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Instruction book

Atlas Copco Stationary Air Compressors

GA55 - GA75 - GA55 W - GA75 W - GA90C - GA90C W With Elektronikon II Regulator Instruction book

Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium. Any unauthorized use or copying of the contents or any part thereof is prohibited. particular to trademarks, model denominations, part numbers and drawings.

This applies in

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.

Important This book applies exclusively to compressors from serial number AII-478 000 onwards. This book must be used together with the “User manual for Elektronikon I and II regulators”, Printed Matter No. 2920 1461 0x.

No. 2920 1464 03 Replaces No. 2920 1464 02 Registration code: APC G55-90C/2000 / 38 / 987 2003-09

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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......................................................................................................................... 4 1.1 General description.............................................................................................................................. 4 1.1.1 Air flow (Figs. 1.6 and 1.7) ............................................................................................................ 5 1.1.2 Oil system (Figs. 1.6 and 1.7) ....................................................................................................... 5 1.1.3 Cooling and condensate drain systems (Figs. 1.6 and 1.7).......................................................... 7 1.2 Unloading/loading system (Figs. 1.6 and 1.7) ................................................................................... 11 1.2.1 Unloading (Fig. 1.6)..................................................................................................................... 11 1.2.2 Loading (Fig. 1.7) ........................................................................................................................ 11 1.3 Elektronikon regulator ........................................................................................................................ 11 1.3.1 Automatic control of the compressor........................................................................................... 11 1.3.2 Protecting the compressor .......................................................................................................... 12 1.3.3 Automatic restart after voltage failure ......................................................................................... 12 1.3.4 Control panel (Fig. 1.8) ............................................................................................................... 13 1.4 Electric cabinet (Figs. 1.9 and 1.10) .................................................................................................. 14 1.5 Menu-driven control programs........................................................................................................... 18 1.5.1 Function of control programs ...................................................................................................... 21 1.5.2 Main screen................................................................................................................................. 21 1.5.3 Calling up other menus ............................................................................................................... 21 1.6 Air dryer ............................................................................................................................................. 22 1.6.1 GA Workplace FF with IFD (Fig. 1.6) .......................................................................................... 22 1.6.2 GA Workplace FF with ICD (Fig. 1.7).......................................................................................... 22 2 INSTALLATION ....................................................................................................................................... 24 2.1 Dimension drawings (Figs. 2.1 and 2.2) ............................................................................................ 24 2.2 Installation proposals (Figs. 2.3 and 2.4)........................................................................................... 27 2.3 Electric cable size 1) .......................................................................................................................... 30 2.3.1 For GA55/GA55 W 2) 3).............................................................................................................. 30 2.3.2 For GA75/GA75 W 2) 3).............................................................................................................. 31 2.3.3 For GA90C/GA90C W 2) 3) ........................................................................................................ 32 2.4 Electrical connections (Figs. 1.9 and 1.10)........................................................................................ 32 2.5 Pictographs ........................................................................................................................................ 33

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Instruction book

2.6 Cooling water requirements............................................................................................................... 34 3 OPERATING INSTRUCTIONS ................................................................................................................ 35 3.1 Initial start-up ..................................................................................................................................... 35 3.1.1 Safety .......................................................................................................................................... 35 3.1.2 Outdoor/altitude operation........................................................................................................... 35 3.1.3 Moving/lifting ............................................................................................................................... 35 3.1.4 External compressor status indication ........................................................................................ 35 3.1.5 Compressor control modes ......................................................................................................... 35 3.2 Start-up .............................................................................................................................................. 36 3.3 Before starting.................................................................................................................................... 39 3.4 Starting............................................................................................................................................... 40 3.5 During operation ................................................................................................................................ 42 3.5.1 Checking the display ................................................................................................................... 42 3.6 Manual control ................................................................................................................................... 43 3.7 Stopping............................................................................................................................................. 43 3.8 Taking out of operation at end of compressor service life ................................................................. 45 4 MAINTENANCE ....................................................................................................................................... 46 4.1 Drive motor (10-Fig. 3.2).................................................................................................................... 46 4.2 Preventive maintenance schedule for the compressor 1) ................................................................. 46 4.3 Oil specifications ................................................................................................................................ 48 4.3.1 Atlas Copco Roto-injectfluid ........................................................................................................ 49 4.3.2 Mineral oil .................................................................................................................................... 49 4.4 Oil and oil filter change ...................................................................................................................... 49 4.5 Storage after installation .................................................................................................................... 49 4.6 Service kits......................................................................................................................................... 50 5 ADJUSTMENTS AND SERVICING PROCEDURES .............................................................................. 51 5.1 Air filter (2-Fig. 3.3) ............................................................................................................................ 51 5.2 Coolers............................................................................................................................................... 51 5.3 Safety valve (2-Fig. 3.6)..................................................................................................................... 51 6 PROBLEM SOLVING .............................................................................................................................. 52 7 PRINCIPAL DATA ................................................................................................................................... 55 7.1 Readings on display (3-Fig. 1.8) 1).................................................................................................... 55 7.2 Settings of safety valve ...................................................................................................................... 55 7.3 Maximum settings of overload relay, circuit breaker and fuses......................................................... 56 7.3.1 For GA55/GA55 W ...................................................................................................................... 56 7.3.2 For GA75/GA75 W ...................................................................................................................... 56 7.3.3 For GA90C/GA90C W ................................................................................................................. 57 7.3.4 Maximum fuse setting ................................................................................................................. 58 7.4 Settings of dryer switches (on GA Workplace Full-Feature with IFD) ............................................... 58 7.5 Compressor specifications................................................................................................................. 58 7.5.1 Reference conditions .................................................................................................................. 58 7.5.2 Limitations ................................................................................................................................... 58 7.5.3 GA55/GA55 W Workplace 4) ...................................................................................................... 59 7.5.4 GA55/GA55 W Workplace Full-Feature with IFD 4) ................................................................... 59 7.5.5 GA75/GA75 W Workplace 4) ...................................................................................................... 59 7.5.6 GA75/GA75 W Workplace Full-Feature with IFD 4) ................................................................... 60 7.5.7 GA90C/GA90C W Workplace 4) ................................................................................................. 60 7.5.8 GA90C/GA90C W Workplace Full-Feature with IFD 4) .............................................................. 61 7.6 Specifications of ICD dryer 4) ............................................................................................................ 61 7.6.1 Pressure dewpoint –40°C variant................................................................................................ 61 7.6.2 Pressure dewpoint –70°C variant................................................................................................ 62 7.7 Conversion list of SI units into US/British units.................................................................................. 62 8 INSTRUCTIONS FOR USE OF AIR RECEIVER..................................................................................... 64

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6. GA Workplace Full-Feature GA Workplace Full-Feature are additionally provided with an ICD or IFD air dryer (1-Fig.1 General description GA are stationary. On GA Workplace FF with ICD. single-stage. oil-injected screw compressors driven by an electric motor. stop and emergency stop buttons. An electric cabinet comprising the motor starter is located behind this panel. 1. GA55. This electronic control module is fitted to the door of the front panel. GA Workplace GA Workplace are enclosed in a sound-insulated bodywork. The compressors are provided with an automatic condensate drain system. GA75 W and GA90C W are water-cooled. the dryer is integrated in the sound-insulated bodywork. However. 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. E1 1 2 3 4 Control module Air outlet valve Electric cable entry Automatic condensate drain outlet of optional oil separator kit (OSD) Manual condensate drain valve Fig. 1. whereas GA55 W. The condensate is automatically drained.3 and 3-Fig. the dryer and compressor module are shipped separately and must be installed at the site. Condensate from the compressed air is removed by the adsorption process of the ICD. the dryer is integrated in the bodywork and removes condensate from the compressed air by cooling the air to near freezing point. On GA Workplace FF with IFD.4). See section 1.1 General view of GA75 Workplace Full-Feature with IFD 2920 1464 03 -4- .Instruction book 1 LEADING PARTICULARS 1. The compressors are controlled by the Atlas Copco Elektronikon® II regulator. 1. GA75 and GA90C are air-cooled.

The air is discharged through the outlet valve via minimum pressure valve (Vp).1 Air flow (Figs. Compressed air and oil flow into air receiver/oil separator (AR) via check valve (CV). The balance is removed by oil separator element (OS).6 and 1. Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure. Check valve (CV) prevents blow-back of compressed air when the compressor is stopped. 1.1.Instruction book 1.7) In air receiver/oil separator (AR).2 Oil system (Figs. 1. 1. air cooler (Ca) and condensate trap (4). optional 6 Air filter 7 Oil filler plug 8 Air receiver 9 Oil level gauge 10 Oil filters 11 Air cooler Fig. most of the oil is removed from the air/oil mixture centrifugally.6 and 1. 1.1. The oil collects in the lower part of air receiver/oil separator (AR).2 Front view of GA75 Workplace Full-Feature with IFD 2920 1464 03 -5- .7) Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. E1 Control module S3 Emergency stop button 1 Fan 2 Fan motor 3 Electric cabinet 4 Drive motor 5 Oil separator kit (OSD). which serves as oil tank. The minimum pressure valve includes a check valve which prevents blow-back of compressed air from the air net.

optional Fig.Instruction book E1 Control module S3 Emergency stop button 1 ICD dryer 2 Dryer by-pass valve 3 Air outlet valve 4 Automatic condensate drain outlet 5 Manual condensate drain outlet 6 Oil separator kit (OSD).3 Front view of GA75 Workplace Full-Feature with ICD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Air outlet valve DD or PD filter (optional) IFD dryer Fan motor Fan Oil cooler Oil filters Unloader Compressor element Check valve Oil stop valve Arrow.4 Rear view of GA75 Workplace Full-Feature with IFD 2920 1464 03 -6- . 1. 1. motor rotation direction (depends on compressor type) Drive motor Automatic condensate drain outlet of optional OSD Manual condensate drain outlet Condensate trap Fig.

When the oil temperature is below 40°C 1).Instruction book The oil system is provided with a by-pass valve (BV). automatic condensate drain outlet Automatic condensate drain outlet Manual condensate drain valve Fig. Water-cooled compressors have a cooling water system.5 Condensate drains 2920 1464 03 -7- . 1. Air 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. 55°C 1) all the oil flows through the oil cooler. Oil cooler (Co) is by-passed.3 Cooling and condensate drain systems (Figs.6 and 1. 1. 1. the tubestacks of the air cooler and oil cooler.1.7) The cooling system comprises air cooler (Ca) and oil cooler (Co). The valve is opened by element outlet pressure when the compressor is started. By-pass valve (BV) starts opening the oil supply from cooler (Co) when the oil temperature has increased to the 40°C. by-pass valve (BV) shuts off the oil supply from oil cooler (Co). 1 2 3 4 Pictograph. At approx. 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). and the outlet pipe. the cooling air is generated by fan (FN). manual condensate drain valve Pictograph. On air-cooled compressors. The water flows through the inlet pipe. A condensate trap (4) is provided in the air outlet system. Oil stop valve (Vs) prevents the compressor element from flooding with oil when the compressor is stopped.

6 Flow diagram (typical example of GA Workplace Full-Feature with IFD) 2920 1464 03 -8- . 1.Instruction book (1) (2) (3) (4) (5) Compressor unloaded Compressed air out Air inlet Compressed air Control air (6) Oil (7) Refrigerant liquid (8) Refrigerant gas (9) Compressor loaded (10)Purge air Fig.

Instruction book Fig. 1.7 Flow diagram (typical example of GA Workplace Full-Feature with ICD) 2920 1464 03 -9- .

control pressure Shut-off valve. air receiver Oil drain plug. 1. control or blow-off air Oil scavenging flexible On GA Workplace FF with IFD also M3 Refrigerant compressor M4 Motor. compressor element outlet Unloader Unloading valve Air filter service indicator Minimum pressure valve Oil stop valve Loading solenoid valve Flexible. tower Tb Rf Restrictor Ta Tower A Tb Tower B 8 9 10 11 12 13 14 15 Fan. condenser fan S2 Condenser fan control switch S3 High-pressure shut-down switch 3 Condensate separator 4 Condensate trap 5 Automatic condensate drain outlet 6 Manual condensate drain valve 7 Capillary tube On GA Workplace FF with ICD also AV1 Air outlet valve.7 Air-oil and unloading-loading systems 2920 1464 03 . condenser Insulating block Accumulator Hot-gas by-pass valve Filter Air/air heat exchanger Condenser Air/refrigerant heat exchanger (evaporator) TT81 Y2 Y3 16 17 18 19 20 21 22 23 24 25 Temperature sensor. air outlet Safety valve Temperature sensor.10 - . dryer inlet Solenoid valve Solenoid valve Pneumatic actuator Exhaust valve Silencer Exhaust valve Silencer Air filter Shut-off valve.6 and 1.Instruction book AF AO AR BV Ca CM Co CV DP1 DP2 DP3 E FC FN Gl IV LP Air filter Air outlet Air receiver/oil separator Oil cooler by-pass valve Air cooler Control module Oil cooler Check valve Oil drain plug. oil stop valve Oil drain plug. dryer by-passed CV1 Check valve CV2 Check valve DDp DDp filter IPD Integrated pre-filter PDP Pressure dewpoint sensor PR Pressure regulator (only on 13 bar compressors) PT81 Pressure sensor. oil separator pressure difference Pressure sensor. check valve Compressor element Oil filler plug Fan Oil level gauge Inlet valve Loading plunger M1 M2 OF OS PDT1 PT20 SV TT11 UA UV VI Vp Vs Y1 1 2 Drive motor Fan motor Oil filters Oil separator element Pressure sensor. tower Ta PT82 Pressure sensor. PDP sensor Dryer inlet valve 3-way valve Figs.

