unload the compressor
setting

List List To list programmed start/stop commands MAIN MENU See Fig. 1.10. It is the gateway to
(day/hour) following menus:

Load Load To load the compressor manually Status data Calling up the status of the compressor
protection functions (service warning,
Main Main To return from a menu to the main shut-down and shut-down warning).
display (Fig. 1.9) Resetting of a shut-down and motor
overload. See section 1.3.1.
Menu Menu Starting from the main display (Fig. 1.9),
to initiate the main menu (Fig. 1.10) Measured data Calling up actually measured values and
which gives access to submenus the status of the motor overload
Starting from a submenu, to return to the protection.
main menu (Fig. 1.10)
Hours Calling up the running hours, loading
Mod Modify To modify programmable settings hours, regulator hours and number of
motor starts.
More More To have a quick look at the compressor
status Service Calling up and resetting the service
messages for the oil, oil filter, oil
Prog Program To program modified settings separator, air filter.

Rset Reset To reset a timer or message Test Allows a display test.

Rtrn Return To return to a previously shown option Modify settings Modifying the settings for regulation
or menu (e.g. loading and unloading pressures),
for protection (e.g. temperature shut-
Slct Select To select a submenu or to read more down level) and for service (e.g. for the
details of a selection shown on display oil).

Unld Unload To unload the compressor manually Timer Programming automatic compressor
start/stop commands.

Configuration Programming the time, date, display

1.3.4 Menu-driven control programs language, units, motor start mode and
date format.
To facilitate programming and controlling the compressor,
menu-driven programs are implemented in the electronic Saved data Calling up the saved data: last shut-
module. down, last emergency stop, longest load,
longest unload.
The User manual for Elektronikon regulator for GA5 up to
GA90C deals elaborately with all regulator functions.

Selecting a menu
Program/ Description
When the voltage is switched on, the MAIN DISPLAY (Fig.
Function
1.9) is shown automatically. The other menus are selected by
pressing one of function keys (5-Fig. 1.8). Pushing the key
MAIN DISPLAY Shows in short the operation status of <<Menu>> initiates the MAIN MENU (Fig. 1.10), giving
the compressor. It is the gateway to all access to most other functions via submenus; the submenus
functions. See Fig. 1.9. can be selected by pressing the key <<Slct>> (select).

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Delivery air
bar 7.0 Status data
Auto loaded ↓
Menu More Unld Main Slct
F1 F2 F3 F1 F2 F3

Fig. 1.9 Example of the main display Fig. 1.10 Example of a main menu

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.

1.4 Air dryer on GA Full-feature (Fig. 1.5)

1.4.1 Compressed air circuit

Compressed air enters heat exchanger (13) and is cooled by

the outgoing, dried air. Moisture in the incoming air starts to
condense. The air then flows through heat exchanger (15)
where the refrigerant evaporates and withdraws 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 condensate trap (4) which separates
condensate from air. The condensate is automatically drained
through outlet (5). The cold, dried air then flows through
heat exchanger (13), where it is warmed up by the incoming
air.

1.4.2 Refrigerant circuit

Compressor (M3) delivers hot, high-pressure refrigerant gas

which flows through condenser (2) where most of the
refrigerant condenses.

The liquid flows through liquid refrigerant dryer/filter (12) to

capillary tube (7). The refrigerant leaves the capillary tube at
evaporating pressure.

The refrigerant enters evaporator (15) where it withdraws heat

from the compressed air by further evaporation at constant
pressure. The heated refrigerant leaves the evaporator and is
sucked in by the compressor.

Footnotes chapter 1

1) The valve starts opening at 60 degrees Celsius and is fully open at 75 degrees Celsius for 13 bar and 175 psi compressors.
2) See User manual for Elektronikon regulator, section "Timer submenu".
3) Air-cooled compressors only.
4) Water-cooled compressors only.

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2 INSTALLATION
2.1 Dimension drawing (Fig. 2.1)

Fig. 2.1 Dimension drawing

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2.2 Installation proposal (Fig. 2.2)

Fig. 2.2 Installation proposal

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Ref. Description/recommendation Ref. Description/recommendation

on on
Fig. 2.2 Fig. 2.2

1 Install the compressor on a solid, level floor suitable 6 Position of control panel.
for taking the weight.
7 Position of mains cables.
2 Position of compressed air outlet valve.
8 Provision for inlet and outlet of energy recovery
3 The maximum total pipe length (including system (system is optional).
interconnecting piping between compressor and
receiver) can be calculated as follows: 9 Filter, type DD, for general purpose filtration
(optional). The filter traps solid particles down to
L = (dP x d5 x P) / (450 x Qc1.85)
1 micron with max. oil carry-over of 0.5 mg/m³. A
L = pipe length in m high-efficiency filter, type PD (optional), may be
dP = maximum allowable pressure drop installed downstream of a DD filter. This filter traps
(recommended 0.1 bar) solid particles down to 0.01 micron with max. oil
d = inner diameter of pipe in mm carry-over of 0.01 mg/m³. If oil vapour and odours
P = compressor outlet pressure in are undesirable, a filter of the QD type (optional)
bar absolute should be installed downstream of the PD filter.
Qc = free air delivery of compressor in l/s
10 The air receiver (optional) should be installed in a
4 Ventilation: the inlet grids and ventilation fan should frost-free room on a solid, level floor.
be installed in such a way that any recirculation of
cooling air to the compressor or dryer is avoided. For normal air consumption, the volume of the air
The air velocity to the grids must be limited to 5 m/ net (receiver and piping) can be calculated as
s. The maximum allowable pressure drop over the follows:
cooling air ducts is 50 Pa.
V = (0.25 x Qc x P1 x To) / fmax x dP x T1
- For alternatives 1 and 3, the required ventilation
capacity to limit the compressor room V = volume of air net in l
temperature can be calculated as follows: Qc = free air delivery of compressor in l/s
P1 = compressor air inlet pressure in
Qv = 1.06 N / dT for GA Pack air-cooled
bar absolute
compressors
fmax = cycle frequency = 1 cycle/30 s
Qv = (1.06 N + 8) / dT for GA Full-feature
dP = Punload - Pload in bar
air-cooled compressors
T1 = compressor air inlet temperature in K
Qv = 0.13 N / dT for GA Pack water-cooled To = air receiver temperature in K
compressors
Qv = (0.13 N + 8) / dT for GA Full-feature By-pass system for compressors with dryer (optional)
water-cooled compressors
11 Dryer by-pass pipe.
Qv = required ventilation capacity in m³/s
N = nominal motor power in kW
12 Condensate trap.
dT = temperature increase in compressor
room
14 Dryer by-pass valve (inside the bodywork).
- For alternatives 2 and 4: the fan capacity should
For water-cooled compressors
match the compressor fan capacity at a pressure
head equal to the pressure drop over the air
13 Position of cooling water pipes.
ducts.

5 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.