1. Take into account that a start command will be executed (if programmed and activated). 1. 3. Loading plunger (LP) moves upwards and causes inlet valve (IV) to close the air inlet opening. the regulator also maintains the pressure dewpoint of the dryer between programmable settings by defining the switching time. the net pressure increases. solenoid valve (Y1) is de-energized. A small amount of air is kept drawn in and is blown to the unloader. A number of programmable settings. 2. The plunger of the valve returns by spring force: 1. 2.2.1 Unloading (Fig. 4. For GA Workplace FF with ICD. A number of programmable settings are taken into account. Unloading valve (UV) is opened by receiver pressure.7) 1. Unloading valve (UV) closes the air blow-off opening.3. Loading plunger (LP) moves downwards and causes inlet valve (IV) to open fully.2 Unloading/loading system (Figs. the compressor is kept running to prevent too-short standstill periods. In case the expected unloading period is too short. Air output is stopped (0 %). the unloading and loading pressures. 1. 2920 1464 03 .6) If the air consumption is less than the air output of the compressor.2.6 and 1. The pressure from air receiver (AR) is released towards unloader (UA). the compressor runs unloaded.3 Elektronikon regulator 1. The regulator stops the compressor whenever possible to reduce power consumption and restarts it automatically when the net pressure decreases. When the net pressure reaches the unloading pressure. e. even after manually stopping the compressor. solenoid valve (Y1) is energized. the compressor runs loaded.g. The pressure is stabilized at a low value. Air output is resumed (100 %). The plunger of solenoid valve (Y1) moves upwards against spring force: 1. 1.2 Loading (Fig.11 - . Control pressure is fed from air receiver (AR) via solenoid valve (Y1) to loading plunger (LP) and unloading valve (UV). Warning A number of time-based automatic start/stop commands may be programmed. 1. The control pressure present in the chambers of loading plunger (LP) and unloading valve (UV) is vented to atmosphere via solenoid valve (Y1).7) When the net pressure decreases to the loading pressure.Instruction book 1. the minimum stop time and the maximum number of motor starts are taken into account.1 Automatic control of the compressor The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor.

the function can be Warning If activated and provided the module was in the automatic operation mode. C and D). The power recovery time (the period within which the voltage must be restored to have an automatic restart) can be set between 10 and 600 seconds or to Infinite. If a time interval is exceeded. allowing e. . the compressor will be stopped.8).3 Automatic restart after voltage failure For compressors leaving the factory.3.8) to warn the operator to carry out the service actions belonging to that plan. the inlet temperature of the compressed air into the dryer exceeds the warning level. .g. a message will appear on display (3Fig. 1. 1.On GA Workplace FF with ICD. the compressor will always restart after a voltage failure. the pressure in the dryer vessels is lower than the minimum or higher than the maximum limit.On Full-Feature compressors. 2920 1464 03 . Each Service plan has a programmed time interval. If the power recovery time is set to Infinite. two compressors to be restarted one after the other.12 - . This will be indicated on display (3-Fig. B. activated. Consult Atlas Copco. this will also be indicated to warn the operator before the shut-down level is reached. 1. 1. Warning A warning message also appears if: . See section 4. Service warning A number of service operations are grouped in plans (called Service plans A.4) or fan motor (4-Fig. the cooling water outlet temperature exceeds the warning level. 3) Shut-down warning If the compressor element outlet temperature exceeds a programmed value below the shut-down level. this function is made inactive. 1.3.Instruction book 1. no matter how long it takes to restore the voltage.On water-cooled compressors.2 Protecting the compressor Shut-down If the compressor element outlet temperature exceeds the programmed shut-down level.4).2. The compressor will also be stopped in case of overload of drive motor (13-Fig.On GA Workplace FF with ICD. A restart delay can also be programmed. If desired. the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period. the dewpoint temperature exceeds the warning level. .

3. 1. if a sensor with shut-down function is out of order or after an emergency stop. 1 2 3 4 5 6 7 7 8 Designation Stop button Start button Display Scroll keys Tabulator key Voltage on LED General alarm LED General alarm LED Automatic operation LED Function keys Emergency stop button Function Push button to stop the compressor.8) Fig. Push button to stop the compressor immediately in case of emergency. After remedying the trouble. Push button to start the compressor.Instruction book 1. Indicates messages concerning the compressor operating condition. Blinks in case of shut-down. Keys to scroll through the display.4 Control panel (Fig. Indicates that the voltage is switched on. 9 S3-Figs. LED (8) goes out. The compressor will stop after running in unloaded condition for about 30 seconds. Only the parameters followed by an arrow pointing to the right are accessible for modifying.13 - . LED (8) lights up indicating that the regulator is operative (in automatic operation). 1. Indicates that the regulator is automatically controlling the compressor: the compressor is loaded. 1. unlock the button by pulling it out. unloaded. a service need or a fault. stopped and restarted depending on the air consumption and the limitations programmed in the regulator. See below. service warning or shut-down warning condition exists or if a sensor is out of order.3 2920 1464 03 . Keys to control and program the compressor. The LED goes out after unloading the compressor manually.8 Control panel LEDs/buttons/keys Ref. Is alight if a warning.2 and 1. Key to select the parameter indicated by a horizontal arrow.

1. 1.4. to return to the previous menu To modify programmable settings To program modified settings To reset a timer or message To return to a previously shown menu To unload the compressor manually To find the module configuration of the regulator 1.3. The actual function is abbreviated and indicated on the bottom line of the display just above the relevant key.10) The cabinet mainly comprises transformers. 1.Instruction book Pictographs 10 11 12 Alarm Automatic operation Voltage on 1. or an emergency stop . Abbreviation Add Back Canc Del Help Lim Load Main Menu Menu Mod Prog Rset Rtrn Unld Xtra Designation Add Back Cancel Delete Help Limits Load Main Menu Menu Modify Program Reset Return Unload Exta Function To add compressor start/stop commands (day/hour) To return to a previously shown option or menu To cancel a programmed setting when programming parameters To delete compressor start/stop commands To find the Atlas Copco internet address To show limits for a programmable setting To load the compressor manually To return from a menu to the main screen (Fig.15): to have access to submenus Starting from a submenu.To call up or to program settings . 2920 1464 03 . The Elektronikon regulator and emergency stop button are fitted in the door of the cabinet. drive motor contactors and for air-cooled compressors the fan motor contactor.15) Starting from the main screen (Fig.To reset a motor overload. fuses.1 Function keys The keys are used: .To manually load/unload the compressor . The most common abbreviations are listed below.9 and 1. shut-down or service message.14 - .4 Electric cabinet (Figs.To have access to all data collected by the regulator The functions of the keys vary depending on the displayed menu.

9 Electric cubicle. 1. GA Workplace FF with ICD (typical example) 2920 1464 03 . 1. fan motor 3) Transformers Terminal strips On Full-Feature with ICD also: F90/91 Fuses Fig. GA Workplace FF with IFD (typical example) F1/5 F21 K21 K22 K23 PE Q15 T1/T2 1X1/4 Fuses Overload relay. condenser fan Fig.Instruction book F1/8 F21 K21 K22 K23 PE Q15 T1/T2 1X1/4 1X2 K11 K12 Fuses Overload relay. drive motor Line contactor Star contactor Delta contactor Earth terminal Circuit breaker. drive motor Line contactor Star contactor Delta contactor Earth terminal Circuit breaker.15 - . mains connections L1/L2/L3 On Full-Feature with IFD also: Contactor. refrigerant compressor Contactor. fan motor 3) Transformers Terminal strips Terminal strip.10 Electric cubicle.

1.16 - .11 Electrical diagram (typical example) 2920 1464 03 .Instruction book Fig.

pressure difference over oil separator Pressure sensor. fan motor Fault. cooling water outlet 4) TT53/54 Temperature sensors. energy recovery water inlet/outlet 2) TT90 Temperature sensor. PD filter High/low air pressure (5-6 closed=high pressure) (11) Manual load/unload (12) Automatic operation (13) General warning (14) (15) (16) (17) (18) (20) (21) (22) (23) (24) (25) General shut-down Auxiliary contacts See motor data plate for correct connection Remote emergency stop Customer's installation Dryer All voltages (50 and 60 Hz) except for 440460 V 60 Hz Star connection: all other voltages Delta connection: 200-220-230 V 50/60 Hz CSA certified and UL listed industrial control panel as shown within dotted lines Phase sequence protection SENSORS/LOADING SOLENOID VALVE PDT1 PT20 TT11 TT51 Pressure sensor. cooling water inlet 4) Temperature sensor. compressor element outlet Temperature sensor. EWD Dp. dewpoint (FullFeature with IFD) Y1 Loading solenoid valve TT52 2920 1464 03 . drive motor Overload. air outlet Temperature sensor.Instruction book Fig. 1.12 Electrical diagram of ICD dryer (typical example) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Emergency stop Remote start/programmed stop Remote load/unload (closed=load) Remote pressure sensing (link=remote) Overload.17 - . DD filter Dp.

K35 Drive motor thermistor protection.5 Menu-driven control programs To facilitate programming and controlling the compressor. A simplified menu flow is shown in Figs. warning ICD DRYER E11 Emix module F90/F91 Fuses PDS81 Differential switch. drying tower A PT82 Pressure sensor. dryer inlet TT82 Pressure dewpoint temperature sensor K23 Q15 T1/T2 1X1/4 Delta contactor Circuit breaker. drying tower B TT81 Temperature sensor.Instruction book CUBICLE E1 Electronic control module (B) F1/9 Fuses F21 Overload relay. power supply Terminal strip. freeze protection Anti-condensation heater Main power isolating switch Thermostat. general shut-down Programmed stop button Emergency stop button M2 Fan motor 3) R3/R4/R7 R96 S10 TSLL91 Y2 Y51 Heaters. dryer Terminal strip. Load/Unload for ES100 K25 Phase sequence protection R1. general warning Auxiliary relay. shutdown R2. fan motor 3) Transformers Terminal strips K06 K07 K08 K09 0 S3 Auxiliary relay. 1. menu-driven programs are implemented in the electronic module. modulating control Water shut-off valve (water-cooled versions) T1 Y1 Y2 1X0 1X2 1X3 1X5 Transformer Solenoid valve 1 Solenoid valve 2 Terminal strip.11 and 1. analog input A1 Dryer (Full-Feature with IFD) B1 Electronic water drain (EWD) K04' Auxiliary relay. earth Terminal strip. 2920 1464 03 . K34 Drive motor thermistor protection. star contactor K03 Auxiliary relay. dryer control Auxiliary relay. loading-unloading K05 Auxiliary relay. delta contactor K04 Auxiliary relay. DDp filter PT81 Pressure sensor. high/low pressure MOTORS M1 Drive motor OPTIONAL EQUIPMENT AIE1 Expansion module.13 and 1. 24 V AC Figs.18 - . 1.14. manual/automatic operation Auxiliary relay.12 Electrical diagrams (typical examples) 1. freeze protection Solenoid valve. drive motor K21 Line contactor K22 Star contactor CONTROL MODULE (E1) I Start button K01 Blocking relay K02 Auxiliary relay.

13 Menu flow of GA Workplace FF with IFD 2920 1464 03 . 1.19 - .Instruction book Fig.

Instruction book Fig.14 Menu flow of GA Workplace FF with ICD 2920 1464 03 . 1.20 - .

It is the gateway to all functions. the Main screen is shown automatically. the display will automatically return to the Main screen. loading and unloading pressures) .number of motor starts . 1. press the key Main to return to the Main screen.5.g.clock functions (automatic compressor start/stop/pressure band commands) . Whenever displayed on a submenu screen.parameters (e.shut-down warning . air temperature shut-down level) .loaded hours . Compr. display language.5.21 - . last emergency stop data Measured data Counters Test Modify settings Service Saved data 1. motor overload and service condition. Calling up: . See section 4. date.regulator (module) hours . typical example ↓ If the function keys or arrow keys are not used for some minutes.status of some inputs such as the motor overload protection Calling up the: .configuration (time.15 Main screen.0 F2 Unld F3 Fig. See Fig.running hours . Calling up the saved data: last shut-down.g. Calling up the status of the compressor protection functions: .number of load cycles Allows a display test.1 Function of control programs Program/Function Main screen Status data Description Shows in short the operation status of the compressor.3 Calling up other menus Starting from the Main screen: 2920 1464 03 . Modifying the settings for: .actually measured data .15. 1. showing in short the operation status of the compressor.5.2 Main screen When the voltage is switched on.service plans (see section 4) . …) Calling up service plans and resetting the timers.warning Resetting of a shut-down. 1.service warning . Outlet bar Auto Loaded Menu F1 7.protections (e.Instruction book 1.shut-down .

1. This purge air flows downwards through the desiccant bed of the regenerating tower. The heated refrigerant leaves the evaporator and is sucked in by compressor (M3). 1. 1. The wet purge air is discharged to atmosphere via exhaust valve (17 or 19) and silencer (18 or 20). The refrigerant enters evaporator (15) where it withdraws heat from the compressed air by further evaporation. The operation cycle of the dryer is repetitive and is controlled by the compressor regulator and PDP sensor.8) to select this menu User manual for Elektronikon I and II regulators For detailed instructions. 1. While the desiccant of one tower is drying the compressed air. Refrigerant circuit Compressor (M3) delivers high-pressure refrigerant gas which flows through condenser (14). dried air. dried air then flows through heat exchanger (13). The condensate is automatically drained through outlet (5). 1.6) Compressed air circuit Compressed air enters heat exchanger (13) and is cooled by the outgoing.7) The dryer has two towers containing desiccant. The cold.2 GA Workplace FF with ICD (Fig. This cools the air to close to the evaporating temperature of the refrigerant. The liquid flows through filter (12) to capillary tube (7).either press the tabulator key (5-Fig. This 3way valve is controlled by pneumatic actuator (16). Regeneration of the desiccant is achieved by means of purge air from the drying tower. where most of the refrigerant condenses. 1. 1.8) to select this menu . The air then flows through heat exchanger (15) where the refrigerant evaporates withdrawing heat from the air. 2920 1464 03 . The cold air then flows through condensate trap (3) which separates condensate from the air.1 GA Workplace FF with IFD (Fig.6. 1.or use the ↓ key (Fig. This desiccant is a very porous grain material that can adsorb large amounts of water vapour.8) to scroll until the desired submenu is followed by a horizontal arrow and then press the tabulator key (5-Fig. 1. The dry compressed air leaves the dryer via the non-return valve (CV1 or CV2) on top of the drying tower. Moisture in the incoming air starts to condense. Regeneration circuit A small quantity of dried air is branched off from the dryer outlet and expanded to atmospheric pressure. As the air flows upwards through the tower. the desiccant adsorbs the water vapours and the compressed air is dried. the desiccant of the other tower is being regenerated and vice versa. consult the User manual for Elektronikon I and II regulators.22 - .Instruction book - Use the ↓ key (Fig. where it is warmed up by the incoming air.6 Air dryer GA Workplace FF with IFD and GA Workplace FF with ICD are provided with a dryer which removes condensate from compressed air.6. the moisture is forced out of the desiccant. the option Status data will be followed by a horizontal arrow: . As the vapour pressure of the purge air is much lower than that of the desiccant. The refrigerant leaves the capillary tube at evaporating pressure.8) for a quick look at the actual compressor status Press the key Menu (F1). More water in the air condenses. Compressed air circuit The compressed air entering the dryer is led to one of the towers by means of 3-way valve (25).

For energy recovery systems only. When one of the solenoid valves is energized.23 - . i. PDP sensor (PDP) measures the pressure dewpoint of the compressed air leaving the drying tower. As soon as the pressure dewpoint exceeds the setpoint. air filter (21) and on 13 bar units pressure regulator (PR) to solenoid valves (Y2 and Y3).Instruction book Control air circuit A second small portion of dried air flows via control air valve (22). the regenerated tower starts drying the compressed air and the other tower will be regenerated.e. Water-cooled compressors only. the Elektronikon regulator will shift towers. Air-cooled compressors only. Footnotes chapter 1 1) 2) 3) 4) The valve starts opening at 60°C and is fully open at 75°C for 13 bar and 175 psi compressors. 2920 1464 03 . the control air is fed to pneumatic actuator (16) and exhaust valve (17 or 19).

Instruction book

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

Fig. 2.1 Dimension drawing of GA Workplace (FF with IFD)

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Instruction book

Fig. 2.2 Dimension drawing of GA Workplace FF with ICD

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Instruction book

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (18) (19) (20) (21) (22)

Centre of gravity Compressor cooling air outlet Dryer cooling air outlet Compressed air outlet Cooling air inlet Cooling water outlet Cooling water inlet Energy recovery water inlet, G 1 (GA55), G 1 1/2 (GA75) Electric cable passage, diameter 65 Outlet for dryer by-pass Manual condensate drain Automatic condensate drain Automatic drain, type OSD (optional) With dryer Without dryer Energy recovery water outlet, G 1 (GA55), G 1 1/2 (GA75) For anchoring Weight Dryer unit Compressor unit Important remark: Never lift the compressor and ICD when mounted together

2920 1464 03

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4) (1) (2) (3) Minimum free area for compressor installation Cooling systems for water-cooled compressors Ventilation proposals for air-cooled compressors Fig.2 Installation proposals (Figs. 2.27 - .3 and 2.3 Installation proposal of GA Workplace (FF with IFD) 2920 1464 03 . 2.Instruction book 2.

2. 1 2 3 Description/recommendation Install the compressor package on a solid.85) 2920 1464 03 .28 - . Position of compressed air outlet valve. level floor suitable for taking the weight.4 Installation proposal of GA Workplace FF with ICD Ref. The maximum total pipe length (including interconnecting piping between compressor and receiver) can be calculated as follows: L = (dP x d5 x P) / (450 x Qc1.Instruction book Fig.

type PD (optional). 6 7 8 9 10 The air receiver (optional) should be installed in a frost-free room on a solid. oil carry-over of 0.29 - . This filter traps solid particles down to 0.13 N / dT for GA Workplace water-cooled compressors Qv = (0. The filter traps solid particles down to 1 micron with max.01 mg/m³. On GA Workplace FF with ICD Filters with regard to filtration of oil and particles are included in the package.5 mg/m³.13 N + 8) / dT for GA Full-Feature with IFD water-cooled compressors Qv N dT = = = required ventilation capacity in m³/s nominal motor power in kW temperature increase in compressor room 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. a filter of the QD type (optional) should be installed downstream of the PD filter. If oil vapour and odours are undesirable. Provision for inlet and outlet of energy recovery system (system is optional).Instruction book L dP d P Qc 4 = = = = = pipe length in m maximum allowable pressure drop (recommended 0. oil carry-over of 0. may be installed downstream of a DD filter. Position of control panel. On GA Workplace FF with IFD Filter.06 N + 8) / dT for GA Workplace Full-Feature with IFD air-cooled compressors Qv = 0. For alternatives 1 and 3.1 bar) inner diameter of pipe in mm compressor outlet pressure in bar absolute free air delivery of compressor in l/s 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. It is recommended to provide by-pass pipes and valves over the filter to isolate the filter during maintenance without disturbing the compressor. The air velocity to the grids must be limited to 5 m/s. for general purpose filtration (optional). the required ventilation capacity to limit the compressor room temperature can be calculated as follows: Qv = 1. If oil vapour and odours are undesirable. A high-efficiency filter. The maximum allowable pressure drop over the cooling air ducts is 50 Pa. type DD. Position of mains cables.06 N / dT for GA Workplace/Workplace Full-Feature with ICD air-cooled compressors Qv = (1. 2920 1464 03 . 5 The drain pipes to the drain collector must not dip into the water of the drain collector. a filter of the QD type (optional) should be installed downstream of the dryer. 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. level floor.01 micron with max.

IEC 60 .IEC 50 .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 On GA Workplace FF with IFD Optional dryer by-pass pipe.3 Electric cable size 1) 2.IEC 50 . On GA Workplace FF with ICD Dryer by-pass pipe.Instruction book 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 11 = = = = = = = = (0.IEC 50 .IEC 50 .IEC 60 .IEC 60 .IEC 50 .IEC 50 . 12 13 Condensate trap.IEC 60 .1 For GA55/GA55 W 2) 3) Supply voltage (V) 200 230 400 440 500 550 690 200 200 220-230 220-230 380 440-460 440-460 575 Frequency Approval 50 .CSA/UL MC cable 2) GA Workplace (mm²/AWG) 2x (3x70) + 70 2x (3x50) + 50 3x70 + 70 3x50 + 50 3x50 + 50 3x35 + 35 3x25 + 25 2x (3x70) + 70 2x (4x AWG 2/0) 2x (3x50) + 50 2x (4x AWG 2/0) 3x70 + 70 3x50 + 50 4x AWG 2/0 or2x (4xAWG 4) 4x AWG 2 or2x (4xAWG 6) LC cable 2) GA Workplace (mm²/AWG) 2x (3x50) + 50 2x (3x35) + 35 3x50 + 50 3x50 + 50 3x35 + 35 3x35 + 35 3x25 + 25 2x (3x50) + 50 -2x (3x50) + 50 -3x50 + 50 3x50 + 50 --MC cable 2) GA Full-Feature (mm²/AWG) 2x (3x70) + 70 2x (3x70) + 70 3x70 + 70 3x70 + 70 3x50 + 50 3x50 + 50 3x25 + 25 2x (3x70) + 70 2x (4x AWG 3/0) 2x (3x70) + 70 2x (4x AWG 2/0) 3x70 + 70 3x70 + 70 4x AWG 250 or2x (4xAWG 2) 4x AWG 1 or2x (4xAWG 4) LC cable 2) GA Full-Feature (mm²/AWG) 2x (3x70) + 70 2x (3x50) + 50 3x70 + 70 3x50 + 50 3x35 + 35 3x35 + 35 3x25 + 25 2x (3x70) + 70 -2x (3x50) + 50 -3x70 + 70 3x50 + 50 --- 2920 1464 03 .CSA/UL 60 .IEC 60 . For water-cooled compressors Position of cooling water pipes.CSA/UL 60 .CSA/UL 60 .30 - . 2.3.

IEC 60 .IEC 60 .CSA/UL 60 .3.IEC 50 .IEC 50 .Instruction book 2.CSA/UL 60 .IEC 60 .IEC 50 .IEC 60 .IEC 50 .CSA/UL MC cable 2) GA Workplace (mm²/AWG) 2x (3x95) + 95 2x (3x70) + 70 3x95 + 95 or2x (3x35) + 35 3x95 + 95 or2x (3x25) + 25 3x70 + 70 3x70 + 70 3x50 + 50 2x (3x120) + 120 2x (4x AWG 250) 2x (3x95) + 95 2x (4x AWG 4/0) 2x (3x35) + 35 3x95 + 95 or2x (3x35) + 35 4x AWG 4/0 or2x (4xAWG 2) 4x AWG 2/0 or2x (4xAWG 3) LC cable 2) GA Workplace (mm²/AWG) 2x (3x70) + 70 2x (3x70) + 70 3x70 + 70 3x70 + 70 3x70 + 70 3x50 + 50 3x35 + 35 2x (3x95) + 95 -2x (3x70) + 70 -3x95 + 95 or2x (3x35) + 35 3x70 + 70 --MC cable 2) GA Full-Feature (mm²/AWG) 2x (3x120) + 120 2x (3x95) + 95 2x (3x35) + 35 3x95 + 95 or2x (3x35) + 35 3x70 + 70 3x70 + 70 3x50 + 50 2x (3x120) + 120 2x (4x AWG 300) 2x (3x95) + 95 2x (4x AWG 250) 2x (3x50 + 50) 3x95 + 95 or2x (3x35) + 35 4x AWG 250 or2x (4xAWG 1) 4x AWG 3/0 or2x (4xAWG 3) LC cable 2) GA Full-Feature (mm²/AWG) 2x (3x95) + 95 2x (3x70) + 70 3x95 + 95 or2x (3x35) + 35 3x70 + 70 3x70 + 70 3x50 + 50 3x35 + 35 2x (3x95) + 95 -2x (3x95) + 95 -3x95 + 95 or2x (3x35) + 35 3x95 + 95 or2x (3x25) + 25 --- 2920 1464 03 .CSA/UL 60 .IEC 50 .31 - .2 For GA75/GA75 W 2) 3) Supply voltage (V) 200 230 400 440 500 550 690 200 200 220-230 220-230 380 440-460 440-460 575 Frequency Approval 50 .IEC 50 .IEC 60 .