16 2920 1428 00
Instruction book

2.3 Electric cable size 1)

2.3.1 For GA55/GA55 W 2) 3)

Supply Frequency - MC cable 2) LC cable 2) MC cable 2) LC cable 2)

voltage Approval GA Pack GA Pack GA Full-feature GA Full-feature
(V) (mm²/AWG) (mm²/AWG) (mm²/AWG) (mm²/AWG)

200 50 - IEC 2x (3x70) + 70 2x (3x50) + 50 2x (3x70) + 70 2x (3x70) + 70

230 50 - IEC 2x (3x50) + 50 2x (3x35) + 35 2x (3x70) + 70 2x (3x50) + 50
400 50 - IEC 3x70 + 70 3x50 + 50 3x70 + 70 3x70 + 70
440 50 - IEC 3x50 + 50 3x50 + 50 3x70 + 70 3x50 + 50
500 50 - IEC 3x50 + 50 3x35 + 35 3x50 + 50 3x35 + 35
550 50 - IEC 3x35 + 35 3x35 + 35 3x50 + 50 3x35 + 35
690 50 - IEC 3x25 + 25 3x25 + 25 3x25 + 25 3x25 + 25

200 60 - IEC 2x (3x70) + 70 2x (3x50) + 50 2x (3x70) + 70 2x (3x70) + 70

200 60 - CSA/UL 2x (4x AWG 2/0) -- 2x (4x AWG 3/0) --
220-230 60 - IEC 2x (3x50) + 50 2x (3x50) + 50 2x (3x70) + 70 2x (3x50) + 50
220-230 60 - CSA/UL 2x (4x AWG 2/0) -- 2x (4x AWG 2/0) --
380 60 - IEC 3x70 + 70 3x50 + 50 3x70 + 70 3x70 + 70
440-460 60 - IEC 3x50 + 50 3x50 + 50 3x70 + 70 3x50 + 50
440-460 60 - CSA/UL 4x AWG 2/0 or -- 4x AWG 250 or --
2x (4xAWG 4) 2x (4xAWG 2)
575 60 - CSA/UL 4x AWG 2 or -- 4x AWG 1 or --
2x (4xAWG 6) 2x (4xAWG 4)

2.3.2 For GA75/GA75 W 2) 3)

Supply Frequency - MC cable 2) LC cable 2) MC cable 2) LC cable 2)

voltage Approval GA Pack GA Pack GA Full-feature GA Full-feature
(V) (mm²/AWG) (mm²/AWG) (mm²/AWG) (mm²/AWG)

200 50 - IEC 2x (3x95) + 95 2x (3x70) + 70 2x (3x120) + 120 2x (3x95) + 95

230 50 - IEC 2x (3x70) + 70 2x (3x70) + 70 2x (3x95) + 95 2x (3x70) + 70
400 50 - IEC 3x95 + 95 or 3x70 + 70 2x (3x35) + 35 3x95 + 95 or
2x (3x35) + 35 2x (3x35) + 35
440 50 - IEC 3x95 + 95 or 3x70 + 70 3x95 + 95 or 3x70 + 70
2x (3x25) + 25 2x (3x35) + 35
500 50 - IEC 3x70 + 70 3x70 + 70 3x70 + 70 3x70 + 70
550 50 - IEC 3x70 + 70 3x50 + 50 3x70 + 70 3x50 + 50
690 50 - IEC 3x50 + 50 3x35 + 35 3x50 + 50 3x35 + 35

200 60 - IEC 2x (3x120) + 120 2x (3x95) + 95 2x (3x120) + 120 2x (3x95) + 95

200 60 - CSA/UL 2x (4x AWG 250) -- 2x (4x AWG 300) --
220-230 60 - IEC 2x (3x95) + 95 2x (3x70) + 70 2x (3x95) + 95 2x (3x95) + 95
220-230 60 - CSA/UL 2x (4x AWG 4/0) -- 2x (4x AWG 250) --
380 60 - IEC 2x (3x35) + 35 3x95 + 95 or 2x (3x50 + 50) 3x95 + 95 or
2x (3x35) + 35 2x (3x35) + 35
440-460 60 - IEC 3x95 + 95 or 3x70 + 70 3x95 + 95 or 3x95 + 95 or
2x (3x35) + 35 2x (3x35) + 35 2x (3x25) + 25
440-460 60 - CSA/UL 4x AWG 4/0 or -- 4x AWG 250 or --
2x (4xAWG 2) 2x (4xAWG 1)
575 60 - CSA/UL 4x AWG 2/0 or -- 4x AWG 3/0 or --
2x (4xAWG 3) 2x (4xAWG 3)

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 Instruction book

2.3.3 For GA90C/GA90C W 2) 3)

Supply Frequency - MC cable 2) LC cable 2) MC cable 2) LC cable 2)

voltage Approval GA Pack GA Pack GA Full-feature GA Full-feature
(V) (mm²/AWG) (mm²/AWG) (mm²/AWG) (mm²/AWG)

200 50 - IEC 2x (3x120) + 120 2x (3x95) + 95 2x (3x120) + 120 2x (3x95) + 95

230 50 - IEC 2x (3x95) + 95 2x (3x70) + 70 2x (3x95) + 95 2x (3x70) + 70
400 50 - IEC 2x (3x35) + 35 3x95 + 95 or 2x (3x50) + 50 3x95 + 95 or
2x (3x35) + 35 2x (3x35) + 35
440 50 - IEC 3x95 + 95 or 3x70 + 70 2x (3x35) + 35 3x95 + 95 or
2x (3x35) + 35 2x (3x35) + 35
500 50 - IEC 3x95 + 95 or 3x70 + 70 3x95 + 95 or 3x70 + 70
2x (3x25) + 25 2x (3x35) + 35
550 50 - IEC 3x70 + 70 3x70 + 70 3x70 + 70 3x70 + 70
690 50 - IEC 3x50 + 50 3x35 + 35 3x50 + 50 3x35 + 35

200 60 - IEC 2x (3x120) + 120 2x (3x95) + 95 2x (3x120) + 120 2x (3x95) + 95

200 60 - CSA/UL 2x (4x AWG 250) -- 2x (4x AWG 300) --
220-230 60 - IEC 2x (3x95) + 95 2x (3x70) + 70 2x (3x120) + 120 2x (3x95) + 95
220-230 60 - CSA/UL 2x (4x AWG 4/0) -- 2x (4x AWG 250) --
380 60 - IEC 2x (3x35) + 35 3x95 + 95 or 2x (3x50) + 50 3x95 + 95 or
2x (3x35) + 35 2x (3x35) + 35
440-460 60 - IEC 3x95 + 95 or 3x70 + 70 2x (3x35) + 35 3x95 + 95 or
2x (3x35) + 35 2x (3x25) + 25
440-460 60 - CSA/UL 4x AWG 4/0 or -- 4x AWG 250 or --
2x (4xAWG 2) 2x (4xAWG 1)
575 60 - CSA/UL 4x AWG 2/0 or -- 4x AWG 3/0 or --
2x (4xAWG 3) 2x (4xAWG 3)

2.4 Electrical connections Recommended Recircula- Open

(Figs. 1.6 and 1.7) maxima - mg/l ting system system

- Provide an isolating switch.

- Check the fuses and the setting of the overload relay. See Chloride (Cl-) < 600 < 150
section 7. Sulphate (SO --) < 400 < 250
4
- Connect the power supply to terminals L1/L2/L3. Total solids < 3000 < 750
- Connect the earth conductor to earth bolt (PE) and the Suspended solids (as SiO ) < 10 < 10
2
neutral conductor (if provided) to connector (N). Free chlorine (Cl ) <4 <2
+ 2
Ammonia (NH ) < 0.5 < 0.5
4
Copper < 0.5 < 0.5
Iron < 0.2 < 0.2
Manganese < 0.1 < 0.1
2.5 Pictographs Oxygen <3 <3
Carbonate hardness (as CaCO ) 50-1000 50-500
3
See next page. Organics (KMnO Consumption) < 25 < 10
4

No algae
No oil
2.6 Cooling water requirements Remark
Chloride and sulphate are interactive. In pass-through systems
Following requirements are given as a general rule to prevent the sum of the squares must not exceed 85,000. For
cooling water problems. If in any doubt, consult Atlas Copco. recirculating systems with proper controls and treatment, the
sum of the squares may be up to 520,000. Note that the
sulphate value must include any sulphite present.