IEC 50 .4 Electrical connections (Figs.CSA/UL 60 . Connect the power supply to terminals L1/L2/L3. Check that the setting at the primary side of this transformer corresponds to the supply voltage of the compressor.IEC 60 .IEC 60 .IEC 60 .IEC 60 .CSA/UL MC cable 2) GA Workplace (mm²/AWG) 2x (3x120) + 120 2x (3x95) + 95 2x (3x35) + 35 3x95 + 95 or2x (3x35) + 35 3x95 + 95 or2x (3x25) + 25 3x70 + 70 3x50 + 50 2x (3x120) + 120 2x (4x AWG 250) 2x (3x95) + 95 2x (4x AWG 4/0) 2x (3x35) + 35 3x95 + 95 or2x (3x35) + 35 4x AWG 4/0 or2x (4xAWG 2) 4x AWG 2/0 or2x (4xAWG 3) LC cable 2) GA Workplace (mm²/AWG) 2x (3x95) + 95 2x (3x70) + 70 3x95 + 95 or2x (3x35) + 35 3x70 + 70 3x70 + 70 3x70 + 70 3x35 + 35 2x (3x95) + 95 -2x (3x70) + 70 -3x95 + 95 or2x (3x35) + 35 3x70 + 70 --MC cable 2) GA Full-Feature (mm²/AWG) 2x (3x120) + 120 2x (3x95) + 95 2x (3x50) + 50 2x (3x35) + 35 3x95 + 95 or2x (3x35) + 35 3x70 + 70 3x50 + 50 2x (3x120) + 120 2x (4x AWG 300) 2x (3x120) + 120 2x (4x AWG 250) 2x (3x50) + 50 2x (3x35) + 35 4x AWG 250 or2x (4xAWG 1) 4x AWG 3/0 or2x (4xAWG 3) LC cable 2) GA Full-Feature (mm²/AWG) 2x (3x95) + 95 2x (3x70) + 70 3x95 + 95 or2x (3x35) + 35 3x95 + 95 or2x (3x35) + 35 3x70 + 70 3x70 + 70 3x35 + 35 2x (3x95) + 95 -2x (3x95) + 95 -3x95 + 95 or2x (3x35) + 35 3x95 + 95 or2x (3x25) + 25 --- 2.32 - .3 For GA90C/GA90C W 2) 3) Supply voltage (V) 200 230 400 440 500 550 690 200 200 220-230 220-230 380 440-460 440-460 575 Frequency Approval 50 .IEC 50 . On GA Workplace FF with ICD (Figs.IEC 50 . 2920 1464 03 .CSA/UL 60 .IEC 50 .3.10) Provide an isolating switch.12): The power supply of the dryer is derived from the main voltage supply of the compressor.11 and 1.9 and 1. 1. A multi-voltage transformer is installed in the dryer cubicle. See section 7. 1.IEC 50 .CSA/UL 60 .Instruction book 2. Check the fuses and the setting of the overload relay.IEC 60 .IEC 50 . Connect the earth conductor to earth bolt (PE) and the neutral conductor (if provided) to connector (N).

13.Instruction book 2. 11. 12. consult Instruction book for motor rotation direction Switch off voltage and depressurize compressor before repairing Torques for steel (Fe) or brass (CuZn) bolts Lightly oil gasket of oil filter.5 Pictographs 1. 8. 2. 2. have possible repair carried out by Atlas Copco Fig. 14. half a turn) Consult Instruction book before greasing Switch off voltage before removing protecting cover inside electric cubicle Consult Instruction book before carrying out maintenance Stop compressor before cleaning coolers Warning: voltage Warning: potential risk of sudden releasing of spring underneath cover of unloader during disassembling. 3. screw it on and tighten by hand (approx. 7.33 - . 6. 9. 10.5 Pictographs (typical examples) 2920 1464 03 . 4. Water outlet Manual condensate drain Water inlet Automatic condensate drain Before connecting compressor electrically. 5.

5 < 0. in cable trays or on walls.5 < 0. Note that the sulphate value must include any sulphite present. the sizes are valid for cables with insulation of 85/90°C. Footnotes chapter 2 1) If the size does not comply with local legislation.MC stands for not more than 3 loose copper conductors in a raceway or in a cable.000. same values for loose conductors in a conduit or in a cable trunking system.mg/l Chloride (Cl-) Sulphate (SO4--) Total solids Suspended solids (as SiO2) Free chlorine (Cl2) Ammonia (NH4+) Copper Iron Manganese Oxygen Carbonate hardness (as CaCO3) Organics (KMnO4 Consumption) No algae No oil Remark Chloride and sulphate are interactive.34 - . In pass-through systems the sum of the squares must not exceed 85.5 < 0.1 <3 50-1000 < 25 Open system < 150 < 250 < 750 < 10 <2 < 0. Recommended maxima .EN 60204 T1 .5 < 0. values according to EN 60204-1 Table 5. values according to CE Code handbook Table 1 and Table 2.6 Cooling water requirements Following requirements are given as a general rule to prevent cooling water problems. For recirculating systems with proper controls and treatment. .For CSA/UL conductors with AWG size.IEC 204-1.000.2 < 0.1 <3 50-500 < 10 2920 1464 03 . 3) For CSA/UL approval: . consult Atlas Copco. 2) For IEC approval: . the sum of the squares may be up to 520. If in any doubt.MC stands for cables in open cable trunking system. .Instruction book 2.LC stands for loose conductors in the air.LC stands for loose copper conductors in the air.2 < 0. values according to DIN VDE 0113 . the stricter of the two shall apply. . Recirculating system < 600 < 400 < 3000 < 10 <4 < 0.

1.1 Initial start-up 3. 3. In this case. Attention Have the modifications checked by Atlas Copco. The lifting equipment must be placed in such a way that the compressor will be lifted perpendicularly. consult Atlas Copco. if programmed. 5-6 closed means high air pressure .1. Make sure that the forks protrude from the other side of the frame. Take care not to damage the bodywork during lifting or transport. compressor module and ICD module must be lifted separately. K08 and K09-Fig.4 External compressor status indication The electronic regulator is provided with auxiliary contacts (K05. The compressor can be moved by a lift truck using the slots in the frame.Instruction book 3 OPERATING INSTRUCTIONS 3. 3. Consult Atlas Copco.35 - .warning condition (K08) .low or high air pressure (K05). Following control modes can be selected: 3. The compressor can also be lifted after inserting beams into the slots.1.1. 1. K07. Compressor 2920 1464 03 . 3.2 Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below 0°C. Stop the compressor and switch off the voltage before connecting external equipment. and also if operating above 1000 m. precautions must be taken.manual load/unload or automatic operation (K07) .1 Local control The compressor will react to commands entered by the buttons on the control panel.1 Safety The operator must apply all relevant safety precautions. start/stop commands via function Clock function are active. 1. including those mentioned in this book. Lift smoothly and avoid twisting.2 and 1.1.11) at the back of electronic module (E1-Figs. 3.shut-down condition (K09) Maximum load for these contacts: 1 A / 250 V AC. Only voltage-free contacts are allowed. section “Configuration menu” if it is desired to switch to another control mode. The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. Make sure that the beams cannot slide and that they protrude from the frame equally. Stop the compressor and switch off the voltage before connecting external equipment.3 Moving/lifting Warning Never lift a GA workplace FF with ICD package.5 Compressor control modes Consult the User manual.3) for external indication of: .5.1.

2 Remote control The compressor will react to commands from external switches.Instruction book 3. 1.1. 3.36 - .2 and 1. Compressor start/stop commands via function Clock function are still possible. Bridge terminals 30 and 34: In this mode.2 Start-up AV Air outlet valve Dma Manual condensate drain valve 1 Condensate drain flexible for automatic drain 2 Condensate drain flexible for manual drain 3 Connection between flexible (2) and valve (Dma) 4 Bottle containing Atlas Copco Rotoinjectfluid Fig.1. For remote starting and stopping: Connect a start/programmed stop button between terminals 30 and 33 of terminal strip (1X1-Figs.9 and 1. 1.3) remains active.1 Components delivered loose with compressor (typical examples) 2920 1464 03 . the outlet pressure is still sensed by pressure transducer (PT20). the compressor is switched out of automatic load/unload operation and remains running unloaded. resulting in loading and unloading of the compressor at the pressures programmed in the electronic regulator.5. If terminals 30 and 34 are not bridged.3 LAN control The compressor is controlled via a local network. For remote loading/unloading (via external pressure switch): Bridge terminals 30 and 35 and connect a load/unload switch between terminals 30 and 34. 3.10).5. Emergency stop (S3-Figs. This results in loading and unloading of the compressor at the closing and opening pressures of the external pressure switch respectively. 3. Consult Atlas Copco.

Instruction book 1 2 3 4 5 DD or PD filter (optional) IFD dryer Fan motor Oil cooler Check valve 6 7 8 9 10 Compressor element Bolt.37 - . 3. bush and nut (to be removed) Bolt (to be removed) Support (to be removed) Drive motor Fig.2 View of compressor compartment 2920 1464 03 .

drain valves should be fitted by the customer in the water inlet and outlet pipes. 5. Connect the air net to the valve(s).3. The pointer of the level gauge (7-Fig. Check the oil level.4. 1. 4. air receiver and motor are secured to the frame. fit valve (2Fig.6 for the water requirements. air receiver Oil level gauge Air receiver Safety valve Fig. Check the connections for correct tightness. reference 5. Close the valve(s). The installation must be earthed and protected against short circuits by fuses of the inert type in all phases.2) and support (9-Fig. 7. Connect the manual condensate drain valve (4-Fig. 3. The compressor element. 3.3 and 2.3 for lubrication of the compressor element.3) immobilizing the vibration dampers of the air receiver. assemble the compressor and dryer as described in the assembly instruction 2920 1515 00 2.1) can be used for topping up.Instruction book 1 2 3 4 5 6 7 8 9 Oil filters Air filter Oil filler plug Bolt and bush (to be removed) Bolt and bush (to be removed) Oil drain plug. immobilizing the vibration dampers during transport. 9. 3. Connect the valve to a drain collector.3). Check section 3. 1. 1.9 and 1.3 Air receiver 1.10) is set for automatic resetting. 6. On compressors provided with a dryer by-pass valve.9 and 1.5) to the drain collector. An isolating switch must be installed near the compressor. 3.3) 2920 1464 03 . and that overload relay (F21-Figs. Remove the bolts. For GA Workplace FF with ICD.3) immobilizing the vibration dampers of the compressor element. On water-cooled compressors. 3. 3.the compressor automatically restarts after voltage failure (see section 1.1). Check transformer (T1-Figs.5). Close the valve. The bottle with Atlas Copco Roto-injectfluid (4-Fig.10) and fan motor circuit breaker (Q15-Figs.9 and 1.10) 2).2 and 4-Fig. See also Figs. 1. 1. Labels are delivered with the compressor. Check that the electrical connections correspond to the local codes. 2. Also provide and open the water inlet and regulating valve. nuts and bushes (7-Fig.3) should register in the green or orange range.10) for correct connection.2). Consult section 2. Connect the automatic condensate drain outlet (3-Fig. 3.9 and 1. 1. the settings of drive motor overload relay (F21-Figs. 10. warning the operator that: . 8. Remove the four bolts and bushes (5-Fig. 1.38 - . 1. 3. Fit the air outlet valve (1-Fig. 3. Remove bolts (8-Fig.

For Workplace FF with IFD and Pack FF. . 3. The pointer should register in the green range or in the orange range.10). Rotation arrows. if the compressor has not been used for 3 months. Check the oil level (7-Fig.3. even after manually stopping (see section 1. First check the drive motor (10-Fig.9 and 1. refer to steps 13 up to 15 of chapter 3. visible through the grating in the roof. 1.1) and take them into account. 5.3) . Make sure that all connections are tight.Check the dryer connections for air leaks . Then check fan motor (3-Fig. it is strongly recommended to improve the lubrication of the compressor element at starting: Disconnect air inlet hose (10-Fig. 7. Open the cooling water inlet valve (customer's installation). 3. 3. Check the rotation direction of the motors.Gradually open the dryer outlet valve and close the by-pass valve. . 3. 1. Open the water flow regulating valve (customer's installation). This step can be overlooked if. replace the air filter element (2-Fig. 13.6).7) Start and run the compressor for a few minutes. 3. On GA Workplace FF with ICD: . remove unloader (9-Fig. On GA Workplace FF with ICD also: 6.4) . The correct rotation direction is indicated by an arrow (8-Fig.Close the dryer outlet valve (3-Fig. 4. 2.For Workplace FF with ICD. 3.4). 1. 15.7). If the rotation direction is wrong.6) shows full out. 3.2 (Start up).3 Before starting If the compressor has not run for the past 6 months. switch off the voltage and reverse two incoming electric lines. Check the programmed settings.Let the dryer operate for several hours with the dryer outlet valve closed . If the coloured part of the air filter service indicator (11-Fig.Instruction book 11. Close the dryer outlet valve (3-Fig.3).Close the dryer inlet valve (1-Fig.39 - . 14. Consult the User manual for Elektronikon I and II regulators.Close the air supply valve towards the PDP sensor (23-Fig. the setting of this valve has not been disturbed.3) .3. Start the compressor and stop it immediately.Slowly open the dryer inlet valve (1-Fig. switch off the voltage and reverse two incoming electric connections at the terminals of circuit breaker (Q15-Figs. On GA Workplace FF with ICD: .3). 2920 1464 03 .3). are provided on the plate below the fan. 3.4) . Reinstall the unloader and reconnect the pipe.6) and pour 3/4 l of oil into the compressor element. On water-cooled compressors also: 3. 1.3) Stick these labels on an obvious place near the control panel. 3. 12. . 1. Check that the cooling water drain valves (customer's installation) in the inlet and outlet pipes are closed. If necessary. Check that the compressor operates normally.2) on air-cooled compressors. 1. 8.Open the air supply valve towards the PDP sensor - 3.2). the compressor is automatically controlled and may be restarted. 1. Reset the service indicator by pushing its knob. switch on the voltage 4 hours before starting to energize the crankcase heater of the refrigerant compressor of the dryer. 3. 3.Open the dryer by-pass valve (2-Fig. Close the air supply valve towards the PDP sensor (23-Fig. Close the dryer inlet valve (1-Fig.6) provided on the gear casing (rotation direction depends on compressor type). Read these warnings (as well as the warnings mentioned in section 1. after previous operation. Switch on the voltage.