18 2920 1428 00
Instruction book

1. Water outlet 9. Consult Instruction book before greasing

2. Manual condensate drain 10. Switch off voltage before removing protecting cover
3. Water inlet inside electric cubicle
4. Automatic condensate drain 11. Consult Instruction book before carrying out
5. Before connecting compressor electrically, consult maintenance
Instruction book for motor rotation direction 12. Stop compressor before cleaning coolers
6. Switch off voltage and depressurize compressor before 13. Warning: voltage
repairing 14. Warning: potential risk of sudden releasing of spring
7. Torques for steel (Fe) or brass (CuZn) bolts underneath cover of unloader during disassembling,
8. Lightly oil gasket of oil filter, screw it on and tighten by have possible repair carried out by Atlas Copco
hand (approx. half a turn)

Fig. 2.3 Pictographs (typical examples)

Footnotes chapter 2

1) If the size does not comply with local legislation, the stricter of the two shall apply.
2) For IEC approval:
- LC stands for loose conductors in the air; values according to DIN VDE 0113 - EN 60204 T1 - IEC 204-1.
- MC stands for cables in open cable trunking system, in cable trays or on walls; same values for loose conductors in a conduit or in
a cable trunking system; values according to EN 60204-1 Table 5.
3) For CSA/UL approval:
- LC stands for loose copper conductors in the air.
- MC stands for not more than 3 loose copper conductors in a raceway or in a cable; values according to CE Code handbook Table
1 and Table 2.
- For CSA/UL conductors with AWG size, the sizes are valid for cables with insulation of 85/90 degrees Celsius.

2920 1428 00 19
 Instruction book

3 OPERATING INSTRUCTIONS 3.1.4 Moving/lifting

The compressor can be moved by a lift truck using the slots in

3.1 Initial start-up the frame. Take care not to damage the bodywork during lifting
or transport. Make sure that the forks protrude from the other
3.1.1 Safety side of the frame. The compressor can also be lifted after
inserting beams into the slots. Make sure that the beams cannot
The operator must apply all relevant safety precautions, slide and that they protrude from the frame equally. The chains
including those mentioned in this book. must be held parallel to the bodywork by chain spreaders in
order not to damage the compressor. The lifting equipment
must be placed in such a way that the compressor will be lifted
3.1.2 User manual perpendicularly. Lift smoothly and avoid twisting.
Read the "User manual for Elektronikon regulator for GA5
up to GA90C" to familiarize yourself with all regulator
functions. 3.1.5 External compressor status indication

The electronic regulator is provided with auxiliary contacts

3.1.3 Outdoor/altitude operation (K05, K06, K07 and K08-Fig. 1.7) at the back of electronic
module (E1-Fig. 1.1) for external indication of:
If the compressor is installed outdoors or if the air inlet - low or high air pressure (K05), 15-13 closed means
temperature can be below 0 degrees Celsius, precautions must high air pressure
be taken. In this case, and also if operating above 1000 m, - manual load/unload or automatic operation (K06)
consult Atlas Copco. - warning condition (K07)
- shut-down condition (K08)

Maximum load for these contacts: 1 A / 250 V AC. Stop the

compressor and switch off the voltage before connecting
external equipment. Consult Atlas Copco.

3.1.6 Compressor control modes

The electronic regulator has two switches (CMS1/2-Fig. 1.6)

to select following compressor control modes (0 = open / 1 =
closed):

CMS1 CMS2 Compressor mode

0 0 The compressor is switched off.

F022-1

1 0 The compressor is in local control mode

(remote control is made inactive): the
compressor will react to commands
1 2 3 Dma 4 AV entered by the buttons on the control
panel. Compressor start/stop commands
via function Timer (see section 1.3.1)
AV. Air outlet valve are active, if programmed.
Dma. Manual condensate drain valve
1. Condensate drain flexible for automatic drain 0 1 The compressor is in remote control
2. Condensate drain flexible for manual drain mode (local control is made inactive):
3. Connection between flexible (2) and valve (Dma) the compressor will react to commands
4. Bottle containing Atlas Copco Roto-injectfluid from external switches. Emergency stop
(S3) remains active. Compressor start/
Fig. 3.1 Components delivered loose with compressor stop commands via function Timer (see
(typical examples) section 1.3.1) are still possible.

20 2920 1428 00
Instruction book

3. Check transformer (T1-Fig. 1.6) for correct connection, the

CMS1 CMS2 Compressor mode
settings of drive motor overload relay (F21-Fig. 1.6) and
fan motor circuit breaker (Q15-Fig. 1.6) 2), and that overload
For remote starting and stopping: relay (F21-Fig. 1.6) is set for automatic resetting.
Connect a remote start button (normally 4. Fit the air outlet valve (1-Fig. 1.1). Close the valve.
open contact) between terminals 30 and Connect the air net to the valve.
31 and connect a remote stop button 5. Connect the manual condensate drain valve (4-Fig. 1.4).
(normally closed contact) between Close the valve. Connect the valve to a drain collector.
terminals 30 and 32 of terminal strip See also Fig. 2.2, reference 5.
(1X1-Fig. 1.6). 6. Connect the automatic condensate drain outlet (3-Fig. 1.4)
Bridge terminals 30 and 34: In this mode, to the drain collector.
the outlet pressure is still sensed by 7. On water-cooled compressors, drain valves should be fitted
pressure transducer (PT20-Fig. 1.5), by the customer in the water inlet and outlet pipes. Also
resulting in loading and unloading of the provide and open the water inlet and regulating valve.
compressor at the pressures programmed Consult section 2.6 for the water requirements.
in the electronic regulator. If terminals 8. Check the oil level. The pointer of the level gauge (7-Fig.
30 and 34 are not bridged, the 3.3) should register in the green or orange range. The
compressor is switched out of automatic bottle with Atlas Copco Roto-injectfluid (4-Fig. 3.1) can
load/unload operation and remains be used for topping up. Check section 3.2 for lubrication
running unloaded. of the compressor element.
For remote loading/unloading (via 9. Labels are delivered with the compressor, warning the
external pressure switch): Bridge operator that:
terminals 30 and 35 and connect a load/ - the compressor automatically restarts after voltage
unload switch between terminals 30 and failure (see section 1.3.1)
34. This results in loading and unloading - the compressor is automatically controlled and may be
of the compressor at the closing and restarted, even after manually stopping (see section
opening pressures of the external 1.3.1)
pressure switch respectively. Stick these labels on an obvious place near the control
panel. Read these warnings (as well as the warnings
1 1 Compressor is computer-controlled via mentioned in section 1.3.1) and take them into account.
communication module (E4-Fig. 1.7). 1) 10. Switch on the voltage. Start the compressor and stop it
Consult Atlas Copco. immediately. Check the rotation direction of the motors.
First check the drive motor (10-Fig. 3.2). The correct
rotation direction is indicated by an arrow (8-Fig. 3.5)
provided on the gear casing (rotation direction depends
Attention on compressor type). If the rotation direction is wrong,
Have the modifications checked by Atlas Copco. Stop the switch off the voltage and reverse two incoming electric
compressor and switch off the voltage before connecting lines.
external equipment. Only voltage-free contacts are allowed. Then check fan motor (3-Fig. 3.2) on air-cooled
compressors. Rotation arrows, visible through the grating
in the roof, are provided on the plate below the fan. If
necessary, switch off the voltage and reverse two incoming
electric connections at the terminals of circuit breaker
(Q15-Fig. 1.6).
Start-up 11. Check the programmed settings. 3)
1. The compressor element, air receiver and motor are secured 12. Start and run the compressor for a few minutes. Check
to the frame, immobilizing the vibration dampers during that the compressor operates normally.
transport.
Remove bolts (8-Fig. 3.2) and support (9-Fig. 3.2).
Remove the bolts, nuts and bushes (7-Fig. 3.2 and 4-Fig.
3.3) immobilizing the vibration dampers of the compressor
element. 3.2 Before starting
Remove the four bolts and bushes (5-Fig. 3.3) immobilizing
the vibration dampers of the air receiver. If the compressor has not run for the past 6 months, it is strongly
2. Check that the electrical connections correspond to the recommended to improve the lubrication of the compressor
local codes. Check the connections for correct tightness. element at starting: Disconnect air inlet hose (10-Fig. 3.5),
The installation must be earthed and protected against short remove unloader (9-Fig. 3.5) and pour 3/4 l of oil into the
circuits by fuses of the inert type in all phases. An isolating compressor element. Reinstall the unloader and reconnect
switch must be installed near the compressor. the pipe. Make sure that all connections are tight.

2920 1428 00 21
 Instruction book

3 4
1 2

6 5
7
9 8
51049F 10

1 DD or PD filter (optional) 5 Check valve 8 Bolt (to be removed)

2 Air dryer (only on Full-feature) 6 Compressor element 9 Support (to be removed)
3 Fan motor 7 Bolt, bush and nut (to be 10 Drive motor
4 Oil cooler removed)

Fig. 3.2 View of compressor compartment

1. Check the oil level (7-Fig. 3.3). The pointer should register 3.3 Starting (Fig. 1.8)
in the green range or in the orange range.
2. If the coloured part of the air filter service indicator (11- Important
Fig. 3.5) shows full out, replace the air filter element (2-
Fig. 3.3). Reset the service indicator by pushing its knob For GA Full-feature, switch on the voltage 4 hours before
and reset the service warning 4). starting to energize the crankcase heater of the refrigerant
compressor.
On water-cooled compressors also:
3. Check that the cooling water drain valves (customer's 1. Switch on the voltage. Check that voltage on LED (2)
installation) in the inlet and outlet pipes are closed. lights up. The message <<compressor off>> appears.
4. Open the cooling water inlet valve (customer's installation). 2. Open the air outlet valve (1-Fig. 1.1).
5. Open the water flow regulating valve (customer's 3. Close the condensate drain valve (4-Fig. 1.4).
installation). This step can be overlooked if, after previous 4. Press start button <<I>> (8). The compressor starts running
operation, the setting of this valve has not been disturbed. and automatic operation LED (1) lights up. Ten seconds
5) after starting, the drive motor switches over from star

22 2920 1428 00
Instruction book

to delta. At the same time 5) the compressor starts running 3.4 During operation
loaded. The message on display (4) changes from <<Auto
unloaded>> to <<Auto loaded>>. 1. Check the oil level during loaded operation: the pointer
of the level gauge (7-Fig. 3.3) must register in the green
On water-cooled compressors also: range.
5. If necessary, regulate the cooling water flow during loaded If the level is in the LOW range, press button O (9-Fig.
running to obtain the most suitable temperature at the 1.8), wait until the compressor has stopped and switch off
outlet of the compressor element, i.e. between 2 and 7 the voltage. Depressurize the oil system by unscrewing
degrees Celsius above the relevant temperature in Fig. 3.4. the oil filler plug (3-Fig. 3.3) one turn, wait a few minutes
For optimum operation, the cooling water outlet and add oil until the level reaches the filler plug. Tighten
temperature 6) must never exceed the value specified in the plug.
section 7.5. Consult Atlas Copco if condensate should be 2. If the coloured part of the air filter service indicator (11-
formed during frequent unloading periods. Fig. 3.5) shows full out, stop the compressor, switch off
the voltage and replace the air filter element (2-Fig. 3.3).
Reset the indicator by pushing its knob and reset the service
warning 4).
3. If automatic operation LED (1-Fig. 1.8) is alight, the
regulator is automatically controlling the compressor, i.e.
loading, unloading, stopping of the motors and restarting.

3.4.1 Checking the display

1. Regularly check the display (4-Fig. 1.8) for readings and

messages. Normally, the main display (Fig. 1.9) is shown,
1 indicating the compressor outlet pressure, the status of the
compressor and the abbreviations of the functions of the
9 keys below the display.
2. Always check the display (4-Fig. 1.8) and remedy the
trouble if alarm LED (3) is alight or blinks. Consult the
User manual for Elektronikon regulator, section "Status
data submenu".
3. The display (4-Fig. 1.8) will show a service message if
2 one of the monitored components is to be serviced; replace
the component and reset the relevant timer. Consult the
8 User manual for Elektronikon regulator, section "Service
submenu".

3 Warning Before carrying out any maintenance, repair or

7 adjustment, stop the compressor, press emergency
stop button (S3-Fig. 1.2), switch off the voltage
4 and depressurize the compressor.

Notes
- Whenever a warning, service request, sensor error or motor
51025F
5 6 5 overload message is displayed, the free spaces on the
display between the function keys (5-Fig. 1.8) are filled
with blinking indicators (**).
1 Oil filters
- When more than one message needs to be displayed (e.g.
2 Air filter
both warning and service), the messages will be displayed
3 Oil filler plug
one after the other for 3 seconds.
4 Bolt and bush (to be removed)
5 Bolt and bush (to be removed)
4. Regularly press the key <<More>> (5-Fig. 1.8) 7) to call
6 Oil drain plug, air receiver
up information about the actual compressor condition:
7 Oil level gauge
- the status of controlling the compressor (automatic or
8 Air receiver
manual, local or remote)
9 Safety valve
- the status of the compressor start/stop timer (on or off)
8)
Fig. 3.3 Air receiver

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 Instruction book

Example:
If operating at a pressure of 10 bar(e) in an ambient temperature of 20 degrees Celsius and at a relative air humidity of 100 %,
the minimum temperature to prevent condensate from forming is 68 degrees Celsius. Regulate the cooling water flow during
loaded operation to obtain a temperature between 70 and approx. 75 degrees Celsius at the outlet of the compressor element.

Fig. 3.4 Minimum compressor element temperature for water-cooled units

- the maximum allowable unloading pressure If required, the compressor can be unloaded manually. In this
- the outlet pressure case, the compressor is switched out of automatic operation,
- the pressure difference over the oil separator i.e. the compressor remains running unloaded unless it is
- the compressor element outlet temperature loaded again manually.
- the actual cooling water outlet temperature 9)
- the status of the overload protection of both the drive Manually unloading
motor and fan motor 10) (normal or not) Press the key <<Unld>> (unload) (5). LED (1) goes out. The
- the total running and loading hours message <<Manual Unloaded>> appears on the display.

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,
i.e. the compressor will be loaded if the air net pressure drops
below the programmed level.
3.5 Manual control (Fig. 1.8) 11)
Manually starting
Normally, the compressor runs in automatic operation, i.e. the In automatic operation, the regulator limits the number of
electronic regulator loads, unloads, stops and restarts the motor starts. If the compressor is stopped manually, it must
compressor automatically. LED (1) is then alight. not be restarted manually within 6 minutes after the last stop.

24 2920 1428 00
Instruction book

3.6 Stopping
1 1. Press stop button <<O>> (9-Fig. 1.8). LED (1) goes out.
13 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-Fig. 1.2). Alarm LED (3) blinks. After
12 remedying the fault, unlock the button by pulling it out
and press key <<Rset>> (5) before restarting. The message
2 <<All conditions are OK>> appears. Press keys
11 <<Menu>> and <<Main>>.
3. Close air outlet valve (1-Fig. 1.1) and switch off the voltage.
10 4. Open condensate drain valve (4-Fig. 1.4).