Starting 1. switch off the voltage and reverse two incoming lines. Check that voltage on LED (6) lights up. switch on the voltage 4 hours before starting to energize the crankcase heater of the refrigerant compressor. The regulator has a control function for correct motor rotation direction.1). In this case. Ten seconds 1) after starting. open the air outlet valve (1-Fig. For GA Full-Feature with IFD. 2920 1464 03 . 3. 2. 2. Press the start button I. 1. 3. 4.Instruction book 1 Shut off valve. dryer inlet Fig.40 - . Switch on the voltage.4 Starting Important 1. The compressor starts running and the automatic operation LED (8) lights up.5). The message on display (3) changes from <<Auto unloaded>> to <<Auto loaded>>. 1. On GA Workplace (FF with IFD). At the same time 1) the compressor starts running loaded. Close the condensate drain valve (4-Fig. the drive motor switches over from star to delta. The message <<Rota>> will appear on the display (3) if the rotation direction is wrong.4 View of ICD dryer 3.

7. Gradually open the dryer outlet valve (3-Fig.41 - . If necessary. Therefore. between 2 and 7°C above the relevant temperature in Fig. the air net must be filled by slowly opening the dryer outlet valve (3-Fig.5. Close the by-pass valve (2-Fig.5. Slowly open the dryer inlet valve (1-Fig. 1. 3.4). the cooling water outlet temperature must never exceed the value specified in section 7. regulate the cooling water flow during loaded running to obtain the most suitable temperature at the outlet of the compressor element. 8. 3. Consult Atlas Copco if condensate should be formed during frequent unloading periods. 1. Note The dryer is sensitive to high air flow velocities because this can damage the desiccant. 2920 1464 03 . For optimum operation. Open the shut-off valve towards the PDP sensor (23-Fig.3). High-speed flow occurs when a compressor starts against an empty air net. 1.7).Instruction book On water-cooled compressors also: 5.3). i.e. On GA Workplace FF with ICD also: 6. 9.3). 1.

indicating the compressor outlet pressure. Depressurize the oil system by unscrewing the oil filler plug (3-Fig.5.42 - . i. Normally.e. 3. 3. wait a few minutes and add oil until the level reaches the filler plug. 3. 3. 3. 2. the minimum temperature to prevent condensate from forming is 68°C. 75°C at the outlet of the compressor element.3) must register in the green range.6) shows full out. press the stop button O. The display (3) will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded. loading. 3. Check the oil level during loaded operation: the pointer of the level gauge (7-Fig. 2. unloading. stop the compressor. If the level is in the LOW range. wait until the compressor has stopped and switch off the voltage.1 Checking the display 1. Regulate the cooling water flow during loaded operation to obtain a temperature between 70 and approx. Fig.3). the status of the compressor and the abbreviations of the functions of the keys below the display. Regularly check the display (3) for readings and messages. If the coloured part of the air filter service indicator (11-Fig. 1.5 During operation 1. the main screen (Fig. stopping of the motors and restarting.5 Minimum compressor element temperature for water-cooled units 3.3) one turn. Tighten the plug. Reset the indicator by pushing its knob. If the automatic operation LED (8) is alight.Instruction book Example: If operating at a pressure of 10 bar(e) in an ambient temperature of 20°C and at a relative air humidity of 100 %. section “Status data menu”. the regulator is automatically controlling the compressor.15) is shown. Carry out the service actions of the 2920 1464 03 . 3. 3. Always check the display (3) and remedy the trouble if alarm LED (7) is alight or blinks. switch off the voltage and replace the air filter element (2-Fig. Consult the User manual.

3. 6. unloads.5. switch off the voltage and depressurize the compressor. Manually loading 3) Press the key Load (F3). stop>> appears. Warning Before carrying out any maintenance.e. LED (8) lights up. If freezing temperatures may be expected. The message <<Manual Unload>> appears on the display.7 Stopping 1.3. . Close the air outlet valve and switch off the voltage. the electronic regulator loads. LED (8) goes out.6 Manual control Normally. LED (8) goes out.Whenever a warning. the messages will be displayed one after the other for 3 seconds. section “Status data menu”. The message <<All conditions are OK>> appears. 1. The message <<Progr. the compressor can be unloaded manually: Press the key Unld (F3). Open the condensate drain valve (4-Fig. unlock the button by pulling it out and press the key Rset (9) before restarting. repair or adjustment.When more than one message needs to be displayed. Consult the User manual. the compressor runs in automatic operation.2 and 1.3). 1. 1. 30 seconds and then stops. consult section 1.3). 4. i.Instruction book indicated plans or replace the component and reset the relevant timer. LED (8) is then alight. the free spaces on the display between the function keys (F1-F2-F3) are filled with blinking indicators (**). Alarm LED (7) blinks. the compressor will be loaded if the air net pressure drops below the programmed level. The command will switch the compressor to automatic operation again. Manually unloading 3) If required. stop the compressor.43 - . sensor error or motor overload message is displayed. the regulator limits the number of motor starts. 4. Close the cooling water inlet valve.5). Notes . The compressor remains running unloaded unless it is loaded again manually. Press the keys Menu and Main. For a quick look at the compressor status. press button (S3-Figs. press emergency stop button (S3-Figs. 3. Manually starting In automatic operation. After remedying the fault. 3. The compressor runs unloaded for approx. If the compressor is stopped manually. stops and restarts the compressor automatically. it must not be restarted manually within 6 minutes after the last stop. On water-cooled compressors only 5. service request. To stop the compressor in case of emergency. Press the stop button O.2 and 1. 2. drain the cooling system completely. 2920 1464 03 .

oil stop valve Arrow.6 View of compressor element 2920 1464 03 . air filter Loading solenoid valve Oil filters Fig.Instruction book 1 2 3 4 5 6 7 8 9 10 11 12 13 Oil cooler Safety valve Compressor element Check valve Oil drain plug.44 - . check valve Oil stop valve Oil drain plug. 3. motor rotation direction (depends on compressor type) Unloader Air inlet hose Service indicator.

press the key Menu (9) until <<Main>> appears above key (F1). Disconnect the compressor air outlet pipe from the air net. Isolate and disconnect the water system from the cooling water net. 6. 2) For air-cooled compressors.Instruction book 3. 2. Shut off and depressurize the part of the air net which is connected to the outlet valve. Footnotes chapter 3 1) Programmable. Switch off the voltage and disconnect the compressor from the mains. 3) If <<Load>> or <<Unld>> is not indicated on display (3). 3. then press the key Main. 7. water and condensate circuits. proceed as follows: 1. Stop the compressor and close the air outlet valve. Disconnect the condensate piping from the condensate net. 4.8 Taking out of operation at end of compressor service life At the end of the service life of the compressor. Depressurize the compressor. Drain the oil. 5. 2920 1464 03 .45 - .

see section 4. C or D. e. General The schedule comprises a summary of the maintenance instructions.5).2) Also consult the manufacturer's instructions stuck on the drive motor.6. replace all disengaged packings. Read the respective section before taking maintenance measures. section “Status data menu”. Remove the bolt fixing the handle. press emergency stop button (S3-Figs.46 - . washers. 4.g. Lock the handle using the special bolt and wrench delivered loose with the compressor. a message will appear on the screen indicating which Service plans are to be carried out. Each plan has a programmed time interval at which all service actions belonging to that plan are to be carried out. press the stop button O.000 operating hours with a high-temperature ball bearing grease ASONIC HQ 72-102. A cartridge with the correct type of grease can be ordered at Atlas Copco. For more details. O-rings.2 and 1. Atlas Copco offers several types of Service contracts. 1. The bearings must be re-greased every 4. After servicing. When servicing. B. 1. consult your nearest Atlas Copco representative.2 Preventive maintenance schedule for the compressor 1) Service plans A number of service operations are grouped in plans.Instruction book 4 MAINTENANCE Attention Before carrying out any maintenance or repair on the compressor. Consult the User manual. The lubrication points are marked. Apply all relevant safety precautions. Service kits For overhauling or carrying out preventive maintenance. When reaching the interval. Quantity: 16 g per bearing. 4. called Service plans A.1 Drive motor (10-Fig. Important Always consult Atlas Copco in case any timer setting should be changed. The air outlet valve can be locked during maintenance or repair as follows: Close the valve.6. service kits are available. gaskets. including those mentioned in this book. Lift the handle and turn it until the slot of the handle fits over the blocking edge on the valve body.3) and switch off the voltage. See section 4. 2920 1464 03 . relieving you of all preventive maintenance work. Close the air outlet valve and open manual drain valve (4-Fig. 3. the intervals are to be reset. wait until the compressor has stopped (approx. 30 seconds).

clean if necessary Remove air filter element (AF).10 bar (100 .150 psi) compressors: If oil as specified in section 4. Clean by air jet and inspect Carry out service plans A and B 3-monthly " Yearly Service plans Running hours 4000 5 5 - 1 - See section 4 See notes below table 2/4 Service plan A Operation If Atlas Copco Roto-injectfluid is used.47 - .2 is used.2 is used. change oil and oil filter For GA 13 bar (175 psi) compressors: If oil as specified in section 4. change oil and oil filter For GA 7. change oil and oil filter 500 4 2/3/4 A 1000 4 2/3/4 A 2920 1464 03 .3.3.5 .Instruction book Preventive maintenance schedule Period Daily " " " “ “ See section 3 3 and 7 -3 3 3 See notes table below Operation Check oil level Check readings on display Check that condensate is discharged during loading Check air filter service indicator Check for cooling water flow (water-cooled compressors) Drain condensate On GA Workplace FF with ICD also Check the pressure dewpoint temperature Check coolers and condenser of dryer.

Or when the pressure drop over the separator exceeds 1 bar. oil or water leakage Replace air filter element Remove. The certificate is only one year valid. Recommended oil: Atlas Copco Roto-injectfluid. Run the compressor: when reaching the setting. 6. 9. 5. dismantle and clean float valve of condensate trap Re-grease bearings of drive motor as specified Test temperature shut-down function Test safety valve For GA Workplace FF with ICD: Replace the silencers of the dryer Replace the elements of the IPD and DDp filters Replace oil separator For GA Workplace FF with ICD: Exchange the dewpoint sensor For GA Workplace FF with ICD: Have the desiccant of the ICD dryer replaced Notes 1. Afterwards. reset the warning and shut-down levels to their original values. humidity or cooling air. 3. for updating consult your Atlas Copco customer centre. 4. For the change interval in extreme conditions of temperature. See User manual. Replace damaged or heavily contaminated elements.3 Oil specifications Attention Never mix oils of different brands or types. the lifetime of the desiccant is approximately 5 years. 2920 1464 03 . 8. At normal working conditions. Decrease the shut-down warning level and shut-down level for the compressor element outlet temperature to the minimum settings. 4. section “Test menu”. The interval for Service plan A is to be reduced to the mentioned interval in case mineral oil is used instead of Roto-injectfluid. Use only non-toxic oils. Damaged flexibles or flexible joints must be replaced.48 - . More frequently when operating in a dusty atmosphere. 7. section “Modify protection settings”. Use genuine Atlas Copco filters. Check the pressure drop when the compressor is running loaded and preferably with a stable working pressure.Instruction book Running hours 4000 " " " " “ " “ “ “ 8000 “ 40000 See section ---4 and 5 -4 -5 ------ See notes below table 7 6 2 8 5 9 10 Service plan B B B B B B B B B B C C D Operation Check pressure and temperature readings Carry out a LED/display test Check for possible air. 2. consult Atlas Copco. See User manual. the unit must shut down. Any leakage should be attended to immediately. 10.

protective measures must be taken. Fill the air receiver with oil until the level reaches the filler opening.4 Oil and oil filter change 1. 3. Remove the oil filters (13-Fig. 3. 3. Reinstall oil filler plug (3-Fig.6) and fill the air receiver with oil until the level reaches the filler plug opening. 2. 3. Load and unload the compressor a few times. 3. This is special oil for screw compressors which keeps the compressor in excellent condition.49 - .the oil must meet the requirements as specified below High-quality. Clean the filter seats on the manifold. Collect the oil in a collector and deliver it to the local oil collection service. Switch off the voltage. Remove the vent plug of the oil cooler. 3. 3. 9. then tighten by hand (approx. half a turn). 5. Unscrew oil filler plug (3-Fig. mineral oil with oxidation inhibitors and anti-foam and anti-wear properties.6 and 7-Fig.3. The viscosity grade must correspond to the ambient temperature and ISO 3448. Reinstall plugs (6-Fig. 5-Fig. Depressurize the system. remove drain plug (7-Fig.the oil filters should be replaced . 2920 1464 03 .1 Atlas Copco Roto-injectfluid It is strongly recommended to use Atlas Copco Roto-injectfluid.5 Storage after installation Run the compressor twice a week until warm. Run the compressor for a few minutes loaded.3. 7.3) and the vent plug of the oil cooler. mineral oil can be used after taking following precautions: . Run the compressor unloaded for 3 minutes. If the compressor is stored without running from time to time. wait 5 minutes. 3. Oil the gaskets of the new elements.3. 3.6) and catch the oil in a receptacle. Stop the compressor. Drain the oil by removing drain plugs (6-Fig. Consult Atlas Copco. Stop the compressor and wait a few minutes to allow the oil to settle.3) only one turn to permit any pressure in the system to escape. reset the timer. Tighten filler plug (3-Fig. Screw the elements into place until the gaskets contact their seats. 3.3 and 5-Fig. 8.the previously used oil should first be drained and the system flushed . as follows: Ambient temperature Consistently above 25°C Between 25 and 0°C Viscosity grade ISO VG 68 ISO VG 46 Viscosity index Minimum 95 Minimum 95 4. section “Status data menu”. See User manual. Atlas Copco Roto-injectfluid can be ordered in following quantities: Quantity 20-litre can 209-litre drum Ordering number 2901 0522 00 2901 0045 01 4.2 Mineral oil Although Roto-injectfluid is recommended.Instruction book 4. 4.6). 4.6). After carrying out the service actions of the related service plan. 3.3). 6.

1. 2920 1464 03 .1 Preventive maintenance kits (typical examples) Service kit for oil filters and air filter For GA55-GA55 W For GA75-GA75 W For GA90C-GA90C W . Any damage or malfunction by the use of unauthorized parts is not covered by Warranty or Product Liability.1). 7.6 Service kits Service kits are available offering the benefits of genuine Atlas Copco parts while keeping the maintenance budget low. 5. 4. 8.Instruction book 4. The local Atlas Copco Sales Company may overrule this schedule depending on the working conditions of the compressor. 6. Footnotes chapter 4 1) Use only authorized parts. The kits comprise all parts needed for servicing. 2. 3. Service kit for oil separator For all GA Service kit for ICD dryers Service plan B and C ICD170 ICD230 ICD280 Service plan D ICD170 ICD230 ICD280 2901 1004 00 2901 0995 00 2901 0995 00 2901 1005 00 2901 0996 00 2901 0996 00 Ordering number 2901 0775 00 2901 0776 00 2901 0776 00 Ordering number 2901 0774 00 Motor grease The ordering number for a motor grease cartridge is 2901 0338 01 (see section 4. Oil separator kit Condensate trap kit Filter kit Minimum pressure valve kit Check valve kit By-pass valve kit Oil stop valve kit Unloading valve kit Fig. 4.50 - .

6) Operate the safety valve. Release the snap clips and remove the dust trap and air filter element.2 Coolers Keep the coolers clean to maintain the cooling efficiency. Stop the compressor. 4.2. Switch off the voltage. Clean the trap. Reset the service indicator (11-Fig.3 Safety valve (2-Fig. 3. If the valve does not open at the pressure specified in section 7. 2920 1464 03 . After carrying out the service actions of the related service plan. consult Atlas Copco.51 - . Never run the compressor without safety valve.6) by pushing the knob in the extremity of the body. 5.or by pulling the valve lifting lever Testing The valve can be tested on a separate compressed air line. Then clean by air jet in reverse direction of normal flow while covering all compressor parts under the coolers.Instruction book 5 ADJUSTMENTS AND SERVICING PROCEDURES 5. On water-cooled compressors Consult Atlas Copco for cleaning. 3. 3.3) 1. Never use a wire brush or metal objects. Discard the filter element. Refit the new element and the trap. If it is necessary to wash the coolers with a cleansing agent. reset the timer.by unscrewing the cap one or two turns and retightening it . Warning No adjustments are allowed. On air-cooled compressors Remove any dirt from the coolers with a fibre brush.1 Air filter (2-Fig. section “Status data menu”. depending on the type of valve: . See User manual. 3. consult Atlas Copco. 2. 5.

1. compressor starts running. Close the air outlet valve and depressurize the air system. b.2 and 1. b. 1. Compressor air output or pressure below normal a. wait until the compressor has stopped (approx. Mechanical faults and suggested remedies (Figs. 30 seconds). a. d. Before starting repairs: Press the stop button O. b. clean and check 4. b. b. including those mentioned in this book. a.52 - . Furthermore. but does not load after a delay time Solenoid valve (Y1) out of order Replace valve Inlet valve (IV) stuck in closed position Have valve checked Leak in control air flexibles Replace leaking flexible Minimum pressure valve (Vp) leaking (when net is depressurized) Have valve checked Compressor does not unload. Air consumption exceeds air output of compressor a. a. 2. press the emergency stop button (S3-Figs. c. Check equipment connected 2920 1464 03 . d. apply all relevant safety precautions.Instruction book 6 PROBLEM SOLVING Consult the User manual. section “Status data menu” if a service message or fault message appears on the display (3) or when the alarm LED (7) is alight or blinks. c. safety valve blows Solenoid valve (Y1) out of order See 1a Inlet valve (IV) does not close See 1b Condensate is not discharged from condensate trap during loading Discharge flexible clogged Check and correct as necessary Float valve malfunctioning Remove float valve assembly.3) and switch off the voltage. b. Start button I is pressed. The air outlet valve can be locked as described in section 4. 3. a. a.6 and 1.7) 1. a.

Excessive oil flow through air inlet filter after stopping a. Pressure dewpoint temperature to high The dryer is not yet regenerated Close the dryer outlet valve and have the desiccant regenerated Free water in compressed air inlet Check that condensate separators and drains upstream of the dryer are operative 2920 1464 03 . If installed. d. See 4i On GA Workplace FF with ICD also: 8 a. Air cooler (Ca) clogged e. Oil level too low b. d. Check valve (CV) leaking or oil stop valve (Vs) jammed a. Check and correct as necessary c. have system cleaned b. d. a. Clean cooler f. h. e. h. a. f.Instruction book b. Oil cooler (Co) clogged c. g. On water-cooled compressors. Have valve tested e. i. f. i. e. 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 Safety valve (SV) leaking Have valve replaced Compressor element (E) out of order Consult Atlas Copco 5. c. c. check capacity of compressor room fan. 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 Dryer piping clogged because of ice formation Have refrigerant system checked by Atlas Copco 7. b. d. Compressor element (E) out of order f. if necessary. Avoid recirculation of cooling air. check cooling water flow. Insufficient cooling air or cooling air temperature too high a. Have defective parts replaced. Replace air filter element (AF) 6. a. By-pass valve (BV) malfunctioning d. b.53 - . c. c. Check for cooling air restriction or improve ventilation of compressor room. b. b. Element outlet or air outlet temperature above normal a. Clean cooler d. g. b. e. e.

Silencers defective or connected badly a. d. Check the silencers and their fixations 10 Insufficient air leaves the dryer a. Check the condition of solenoid valves. Replace if defective. c. Too much purge air flow a. d.54 - . e. e. pneumatic valves and 3-way valve. Air flow through the dryer too high Correct as necessary Outlet pressure too low Check whether the compressor provides enough air for the application Compressed air temperature at dryer inlet too high Check compressor aftercooler 9 The dryer produces a lot of noise a. 2920 1464 03 .Instruction book c.

4°C Use ↓ key on main screen (Fig.55 - . Reading: Shown: Ref. 1. Reading: Shown: Ref.5-8 bar GA 10 bar GA 13 bar GA 100 psi GA 125 psi GA 150 psi GA 175 psi GA 7.5 bar(e) 200 psig 200 psig 200 psig 215 psig 11 bar(e) 11 bar(e) 14 bar(e) Always check the set pressure stamped on the valve.1 Readings on display (3-Fig. 1. 1. -70°C Use ↓ key on main screen (Fig.8) 1) Ref. 1. 2920 1464 03 .15) Cooling water outlet temperature Below 50°C Use ↓ key on main screen (Fig.15) On GA Workplace FF with IFD Pressure dewpoint temperature Approx. Reading: Shown: Ref. 1. Reading: Shown: Ref.5-8 bar/ISPESL approved GA 10 bar/ISPESL approved GA 13 bar/ISPESL approved Safety valve set pressure(e) 12 bar(e) 12 bar(e) 14.15) On GA Workplace FF with ICD (-70°C variant) Pressure dewpoint temperature Approx.15) Pressure difference over oil separator Below 1 bar Use ↓ key on main screen (Fig. 1.Instruction book 7 PRINCIPAL DATA 7.15) Compressor element outlet temperature Approx. 1. Reading: Shown: Air outlet pressure Modulates between programmed unloading and loading pressures On main screen (Fig.15) 7. -40°C Use ↓ key on main screen (Fig.15) On GA Workplace FF with ICD (-40°C variant) Pressure dewpoint temperature Approx. Reading: Shown: Ref. 60°C above ambient temperature Use ↓ key on main screen (Fig. Reading: Shown: Ref. 1.2 Settings of safety valve Compressor type GA 7.

4 See 7.IEC 60 Hz CSA/UL 60 Hz CSA/UL Overload relay F21 (A) 137 119 68 62 57 50 40 137 137 125 125 71 63 58 48 Circuit breaker Q15 3) (A) 9.4 See 7.3 Maximum settings of overload relay.4 See 7. circuit breaker and fuses 7.5 2.IEC 50 Hz .IEC 50 Hz .3.8 4.3.4 See 7.IEC 60 Hz .4 See Fuses CSA HRCII-C (A) - Fuses UL Class K5 (A) - 2920 1464 03 .3.6 4.6 9 4.3.3.3.3.3.5 10.3.8 Fuses (A) See 7.3.4 See 7.4 See 7.Instruction book 7.3.4 See 7.7 Fuses (A) See 7.8 3.IEC 50 Hz .IEC Overload relay F21 (A) 188 164 94 Circuit breaker Q15 3) (A) 9.6 9 4.5 3.4 See 7.3.56 - .IEC 50 Hz .IEC 60 Hz CSA/UL 60 Hz .IEC 60 Hz .8 10.1 For GA55/GA55 W Supply voltage (V) 200 230 400 440 500 550 690 200 200 220-230 220-230 380 440-460 440-460 575 Frequency 50 Hz .3.5 9 9 4.3.6 3.4 Fuses CSA HRCII-C (A) 250 250 110 100 Fuses UL Class K5 (A) 250 250 125 100 7.8 4.IEC 50 Hz .IEC 50 Hz .4 See 7.IEC 60 Hz CSA/UL 60 Hz .3.IEC 50 Hz .2 For GA75/GA75 W Supply voltage (V) 200 230 400 Frequency 50 Hz .IEC 50 Hz .4 See 7.4 See 7.

IEC 60 Hz .4 See 7.4 See 7.4 See 7.IEC 60 Hz CSA/UL 60 Hz CSA/UL - Overload relay F21 85 75 69 55 201 201 182 182 105 91 92 71 Circuit breaker Q15 3) 4.4 See 7.3.IEC 50 Hz .3.3 For GA90C/GA90C W Supply voltage (V) 200 230 400 440 500 550 690 200 200 220-230 Frequency 50 Hz .6 5.8 4.3.6 3.3.4 See 7.4 See 7.IEC 60 Hz CSA/UL 60 Hz .4 See 7.8 3.3.8 10.4 See 7.IEC 50 Hz .3.4 See 7.4 See 7.IEC 60 Hz .57 - .4 See 7.3.3.IEC 50 Hz .3.6 Fuses 7.4 See 7.3.Instruction book Supply voltage 440 500 550 690 200 200 220-230 220-230 380 440-460 440-460 575 Frequency 50 Hz .3.5 9 9 4.4 - Fuses CSA HRCII-C 400 350 175 150 Fuses UL Class K5 400 350 175 150 7.4 See 7.3.6 4.5 Fuses (A) See 7.4 Fuses CSA HRCII-C (A) 400 Fuses UL Class K5 (A) 400 - 2920 1464 03 .4 See 7.4 See 7.IEC 50 Hz .3.IEC 50 Hz .5 10.1 4.4 3.3.3.IEC 50 Hz .IEC 60 Hz .4 See 7.3.IEC 50 Hz .IEC 50 Hz .IEC 60 Hz CSA/UL 60 Hz .5 2.IEC 50 Hz .IEC Overload relay F21 (A) 203 177 102 92 82 74 59 199 200 180 Circuit breaker Q15 3) (A) 14 12 7 6.3.3 5.3.1 15 15 13.IEC 60 Hz CSA/UL 60 Hz .3.

Instruction book Supply voltage 220-230 380 440-460 440-460 575 Frequency 60 Hz CSA/UL 60 Hz .4 See 7.3.4 Settings of dryer switches (on GA Workplace Full-Feature with IFD) The regulating and safety devices are factory-adjusted to obtain optimum performance of the dryer.3 5 Fuses See 7.5 Compressor specifications 7.4 Maximum fuse setting Cable size (mm²) 16 25 35 50 70 95 120 150 Maximum fuse (A) 63 80 100 125 160 200 250 250 7.3 6.1 Reference conditions Air inlet pressure (absolute) Air inlet temperature Relative humidity Working pressure On water-cooled units also: Cooling water inlet temperature bar Celsius % bar(e) Celsius 1 20 0 See nominal values below 20 7.4 - Fuses CSA HRCII-C 350 175 150 Fuses UL Class K5 350 175 150 7. 7.3.5 7.3 6.IEC 60 Hz CSA/UL 60 Hz CSA/UL - Overload relay F21 180 110 91 91 69 Circuit breaker Q15 3) 13.IEC 60 Hz . Do not alter the setting of any of the devices.58 - .5.3.2 Limitations Maximum working pressure Minimum working pressure Maximum air inlet temperature Minimum air inlet temperature bar(e) bar(e) Celsius Celsius See maximum values below 4 40 0 2920 1464 03 .5.