On water-cooled compressors only

5. Close the cooling water inlet valve.
9 6. If freezing temperatures may be expected, drain the
cooling system completely.

3
3.7 Taking out of operation at end of
8 compressor service life

4 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.
4. Shut off and depressurize the part of the air net which is
51050F
connected to the outlet valve. Disconnect the compressor
6 5 air outlet pipe from the air net.
7
5. Isolate and disconnect the water system from the cooling
1 Oil cooler 8 Arrow, motor rotation water net.
2 Safety valve direction (depends on 6. Drain the oil, water and condensate circuits.
3 Compressor element compressor type) 7. Disconnect the condensate piping from the condensate net.
4 Check valve 9 Unloader
5 Oil drain plug, check 10 Air inlet hose
valve 11 Service indicator, air
6 Oil stop valve filter
7 Oil drain plug, oil stop 12 Loading solenoid valve
valve 13 Oil filters

Fig. 3.5 View of compressor element

Footnotes chapter 3
1) Optional.
2) Air-cooled compressors only.
3) Consult User manual for Elektronikon regulator, section "Programmable settings".
4) Using key <<Rset>> in submenu <<Service>>: see User manual for Elektronikon regulator, section "Service submenu".
5) Programmable.
6) Consult User manual for Elektronikon regulator, section "Modifying protection settings".
7) If the function <<More>> is not indicated on the bottom line of display (4-Fig. 1.8), press key <<Menu>> (5) until function <<Main>>
appears above key (F1), then press the key <<Main>>.
8) The compressor is automatically started and stopped if these start/stop commands are programmed and activated; consult section 1.3.1.
9) For water-cooled compressors.
10) For air-cooled compressors.
11) 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>>.

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4 MAINTENANCE
Attention The bearings must be re-greased every 4,000 operating hours
Before carrying out any maintenance or repair on the with a high-temperature ball bearing grease ASONIC HQ
compressor, press stop button (9-Fig. 1.8), wait until the 72-102. Quantity: 16 g per bearing. The lubrication points
compressor has stopped (approx. 30 seconds), press are marked. A cartridge with the correct type of grease can be
emergency stop button (S3-Fig. 1.2) and switch off the voltage. ordered at Atlas Copco; see section 4.6.
Close the air outlet valve and depressurize the air system.
Apply all relevant safety precautions, including those
mentioned in this book. 4.2 Preventive maintenance schedule for
the compressor 1) (Fig. 1.5)
The air outlet valve can be locked during maintenance or repair
as follows:
Attention
- Close the valve.
For overhauling or carrying out preventive maintenance,
- Remove the bolt fixing the handle.
service kits are available. See section 4.6. Atlas Copco offers
- Lift the handle and turn it until the slot of the handle fits
several types of Service contracts, relieving you of all
over the blocking edge on the valve body.
preventive maintenance work. For more details, consult your
- Lock the handle using the special bolt and wrench delivered
nearest Atlas Copco representative.
loose with the compressor.
The schedule comprises a summary of the maintenance
instructions. Read the respective section before taking
4.1 Drive motor (10-Fig. 3.2) maintenance measures. The "longer interval" checks must
also include the "shorter interval" checks. When servicing,
Also consult the manufacturer's instructions stuck on the drive replace all disengaged packings, e.g. gaskets, O-rings, washers.
motor.

26 2920 1428 00
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Period 2) Running See See notes Operation

hours 2) section below table

Daily Before starting

" -- 3.2 - Check oil level (Gl)
During operation
" -- 3.4/7.1 - Check readings on display
" -- -- - Check that condensate is discharged (5) during loading
" -- 3.4 - Check oil level (Gl)
" -- 3.4 - Check air filter service indicator (VI)
-- -- 3.3 - Regulate cooling water flow (water-cooled compressors)

After stopping
-- -- 3.6 - Drain condensate (6)

3-monthly -- 5.3 3 Operate safety valve (SV)

" 500 5.2 - Check coolers (Co/Ca) and condenser of dryer; clean if necessary
" 500 5.1 1 Remove air filter element (AF). Clean by air jet and inspect
" -- -- - Remove, dismantle and clean float valve of condensate trap (4)
" -- -- 6 Check for possible leakage
" -- -- 7 Carry out a LED/display test

Yearly -- 5.3 - Have safety valve (SV) tested

" -- -- 8 Have the temperature shut-down function tested
" -- -- - Have the operation of the electrical interlockings, motor breakers,
etc. tested by an electrician
" 2000 -- - Check scavenge line (14) for cleanness
" 4000 4.6/5.1 2 Replace air filter element (AF)
" 4000 4.3/4.4/4.6 4 If Atlas Copco Roto-injectfluid is used, change oil and oil filter
For GA 7.5-8-10 bar and 100-125-150 psi
" 1000 4.3/4.4 - If oil as specified in section 4.3.2 is used, change oil and oil filter

For GA 13 bar and 175 psi

" 500 4.3/4.4 - If oil as specified in section 4.3.2 is used, change oil and oil filter

" -- -- 9 Have all flexibles/flexible joints inspected

-- -- 4.1 - Re-grease bearings of drive motor as specified

2-Yearly 8000 -- 5 Have oil separator (OS) replaced

Notes
1. More frequently when operating in a dusty atmosphere. Replace damaged or heavily contaminated elements.
2. Use genuine Atlas Copco filters.
3. By unscrewing the cap one or two turns and retightening it or by pulling the valve lifting lever.
4. Recommended oil: Atlas Copco Roto-injectfluid. For the change interval in extreme conditions of temperature, humidity
or cooling air, consult Atlas Copco.
5. Or when the pressure drop over the separator exceeds 1 bar. See section 3.4.1 to call up this value. Check the pressure drop
when the compressor is running loaded and preferably with a stable working pressure.
6. Any leakage should be attended to immediately.
7. Consult the User manual for Elektronikon regulator, section "Test submenu".
8. Consult the User Manual for the 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
settings. Run the compressor: when reaching the setting, the unit must shut down. Afterwards, reset the warning and shut-
down levels to their original values.
9. Damaged flexibles or flexible joints must be replaced.

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4.3 Oil specifications High-quality, mineral oil with oxidation inhibitors and anti-
foam and anti-wear properties. The viscosity grade must
Attention correspond to the ambient temperature and ISO 3448, as
Never mix oils of different brands or types. Use only non- follows:
toxic oils.
Ambient Viscosity Viscosity
temperature grade index
4.3.1 Atlas Copco Roto-injectfluid

It is strongly recommended to use Atlas Copco Roto- Consistently above

injectfluid. This is special oil for screw compressors which 25 degrees Celsius . . . . . . ISO VG 68 Minimum 95
keeps the compressor in excellent condition. Between 25 and
0 degrees Celsius . . . . . . . ISO VG 46 Minimum 95
Atlas Copco Roto-injectfluid can be ordered in following
quantities:

Quantity Ordering number

20-litre can 2901 0522 00
209-litre drum 2901 0045 01 4.4 Oil and oil filter change
(Figs. 3.3 and 3.5)

4.3.2 Mineral oil 1. Run the compressor unloaded for 3 minutes.

2. Stop the compressor. Switch off the voltage. Unscrew oil
Although Roto-injectfluid is recommended, mineral oil can filler plug (3-Fig. 3.3) only one turn to permit any pressure
be used after taking following precautions: in the system to escape.
- the previously used oil should first be drained and the 3. Remove the vent plug of the oil cooler, wait 5 minutes,
system flushed remove drain plug (7-Fig. 3.5) and catch the oil in a
- the oil filters should be replaced receptacle.
- the oil must meet the requirements as specified below 4. Remove the oil filters (13-Fig. 3.5).