8 3 8 bar 50 7.5 26.5 26. cooling water outlet temperature Max.85 8.4 6. GA Oil capacity.5.4 69.9 26.5 66 56 84 8 bar 50 8 8 30 2960 67. Motor shaft speed Power input.5 26.3 30 175 psi 60 12.5 66 56 84 10 bar 50 10 9.3 67.6 66.5 26.5 26.75 25 2960 71.2 26.5 66 56 84 R404a 1. GA W Mean sound pressure level 5) Cooling water consumption.6 30 3565 64.5 GA75/GA75 W Workplace 4) Compressor type Frequency Maximum (unloading) pressure Nominal working pressure Temperature of air leaving outlet valve.5 67 56 84 R404a 1. GA W 6) Cooling water consumption.5.59 - . approx.4 26.4 26.0 26.0 67. approx. approx.5 7 30 2960 65.75 7.8 10.7 62.5 26.5 26. GA Power input.5 30 100 psi 60 7.8 26.1 68.4 6.8 3 100 psi 60 7.5 30 13 bar 50 13 12. GA Power input.7 63.5 12 30 2920 1464 03 .2 61.5.6 30 150 psi 60 10.7 26.5 67 56 84 R404a 1.9 63.Instruction book On water-cooled units also: Max.5 bar 50 7.3 GA55/GA55 W Workplace 4) Compressor type Frequency Maximum (unloading) pressure Nominal working pressure Temperature of air leaving outlet valve.9 30 125 psi 60 9.1 8.5 26.5 67 56 84 125 psi 60 9.4 GA55/GA55 W Workplace Full-Feature with IFD 4) Compressor type Frequency Maximum (unloading) pressure Nominal working pressure Temperature of air leaving outlet valve.5 26.1 8. Full-Feature 8) Hz bar(e) bar(e) Celsius r/min kW kW l l dB l/min l/min kg Celsius 7.5 66 56 84 R404a 1. GA W Oil capacity.9 26.5 30 2960 64.15 6.5 bar 50 7.5 66 56 84 R404a 1.9 25 3565 71.5 7 30 8 bar 50 8 8 30 10 bar 50 10 9.6 25 3565 69.5 bar 50 7.5 26.8 3 10 bar 50 9. GA W 6) Cooling water consumption. cooling water inlet pressure Celsius bar(e) 50 5 7. GA Oil capacity.5 66 56 84 100 psi 60 7.5 26. GA W Mean sound pressure level 5) Cooling water consumption.2 64.9 30 3565 65.75 9. Hz bar(e) bar(e) Celsius 7.25 7 25 2960 70. GA W Oil capacity. GA W 7) Refrigerant type Refrigerant charge Pressure dewpoint.8 3 125 psi 60 8.7 26.5 25 2960 68.5 67 56 84 7. GA W 7) Hz bar(e) bar(e) Celsius r/min kW kW l l dB l/min l/min 7. Motor shaft speed Power input.8 3 7.

5 69 76 114 R404a 2.6 29.5 86.0 86.5 26.4 93 29.6 30 3575 101.1 8 bar 50 8 8 30 2970 105.3 85.5 26. GA W Mean sound pressure level 5) Cooling water consumption.8 29.2 150 psi 60 10.6 3 8 bar 50 7.7 92.5 10 bar 50 10 9.0 29.2 29. GA Oil capacity.3 30 3575 101. Motor shaft speed Power input.5 12 30 3575 101. GA W 6) Cooling water consumption. GA W Oil capacity.6 3 13 bar 50 12.25 7 25 2965 93. GA Hz bar(e) bar(e) Celsius r/min kW 7.5 26.25 12 25 3570 93.15 6.8 10.5 69 76 114 7.1 8.5 30 2970 99.75 12.9 175 psi 60 12. GA W Oil capacity.5 69 76 114 R404a 2.5.6 3 125 psi 60 8.4 6.3 25 3570 93.5 25 2965 92.5 bar 50 7.1 90.5 68 76 114 3570 89.6 29.9 29.5 29. GA W Mean sound pressure level 5) Cooling water consumption.2 2920 1464 03 .6 GA75/GA75 W Workplace Full-Feature with IFD 4) Compressor type Frequency Maximum (unloading) pressure Nominal working pressure Temperature of air leaving outlet valve.4 91.5 26.5 7 30 2970 99.5 68 76 114 R404a 2.7 GA90C/GA90C W Workplace 4) Compressor type Frequency Maximum (unloading) pressure Nominal working pressure Temperature of air leaving outlet valve.Instruction book Motor shaft speed Power input.5 26.6 29.4 125 psi 60 9.85 8.5.55 10.8 90.7 85.6 13 bar 50 13 12.75 9.5 26.5 25 2965 92.5 69 76 114 R404a 2.5 26.6 3 100 psi 60 7.5 68 76 114 2965 87. GA Power input.9 25 3570 95.5 68 76 114 R404a 2. approx.6 3 150 psi 60 10.5 26.75 25 2965 94.9 30 3575 100.75 7. GA W 7) r/min kW kW l l dB l/min l/min 2965 88.5 69 76 114 R404a 2.0 29.8 90.5 68 76 114 2965 88. Full-Feature 8) Hz bar(e) bar(e) Celsius r/min kW kW l l dB l/min l/min kg Celsius 7.9 100 psi 60 7.5 26.5 26.5 69 76 114 3570 87. approx.3 85.5 29.9 85.5 69 76 114 3570 87. Motor shaft speed Power input.5 68 76 114 R404a 2.5 bar 50 7.5 26.6 25 3570 95.5 26.5 29.1 92.6 3 175 psi 60 12.6 3 7. GA W 6) Cooling water consumption.5 68 76 114 R404a 2.5 26.5 69 76 114 3570 87.5 26.5 68 76 114 2965 89. GA Oil capacity.7 29. GA Power input.60 - .6 3 10 bar 50 9.0 90.3 29. GA W 7) Refrigerant type Refrigerant charge Pressure dewpoint.7 87.5 26.6 29.5 30 2970 99.7 29.1 85.5 26.

75 7.5 74 86 129 96.8 bar .8 29.7 3 125 psi 60 8.2 18 85 230 253 276 299 0.8 29. GA Mean sound pressure level 5) Cooling water consumption 6) Cooling water consumption 7) Refrigerant type Refrigerant charge Pressure dewpoint.1 For compressors with a working pressure up to 10 bar Dryer type Volume flow at dryer inlet .5 26.3 25 3575 108.5 74 86 129 R404a 2.5 73 86 129 95.1 29.8 GA90C/GA90C W Workplace Full-Feature with IFD 4) Compressor type Frequency Maximum (unloading) pressure Nominal working pressure Temperature of air leaving outlet valve.10 bar Pressure drop over the dryer Regeneration air consumption Amount of desiccant per vessel ICD170C l/s 170 187 204 221 0.5 73 86 129 101.7 3 10 bar 50 9.7 3 175 psi 60 12.75 12.0 29.5 73 86 129 95.5 73 86 129 R404a 2.5 26. GA W Oil capacity.6.5 26.5 73 86 129 96.5 73 86 129 R404a 2.6 104. GA Oil capacity.1 29.7 bar .5 26. approx.5 103.7 29.2 18 140 ICD230C ICD280C bar % Kg 2920 1464 03 .5 29.25 7 25 2970 104.55 10. Motor shaft speed Power input.5 29.5 26.9 103.Instruction book Power input.5 26.7 3 8 bar 50 7.5 73 86 129 R404a 2.5 bar 50 7.0 106.9 29.6 102.6 25 3575 107.7 3 100 psi 60 7.75 25 2970 111.1. GA W Oil capacity.7 100.2 29.61 - .0 29.5 74 86 129 R404a 2.7 3 150 psi 60 10.9 29.5 74 86 129 96.5 25 2970 104.2 18 115 280 308 336 364 0.5 25 2970 106.7 3 13 bar 50 12.5 29.5 74 86 129 R404a 2.9 25 3575 107.7 3 7.9 bar .1 Pressure dewpoint –40°C variant 7.85 8.5 26.5 74 86 129 7.5 100.6 29.5 74 86 129 R404a 2.5. GA W Mean sound pressure level GA 5) Cooling water consumption 6) Cooling water consumption 7) kW l l dB l/min l/min 95.5 26.6 Specifications of ICD dryer 4) 7.6 29. GA Power input. Full-Feature 8) Hz bar(e) bar(e) Celsius r/min kW kW l dB l/min l/min kg Celsius 7.5 74 86 129 97.75 9.5 103.5 29.15 6.5 73 86 129 R404a 2.25 12 25 3575 107.6.

7 bar .264 US gal 1 l = 0.2 20 85 ICD230C 232 0.035 cu.9 bar .8 bar .2 For compressors with a working pressure of 13 bar Dryer type Volume flow at dryer inlet Pressure drop over the dryer Regeneration air consumption Amount of desiccant per vessel l/s bar % Kg ICD170C 172 0.2 20 140 7.2 20 115 ICD280C 282 0.8 degrees Fahrenheit.10 bar Pressure drop over the dryer Regeneration air consumption Amount of desiccant per vessel ICD170C l/s 136 149 163 176 0. A temperature difference of 1 degree Celsius = a temperature difference of 1.2 23 140 ICD230C ICD280C bar % Kg 7.6.2 16 140 7.1.2.2 23 115 224 246 268 291 0.2 23 85 184 202 220 239 0.2 For compressors with a working pressure of 13 bar Dryer type Volume flow at dryer inlet Pressure drop over the dryer Regeneration air consumption Amount of desiccant per vessel l/s bar % Kg ICD170C 215 0.2 Pressure dewpoint –70°C variant 7.2 16 115 ICD280C 353 0. At reference conditions.Instruction book 7.035 oz 1 kW = 1.341 hp (UK and US) 1 l = 0.6.117 cfm 1 mm = 0.3.220 Imp gal (UK) 1 l = 0.225 lbf 1 Nm = 0. On air-cooled compressors only.504 psi 1 g = 0.ft x°C = (32 + 1.1 For compressors with a working pressure up to 10 bar Dryer type Volume flow at dryer inlet . 2920 1464 03 .738 lbf.401 in water column 1 N = 0.62 - .ft 1 l/s = 2.6.5.8 x) degrees Fahrenheit 2) Footnotes chapter 7 1) 2) 3) 4) See section 1.6.2 16 85 ICD230C 291 0.7 Conversion list of SI units into US/British units 1 bar = 14.039 in 1 mbar = 0.2.

With a tolerance of 2 dB.63 - . At water inlet temperature between 35 and 40°C and temperature rise=10°C. At water inlet temperature below 35°C and temperature rise=15°C.Instruction book 5) 6) 7) 8) According to PNEUROP PN8NTC2.2. 2920 1464 03 . At 20°C / 100% relative humidity.

The safety valve must correspond with pressure surges of 1. 7. This vessel has been designed and built to guarantee an operational lifetime in excess of 20 years and an infinite number of pressure load cycles. No alterations shall be made to this vessel by welding. Therefore. drilling or other methods of mechanical work without written permission of the manufacturer.1 times the maximum allowable operating pressure. 2.45). there is no intrinsic need for in service inspection of the vessel when used within the design limits and in its intended application. However. for M16 bolts 185 Nm (+/. It should guarantee that the pressure will not permanently exceed the maximum allowable operating pressure of the vessel. This vessel can contain pressurized air.64 - . be aware of its potential danger in case of misuse. Original bolts have to be used after opening for inspection. Pressure and temperature of this vessel must be clearly indicated.18). 4. The maximum torque has to be taken into consideration: for M12 bolts 73 Nm (+/. 6. 5. 8. 2920 1464 03 . This vessel shall only be used as compressed air/oil separator and be operated within the specified limits as mentioned on the data plate. national legislation may require in service inspection. Use only oil as specified by the manufacturer.Instruction book 8 INSTRUCTIONS FOR USE OF AIR RECEIVER 1. 3.