1 2 3

F105
8 7 6 5 4

1. Oil separator kit 4. Minimum pressure valve kit 7. Oil stop valve kit
2. Condensate trap kit 5. Check valve kit 8. Unloading valve kit
3. Filter kit 6. By-pass valve kit

Fig. 4.1 Preventive maintenance kits (typical examples)

28 2920 1428 00
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5. Clean the filter seats on the manifold. Oil the gaskets of 5 ADJUSTMENTS AND SERVICING
the new elements. Screw the elements into place until the
gaskets contact their seats, then tighten by hand (approx. PROCEDURES
half a turn).
6. Drain the oil by removing drain plugs (6-Fig. 3.3 and 5- 5.1 Air filter (2-Fig. 3.3)
Fig. 3.5). Collect the oil in a collector and deliver it to the
local oil collection service. 1. Stop the compressor. Switch off the voltage. Release the
7. Reinstall plugs (6-Fig. 3.3, 5-Fig. 3.5 and 7-Fig. 3.5) and snap clips and remove the dust trap and air filter element.
fill the air receiver with oil until the level reaches the filler Clean the trap. Discard the filter element.
plug opening. Reinstall oil filler plug (3-Fig. 3.3) and the 2. Refit the new element and the trap.
vent plug of the oil cooler. 3. Reset the service indicator (11-Fig. 3.5) by pushing the
8. Run the compressor for a few minutes loaded. Stop the knob in the extremity of the body.
compressor and wait a few minutes to allow the oil to settle. 4. Reset the air filter service warning 1).
Depressurize the system. Fill the air receiver with oil until
the level reaches the filler plug opening. Tighten filler
plug (3-Fig. 3.3). 5.2 Coolers
9. Reset the oil and oil filter service warnings 3).
Keep the coolers clean to maintain the cooling efficiency.

4.5 Storage after installation On air-cooled compressors

Remove any dirt from the coolers with a fibre brush. Never
Run the compressor twice a week until warm. Load and unload use a wire brush or metal objects. Then clean by air jet in
the compressor a few times. If the compressor is stored without reverse direction of normal flow while covering all compressor
running from time to time, protective measures must be taken. parts under the coolers. If it is necessary to wash the coolers
Consult Atlas Copco. with a cleansing agent, consult Atlas Copco.

On water-cooled compressors
4.6 Service kits Consult Atlas Copco for cleaning.

Service kits are available offering the benefits of genuine Atlas

Copco parts while keeping the maintenance budget low. The 5.3 Safety valve (2-Fig. 3.5)
kits comprise all parts needed for servicing.
Operate the safety valve, depending on the type of valve:
Service kit for oil filters Ordering number - by unscrewing the cap one or two turns and retightening it
and air filter - or by pulling the valve lifting lever
For GA55-GA55 W 2901 0775 00
For GA75-GA75 W 2901 0776 00 Testing
For GA90C-GA90C W 2901 0776 00 The valve can be tested on a separate compressed air line. If
. the valve does not open at the pressure specified in section
Service kit for oil separator Ordering number 7.2, consult Atlas Copco.
For all GA 2901 0774 00
Warning No adjustments are allowed. Never run the
Motor grease compressor without safety valve.
The ordering number for a motor grease cartridge is 2901 0338
01 (see section 4.1).

Footnotes chapter 4

1) Use only authorized parts. Any damage or malfunction by the

use of unauthorized parts is not covered by Warranty or Product
Liability.
2) Whichever interval comes first. The local Atlas Copco Sales
Company may overrule this schedule depending on the working Footnotes chapter 5
conditions of the compressor.
3) Using key <<Rset>> in submenu <<Service>>: see User manual 1) Using key <<Rset>> in submenu <<Service>>: see User manual
for Elektronikon regulator, section "Service submenu". for Elektronikon regulator, section "Service submenu".

2920 1428 00 29
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6 PROBLEM SOLVING
Consult the User manual for Elektronikon regulator (section d. Leak in control air flexibles
"Status data submenu") if a service message or fault message d. See 1c
appears on the display (4-Fig. 1.8) or when alarm LED (3- e. Inlet valve (IV) does not fully open
Fig. 1.8) is alight or blinks. e. See 1b
f. Oil separator element (OS) clogged
Before starting repairs: f. Have element replaced
Press stop button (9-Fig. 1.8), wait until the compressor has g. Air leakage
stopped (approx. 30 seconds), press emergency stop button g. See 1c
(S3-Fig. 1.2) and switch off the voltage. Close the air outlet h. Safety valve (SV) leaking
valve and depressurize the air system. Furthermore, apply all h. Have valve replaced
relevant safety precautions, including those mentioned in this i. Compressor element (E) out of order
book. The air outlet valve can be locked as described in section i. Consult Atlas Copco
4.
5. Excessive oil flow through air inlet filter after stopping
Mechanical faults and suggested remedies (Fig. 1.5) a. Check valve (CV) leaking or oil stop valve (Vs) jammed
a. Have defective parts replaced. Replace air filter element
1. Push button I is pressed, compressor starts running, (AF)
but does not load after a delay time
a. Solenoid valve (Y1) out of order 6. Safety valve (SV) blows after loading
a. Replace valve a. Inlet valve (IV) malfunctioning
b. Inlet valve (IV) stuck in closed position a. See 1b
b. Have valve checked b. Minimum pressure valve (Vp) malfunctioning
c. Leak in control air flexibles b. See 1d
c. Replace leaking flexible c. Oil separator element (OS) clogged
d. Minimum pressure valve (Vp) leaking (when net is c. See 4f
depressurized) d. Safety valve (SV) out of order
d. Have valve checked d. See 4h
e. Dryer piping clogged because of ice formation
2. Compressor does not unload, safety valve blows e. Have refrigerant system checked by Atlas Copco
a. Solenoid valve (Y1) out of order
a. See 1a 7. Element outlet 1) or air outlet temperature above
b. Inlet valve (IV) does not close normal
b. See 1b a. Insufficient cooling air or cooling air temperature too high
a. Check for cooling air restriction or improve ventilation of
3. Condensate is not discharged from condensate trap compressor room. Avoid recirculation of cooling air. If
during loading installed, check capacity of compressor room fan. On
a. Discharge flexible clogged water-cooled compressors, check cooling water flow; if
a. Check and correct as necessary necessary, have system cleaned
b. Float valve malfunctioning b. Oil level too low
b. Remove float valve assembly, clean and check b. Check and correct as necessary
c. Oil cooler (Co) clogged
4. Compressor air output or pressure below normal c. Clean cooler
a. Air consumption exceeds air output of compressor d. By-pass valve (BV) malfunctioning
a. Check equipment connected d. Have valve tested
b. Choked air inlet filter element (AF) e. Air cooler (Ca) clogged
b. Replace filter element e. Clean cooler
c. Solenoid valve (Y1) malfunctioning f. Compressor element (E) out of order
c. See 1a f. See 4i

Footnotes chapter 6

1) A warning message will appear on display (4-Fig. 1.8).