........ i s a l a s c i n d c .................... Delivery date: .............. h nt hl er n biu in raig edn: DANGER: This machine is remotely controlled and may start without warning..... a sign stating "This 0 machine may start without warning" s a l b a t c e n a t e hl e tahd er h instrument panel. Contact persons: S r i e ..................... evc: Te e : .......... diinl aey rcuin yia o h plcto hc r o nldd een I a d t o t n r a s f t r l sw i hs o l b o s r e w t s a i n r n diin o oml aey ue hc hud e bevd ih ttoay air compressors and equipment. Installation......... caps and desiccant bags shall be ...................................... Capacity: ........... Dryer gearbox .......... trained......................... Atlas Copco compressor instruction book: ............... 5 A r....... utbe oie salb a i e t t e s a t e u p e t h l e ff x d o h t r q i m n ........ y rsuerleig eie r eie s eurd 1 ..................... hl e ae o iiie h nr f osue ih h ne i 4 The aspirated air shall be free from flammable fumes or vapours. Motor serial No..... Owner's machine No...... rsue 3 Paeteui weeteabetari a co adcena psil........ On units with automatic start-stop system..................................... N v r o s r c t e a r i l t C r f eesr ntl uto ut ee btut h i ne........................................... ukd n 7 E s r t a t e d s h rge pipe from the compressor to the aftercooler....... i coe nt hl e ntle n uh a ht n dqae fo o coigari aalbeadta teehutdarde nt lw f oln i s vial n ht h xase i os o rcruaet teilt eiclt o h ne.. hence some statements may not apply to the unit(s) described i ti bo....... ..... guards or insulations 2 f t e o t eu i ... F r t s a t u d t : ................. Telephone: ... Atlas Copco air dryer instruction book: ....... (continued on inside of cover) Installation Apart from general engineering practice in conformity with the local sft rgltos tefloigdrcie aeseilysrse: aey euain........... Distribution pipes and connections shall be of correct size and suitable for the working pesr.......................... persons switching on remotely controlled uissaltk aeut peatost esr ta teei n oe nt hl ae dqae rcuin o nue ht hr s o n checking or working on the machine.................. competent personnel. electric motor: ...... ec) sal b oml aig pesrs eprtrs ie etns t.... an ovns ht a ed o nenl ie r xlso.... ta oc i re at it Atlas Copco logbook: .. hl e durably marked....... epcal wt rgr t sft de nt f n t t m n n h s o k s e i l y i h e a d o a e y.................... Printed Matter Nos......... competent personnel............................ the operator must employ safe working practices and observe all related local work safety requirements and ordinances. Any modification on the compressor or air dryer shall only be performed in agreement with Atlas Copco and under supervision of authorized................ h titr f h w hl pl These precautions are general and cover several machine types and equipment....... The owner is responsible for maintaining the unit in a safe operating cniin Prsadacsoissalb rpae i usial frsf odto..... Unit serial No.............. plugs......... the following safety directions and peatosaeo seiliprac...... o e a i g o repairing the unit.............................. f eoe oto s ntle............................................ o s o c m l w t l c l l g s a i n t e s r c e o t e t o s a l a p y. maintenance and repair shall only be performed by authorized.. 6 Arne te ar itk s ta loe cohn o pol c o b ......: ... Selected lubricants Compressor: ............ ie ut e re f tan 9 I rmt cnrl i isald te ui sal ba a ovos sg ... I ay saeet i ti bo............. at: E-mail .. Nra rtns (rsue....... opy ih oa eilto...: ......... 8 N e t r a f r em yb e e t do t ea ro t e v l e t ec n e t d ..................... compressor: ........................ lx P r s ............. r a g h i n a e o h t o s l t i g f e p e ann t e sce i............... Other high-temperature pipework shall be clearly marked.................. tmeaue.. nue ht h ica ardyro arnti fe t epn udrha adta i i nti i re r i e s re o xad ne et n ht t s o n contact with or close to flammable material........... t s s r c l f r i d nt d e lo s a i t er s z n u d ral f e l a . Never remove or tamper with the safety devices....... tm stig....................O WNERSHIP DA TA Compressor type: .......... A r d y r t p : ................. N n r t r v l e ( h c v l e ) s a l n t o-eun avs cek avs hl o b rle uo frioaigpesr sses e eid pn o sltn rsue ytm.......................... As a further safeguard.. A l s C p o a r d y r p r s l s : ............................................. i cnomt wt lclsft rls n ofriy ih oa aey ue..... 1 ....... Bearing grease type................................. To t i e d a s i a l n t c hs n......... Address: ................. d y r .................. 2 Any blanking flanges.......... rcuin r f pca motne When operating this unit. Atlas Copco compressor parts list: .... 11 In multiple compressor systems manual valves shall be installed to ........................... at n cesre hl e elcd f nutbe o ae oeain prto...................................... is tr-p ae Service Plan: .............................................................................. h olwn ietvs r pcal tesd 1 A compressor or air dryer shall be lifted only with adequate equipment ........ 1 ............ta cnla t itra fr o epoin . o xenl oc a e xre n h i ult av......... i re ye U i s r a N ......................................... itn ceeain n eadto hl e et ihn ae iis W ear a safety helmet when working in the area of overhead or lifting equipment.. L o eo p v t n p r ss a lb s c r l f s e e b f r l f i g I i os r ioig at hl e euey atnd eoe itn....... E e yp e s r v s e o a x l a yi s a l do t i e itd n h nt vr rsue esl r uiir ntle usd teui t cnanaraoeamshrcpesr salb p tce h n t o o t i i b v t o p e i r s u e h l e ro e t d b apesr-eivn dvc o dvcsa rqie................... SAFETY PRECA U T I O N S To b read attentively and acted accordingly before i s a l n .... Capacity ...... Processing of any other gas requires adtoa sft peatostpclt teapiainwihaenticue hri. operation......... Pipework or other parts with a temperature in excess of 80 degrees 3 celsius and which may be accidentally touched by personnel in normal operation shall be guarded or insulated.. e ntlig prtn r These recommendations apply to machinery processing or consuming air or inert gas.......... n hs ok I n c s a y. .....o l d u i s s a l b i s a l d i s c a w y t a a a e u t . h once pp ms b fe o sri............................................. Local Atlas Copco Representative Name: .. isolate each compressor........... removed before connecting up the pipes........ eg pitslet.. nt eil o re: Motor type: .. tity obde o wl r ty n h ik oe ne itd od Lfigaclrto adrtrainsalb kp wti sf lmt..... lc h nt hr h min i s s ol n la s osbe 2920 1377 03 12 / ........... ae s a l b t k n t m n m z t e e t y o m i t r w t t e i l t a r.... ...

. eidcly hc ht a All guards are in place and securely fastened . damaged or deteriorated hoses. undertaken when the unit is stopped. prs Take safety precautions against toxic vapours of cleaning at.e g w e s e m c e n n . c Always wear safety glasses. rsue esl t. do so with extreme caution lte. l atnr r ih e Aleetia lasaescr adi go odr . rsue Note: W i h s a i n r m c i e u i s d i e b a i t r a c m u t o t ttoay ahn nt rvn y n nenl obsin egn. or in any way modify. 3 All maintenance work.alwnehst b md fretasft peatos eg sak nie loac a o e ae o xr aey rcuin. i oe hl e f orc ie n utbe o h okn rsue Never use frayed. 9 Do not remove any of. etvl slt h ui fo al sucs o pesr ad rlee te etr sse o nt rm l ore f rsue n eiv h nie ytm f pesr. The following safety precautions are stressed when handling 4 rfieat ergrn: a Never inhale refrigerant vapours. 9 Before clearing the unit for use after maintenance or overhaul. osl 1 . e. 8 Mk sr ta n tos loeprso rg aelf i o o teui. . . the deposits should be removed. i ult av n i e. . 1 .g. I t e g o n i n t l v l o c n b s b e t t v r a l i c i a i n 4 f h rud s o ee r a e ujc o aibe nlnto. Protect hands to avoid injury from hot machine parts. Never use a light source with open flame for inspecting the interior o amcie pesr vse. nvr ta o o rmv te lte. ie. shall only be . ae r ae 7 Never weld or perform any operation involving heat near the oil . r e f e r r b s 8 If warm cooling air from compressors is used in air heating systems. the compressed air must rahn ult o rahn i ult b aeutl prfe acrigt lcllgsainadsadrs e dqaey uiid codn o oa eilto n tnad. o ar u hcs a a protectors when opening a door. eprtrs n ie etns r orc and that the control and shut-down devices function correctly. e g t c r y o t c e k . f aae. ulig ae t.. 6 Scrupulously observe cleanliness during maintenance and repair. . Never weld on. i aeutl vniae. eff c i e y i o a e t e . l oe n/r ie nie h nt r n od odto. the machine shall be stopped but no inspection covers shall be opened b f r s ff c e t c o i g t m eoe u iin oln ie hseasd ti t aodters o sotnosinto o teol a lpe. Take positive p e a t o t e s r t a t e u i c n o b s a t d i a v r e t y. Make sure that all sound-damping material.e i fd v c sa en to s r c e f aey avs n te rsuerle eie r o btutd b dr o pit y it r an g Ar ote vle ad ar nt ie pps culns mnfls . (continued) 5 Never use flammable solvents or carbon tetrachloride for cleaning . rcuin o nue ht h nt ant e tre ndetnl In addition. or tamper with. vle.esr ta teoe edi hl scrl hog o e r i i e n u e h t h p n n s e d e u e y. .uebetigpoeto. y ta-laig before carrying out such operations. t . 5 Keep all bodywork doors shut during operation. Nvruei t cendr fo yu iet n i tem t epe ee s t o la it rm or c o h s When using it to clean equipment. . Whenever there is an indication or any suspicion that an internal part of a machine is overheated. flammable or toxic fumes. 1 Use only the correct tools for maintenance and repair work. b e t i g q a i y. other than routine attention. i itr. M k s r t a a h s i ae ue ht oe s flydpesrzdbfr dsoncigi. maintenance or repair.. 2 Use only genuine spare parts. . F r b e t i g a r q a i y. e. or by non-observance of ordinary caution and due c rerequired in handling. elc t y eun to prevent the sound pressure level from increasing. 4 Before removing any pressurized component. examine the discharg 0 e pp adteisd o teolsprtrvse frcro dpst. and use eye protection. o rvn osue rm neig hm . the main power supply is switched off and the machine has cooled down. r n e t e s i w t w t r. . 1 . on the bodywork 2 a d i t e a r i l t a d o t e s s e s o t e c m r s o i i go n n h i n e n u l t y t m f h o p e s r.g. 1 . I f removed. osl A l re p n i i i y f r any damage or i j ryre u t n f l sosblt o nu s l i g rom neglecting these precautions. will be disclaimed by Atlas Copco. Never use caustic solvents which can damage materials of the air 3 net. Maintenance Maintenance and repair work shall only be carried out under supervision o smoeqaiidfrtejb f oen ulfe o h o. 2 The compressor is not considered as capable of producing air of . o o t rt h l e t a h d o h t r i g q i m n .g. truhahs o arln..te se mdclfrtad ergrn s lse wy hn ek eia is i. polycarbonate bowls. Use only the correct t p a d s z o h s e d f t i g a d c n e t o s When blowing ye n ie f oe n itns n oncin. ul ersuie eoe icnetn t Never play with compressed air.i ie n h nie f h i eaao esl o abn eois f excessive. opened for short periods only. e. ee prt h nt t rsue eo r n xes f hi ii rtnsa idctdo tePicplDt set aig s niae n h rnia aa he.g. operating. t e s i . 7 Proial cekta: . 1 . Oil tanks must be completely purg d e g b s e m c e n n . uissalb gone adpoetdaantsotcrut b fss nt hl e rudd n rtce gis hr icis y ue. h k n h o g l t i g e e e r ff r e o e h a t r flush abundantly with fresh water over the clothing until all rfieati fuhdaa. .. Check that the working area . check that the coupling guard of the compressor drive shaft hsbe risald a en entle. 3 Never operate the units when there is a possibility of taking in . Keep dirt away by covering the parts and exposed openings with a cencoh ppro tp. s n o d c n i i n I d m g d r p a e i b g n i e Atlas Copco material odto. A free end will whip and may cause injury.. ta oeaigpesrs tmeaue adtm stig aecret ht prtn rsue. l lcrcl ed r eue n n od re . 22 17 0 90 37 3 22 / . during 5 dann o ol riig f i. . p e s r v s e s rsue esl. e. I l q i r f i e a t c n a t h kn is h kn ih ae f iud ergrn otcs te si truh cohn. hn ta-laig 1 . os at r as r et n r n h nt Operation 1 A rh s ss a lb o c r e ts z a ds i a l f rt ew r i gp e s r . S f t v l e a do h rp e s r . s dqaey etltd f eurd s rahn rtcin b Always wear special gloves.SAFETY PRECA UTIONS 1. la lt. e c C n u t Atlas Copco. to warm up a workroom. check . In case of refrigerant contact with . retr. pr a r s o s f e l n c r . d Alfseesaetgt . t. level reaches or exceeds 90 dB(A) shall wear ear protectors. take precautions against air pollution and possible contamination of the breathing air. 11 Protect the motor. hs o vi h ik f pnaeu giin f h i vapour when air is admitted. The doors may be . 6 People staying in environments or rooms where the sound pressure . a warning sign bearing a legend such as "work in progre s d n t s a " s a l b a t c e t t e s a t n e u p e t s . b A lh s sa d o p p si s d t eu i a ei g o c n i i n s c r . system. e. e e i a vn f not expressly mentioned in this book. e c t p e e tm i t r f o e t r n t e . . c n u t Atlas Copco. D n t a p y i t y u s i o o o pl t o or kn r drc a arsra a pol.hss ec aei go rpi fe o wa o aue a v s o e . ar fle electrical and regulating components. W e r e r . ae ue ht o ol. lqis iud. T e e e t i a c n e t o s s a l c r e p n t t e l c l c d s The 5 h lcrcl oncin hl orsod o h oa oe. aiod.ec f ahn. eue and not rubbing c There are no leaks . the sound-damping material. opig.i rqie. Every time the separator element is renewed. r n o d e a r. 4 Nvroeaeteuisa pesrsblwo i ecs o terlmt .