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7 PRINCIPAL DATA

7.1 Readings on display (4-Fig. 1.8) 1)

Ref. Air outlet pressure

Reading: Modulates between programmed unloading and loading pressures
Shown: On main display (Fig. 1.9)
Sensor: PT20-Fig. 1.5

Ref. Compressor element outlet temperature

Reading: Approx. 60 degrees Celsius above ambient temperature
Shown: When using the key <<More>> (5-Fig. 1.8) 2)
Sensor: TT11-Fig. 1.5

Ref. Pressure difference over oil separator

Reading: Below 1 bar
Shown: When using the key <<More>> (5-Fig. 1.8) 2)
Sensor: PDT1-Fig. 1.5

Ref. Cooling water outlet temperature

Reading: Below 50 degrees Celsius
Shown: When using the key <<More>> (5-Fig. 1.8) 2)
Sensor: TT51-Fig. 1.7

7.2 Settings of safety valve

Compressor type Safety valve set pressure(e)

GA 7.5-8 bar 12 bar(e)

GA 10 bar 12 bar(e)
GA 13 bar 14.5 bar(e)

GA 100 psi 200 psig

GA 125 psi 200 psig
GA 150 psi 200 psig
GA 175 psi 215 psig

GA 7.5-8 bar/ISPESL approved 11 bar(e)

GA 10 bar/ISPESL approved 11 bar(e)
GA 13 bar/ISPESL approved 14 bar(e)

Always check the set pressure stamped on the valve.

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7.3 Maximum settings of overload relay, circuit breaker and fuses

7.3.1 For GA55/GA55 W

Supply Frequency Overload Circuit Fuses Fuses Fuses

voltage relay F21 breaker Q15 3) CSA HRCII-C UL Class K5
(V) (A) (A) (A) (A) (A)

200 50 Hz - IEC 137 9.6 See 7.3.4 - -

230 50 Hz - IEC 119 9 See 7.3.4 - -
400 50 Hz - IEC 68 4.8 See 7.3.4 - -
440 50 Hz - IEC 62 4.5 See 7.3.4 - -
500 50 Hz - IEC 57 3.8 See 7.3.4 - -
550 50 Hz - IEC 50 3.5 See 7.3.4 - -
690 50 Hz - IEC 40 2.8 See 7.3.4 - -

200 60 Hz - IEC 137 10.5 See 7.3.4 - -

200 60 Hz - CSA/UL 137 10.5 - 250 250
220-230 60 Hz - IEC 125 9 See 7.3.4 - -
220-230 60 Hz - CSA/UL 125 9 - 250 250
380 60 Hz - IEC 71 4.8 See 7.3.4 - -
440-460 60 Hz - IEC 63 4.6 See 7.3.4 - -
440-460 60 Hz - CSA/UL 58 4.6 - 110 125
575 60 Hz - CSA/UL 48 3.7 - 100 100

7.3.2 For GA75/GA75 W

Supply Frequency Overload Circuit Fuses Fuses Fuses

voltage relay F21 breaker Q15 3) CSA HRCII-C UL Class K5
(V) (A) (A) (A) (A) (A)

200 50 Hz - IEC 188 9.6 See 7.3.4 - -

230 50 Hz - IEC 164 9 See 7.3.4 - -
400 50 Hz - IEC 94 4.8 See 7.3.4 - -
440 50 Hz - IEC 85 4.4 See 7.3.4 - -
500 50 Hz - IEC 75 3.8 See 7.3.4 - -
550 50 Hz - IEC 69 3.5 See 7.3.4 - -
690 50 Hz - IEC 55 2.8 See 7.3.4 - -

200 60 Hz - IEC 201 10.5 See 7.3.4 - -

200 60 Hz - CSA/UL 201 10.5 - 400 400
220-230 60 Hz - IEC 182 9 See 7.3.4 - -
220-230 60 Hz - CSA/UL 182 9 - 350 350
380 60 Hz - IEC 105 4.8 See 7.3.4 - -
440-460 60 Hz - IEC 91 4.6 See 7.3.4 - -
440-460 60 Hz - CSA/UL 92 4.6 - 175 175
575 60 Hz - CSA/UL 71 3.6 - 150 150

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7.3.3 For GA90C/GA90C W

Supply Frequency Overload Circuit Fuses Fuses Fuses

voltage relay F21 breaker Q15 3) CSA HRCII-C UL Class K5
(V) (A) (A) (A) (A) (A)

200 50 Hz - IEC 203 14 See 7.3.4 - -

230 50 Hz - IEC 177 12 See 7.3.4 - -
400 50 Hz - IEC 102 7 See 7.3.4 - -
440 50 Hz - IEC 92 6.3 See 7.3.4 - -
500 50 Hz - IEC 82 5.6 See 7.3.4 - -
550 50 Hz - IEC 74 5.1 See 7.3.4 - -
690 50 Hz - IEC 59 4.1 See 7.3.4 - -

200 60 Hz - IEC 199 15 See 7.3.4 - -

200 60 Hz - CSA/UL 200 15 - 400 400
220-230 60 Hz - IEC 180 13.5 See 7.3.4 - -
220-230 60 Hz - CSA/UL 180 13.5 - 350 350
380 60 Hz - IEC 110 7.3 See 7.3.4 - -
440-460 60 Hz - IEC 91 6.3 See 7.3.4 - -
440-460 60 Hz - CSA/UL 91 6.3 - 175 175
575 60 Hz - CSA/UL 69 5 - 150 150

7.3.4 Setting maximum fuse

Cable size (mm²) Maximum fuse (A)

16 63
25 80
35 100
50 125
70 160
95 200
120 250
150 250

7.4 Settings of dryer switches (on GA Full-feature)

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.

7.5 Compressor specifications

7.5.1 Reference conditions

Air inlet pressure (absolute) . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 1

Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Celsius 20
Relative humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . % 0
Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) See nominal values below

On water-cooled units also:

Cooling water inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . Celsius 20

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 Instruction book

7.5.2 Limitations

Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) See maximum values below

Minimum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 4
Maximum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . Celsius 40
Minimum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . Celsius 0

On water-cooled units also:

Max. cooling water outlet temperature . . . . . . . . . . . . . . . . . . Celsius 50
Max. cooling water inlet pressure . . . . . . . . . . . . . . . . . . . . . . bar(e) 5

7.5.3 GA55/GA55 W Pack 4)

Compressor type 7.5 bar 8 bar 10 bar 100 psi 125 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hz 50 50 50 60 60
Maximum (unloading) pressure . . . . . . . . . . . . . . . . . bar(e) 7.5 8 10 7.4 9.1
Nominal working pressure . . . . . . . . . . . . . . . . . . . . . bar(e) 7 8 9.5 6.9 8.6
Temperature of air leaving outlet valve, approx. . . . . Celsius 30 30 30 30 30
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 2960 2960 2960 3565 3565
Power input, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW 65.9 67.2 64.7 65.7 64.2
Power input, GA W . . . . . . . . . . . . . . . . . . . . . . . . . . kW 63.7 64.9 62.5 63.4 61.9
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 26.5 26.5 26.5 26.5 26.5
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . . l 26.5 26.5 26.5 26.5 26.5
Mean sound pressure level 5) . . . . . . . . . . . . . . . . . . . dB 66 66 66 67 67
Cooling water consumption, GA W 6) . . . . . . . . . . . l/min 56 56 56 56 56
Cooling water consumption, GA W 7) . . . . . . . . . . . l/min 84 84 84 84 84

7.5.4 GA55/GA55 W Full-feature 4)

Compressor type 7.5 bar 8 bar 10 bar 100 psi 125 psi

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hz 50 50 50 60 60
Maximum (unloading) pressure . . . . . . . . . . . . . . . . . bar(e) 7.25 7.75 9.75 7.15 8.85
Nominal working pressure . . . . . . . . . . . . . . . . . . . . . bar(e) 7 7.75 9.5 6.9 8.6
Temperature of air leaving outlet valve, approx. . . . . Celsius 25 25 25 25 25
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 2960 2960 2960 3565 3565
Power input, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW 70.0 71.4 68.6 71.1 69.3
Power input, GA W . . . . . . . . . . . . . . . . . . . . . . . . . . kW 67.8 69.2 66.4 68.7 67.0
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 26.5 26.5 26.5 26.5 26.5
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . . l 26.5 26.5 26.5 26.5 26.5
Mean sound pressure level 5) . . . . . . . . . . . . . . . . . . . dB 66 66 66 67 67
Cooling water consumption, GA W 6) . . . . . . . . . . . l/min 56 56 56 56 56
Cooling water consumption, GA W 7) . . . . . . . . . . . l/min 84 84 84 84 84
Refrigerant type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R404a R404a R404a R404a R404a
Refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 1.8 1.8 1.8 1.8 1.8
Pressure dewpoint, Full-feature 8) . . . . . . . . . . . . . . . Celsius 3 3 3 3 3

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7.5.5 GA75/GA75 W Pack 4)

Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . Hz 50 50 50 50 60 60 60 60
Maximum (unloading)
pressure . . . . . . . . . . . . . . . . . . bar(e) 7.5 8 10 13 7.4 9.1 10.8 12.5
Nominal working pressure . . . bar(e) 7 8 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving
outlet valve, approx. . . . . . . . . Celsius 30 30 30 30 30 30 30 30
Motor shaft speed . . . . . . . . . . r/min 2965 2965 2965 2965 3570 3570 3570 3570
Power input, GA . . . . . . . . . . . kW 88.5 89.7 87.1 87.7 89.0 87.9 87.3 86.4
Power input, GA W . . . . . . . . kW 86.3 87.5 84.9 85.5 86.7 85.6 85.0 84.1
Oil capacity, GA . . . . . . . . . . . l 29.5 29.5 29.5 29.5 29.5 29.5 29.5 29.5
Oil capacity, GA W . . . . . . . . l 26.5 26.5 26.5 26.5 26.5 26.5 26.5 26.5
Mean sound pressure
level 5) . . . . . . . . . . . . . . . . . . dB 68 68 68 68 69 69 69 69
Cooling water consumption,
GA W 6) . . . . . . . . . . . . . . . . . l/min 76 76 76 76 76 76 76 76
Cooling water consumption,
GA W 7) . . . . . . . . . . . . . . . . . l/min 114 114 114 114 114 114 114 114

7.5.6 GA75/GA75 W Full-feature 4)

Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . Hz 50 50 50 50 60 60 60 60
Maximum (unloading)
pressure . . . . . . . . . . . . . . . . . . bar(e) 7.25 7.75 9.75 12.75 7.15 8.85 10.55 12.25
Nominal working pressure . . . bar(e) 7 7.75 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving
outlet valve, approx. . . . . . . . . Celsius 25 25 25 25 25 25 25 25
Motor shaft speed . . . . . . . . . . r/min 2965 2965 2965 2965 3570 3570 3570 3570
Power input, GA . . . . . . . . . . . kW 93.4 94.7 91.6 92.0 95.4 95.1 93.1 92.2
Power input, GA W . . . . . . . . kW 91.2 92.5 89.4 89.8 93 92.7 90.8 89.8
Oil capacity, GA . . . . . . . . . . . l 29.5 29.5 29.5 29.5 29.5 29.5 29.5 29.5
Oil capacity, GA W . . . . . . . . l 26.5 26.5 26.5 26.5 26.5 26.5 26.5 26.5
Mean sound pressure
level 5) . . . . . . . . . . . . . . . . . . dB 68 68 68 68 69 69 69 69
Cooling water consumption,
GA W 6) . . . . . . . . . . . . . . . . . l/min 76 76 76 76 76 76 76 76
Cooling water consumption,
GA W 7) . . . . . . . . . . . . . . . . . l/min 114 114 114 114 114 114 114 114
Refrigerant type . . . . . . . . . . . R404a R404a R404a R404a R404a R404a R404a R404a
Refrigerant charge . . . . . . . . . kg 2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.6
Pressure dewpoint,
Full-feature 8) . . . . . . . . . . . . . Celsius 3 3 3 3 3 3 3 3

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7.5.7 GA90C/GA90C W Pack 4)

Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . Hz 50 50 50 50 60 60 60 60
Maximum (unloading)
pressure . . . . . . . . . . . . . . . . . . bar(e) 7.5 8 10 13 7.4 9.1 10.8 12.5
Nominal working pressure . . . bar(e) 7 8 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving
outlet valve, approx. . . . . . . . . Celsius 30 30 30 30 30 30 30 30
Motor shaft speed . . . . . . . . . . r/min 2970 2970 2970 2970 3575 3575 3575 3575
Power input, GA . . . . . . . . . . . kW 99.1 105.5 98.6 99.9 100.4 101.2 101.0 100.2
Power input, GA W . . . . . . . . kW 95.0 101.5 94.6 95.9 96.0 96.8 96.6 95.8
Oil capacity, GA . . . . . . . . . . . l 29.5 29.5 29.5 29.5 29.5 29.5 29.5 29.5
Oil capacity, GA W . . . . . . . . l 26.5 26.5 26.5 26.5 26.5 26.5 26.5 26.5
Mean sound pressure
level GA 5) . . . . . . . . . . . . . . . dB 73 73 73 73 74 74 74 74
Cooling water
consumption 6) . . . . . . . . . . . . l/min 86 86 86 86 86 86 86 86
Cooling water
consumption 7) . . . . . . . . . . . . l/min 129 129 129 129 129 129 129 129

7.5.8 GA90C/GA90C W Full-feature 4)

Compressor type 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi

Frequency . . . . . . . . . . . . . . . . Hz 50 50 50 50 60 60 60 60
Maximum (unloading)
pressure . . . . . . . . . . . . . . . . . . bar(e) 7.25 7.75 9.75 12.75 7.15 8.85 10.55 12.25
Nominal working pressure . . . bar(e) 7 7.75 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving
outlet valve, approx. . . . . . . . . Celsius 25 25 25 25 25 25 25 25
Motor shaft speed . . . . . . . . . . r/min 2970 2970 2970 2970 3575 3575 3575 3575
Power input, GA . . . . . . . . . . . kW 104.5 111.0 103.8 104.7 107.5 107.9 107.6 106.5
Power input, GA W . . . . . . . . kW 100.5 106.9 99.7 100.7 103.1 103.5 103.2 102.1
Oil capacity, GA . . . . . . . . . . . l 29.5 29.5 29.5 29.5 29.5 29.5 29.5 29.5
Mean sound pressure
level 5) . . . . . . . . . . . . . . . . . . dB 73 73 73 73 74 74 74 74
Cooling water
consumption 6) . . . . . . . . . . . . l/min 86 86 86 86 86 86 86 86
Cooling water
consumption 7) . . . . . . . . . . . . l/min 129 129 129 129 129 129 129 129
Refrigerant type . . . . . . . . . . . R404a R404a R404a R404a R404a R404a R404a R404a
Refrigerant charge . . . . . . . . . kg 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7
Pressure dewpoint,
Full-feature 8) . . . . . . . . . . . . . Celsius 3 3 3 3 3 3 3 3

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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 9)

Footnotes chapter 7

1) See User manual for Elektronikon regulator, sections "Main display" and "More function".
2) See also section 3.4.1.
3) On air-cooled compressors only.
4) At reference conditions.
5) According to PNEUROP PN8NTC2.2. With a tolerance of 2 dB.
6) At water inlet temperature below 35 degrees Celsius and temperature rise=15 degrees Celsius.
7) At water inlet temperature between 35 and 40 degrees Celsius and temperature rise=10 degrees Celsius.
8) At 20 degrees Celsius / 100% relative humidity.
9) A temperature difference of 1 degree Celsius = a temperature difference of 1.8 degrees Fahrenheit.

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