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Registration code Collection: Tab: Sequence:

APC G30-55C 3 993

APC G55-90C 3 994

Replaces 2934 0612 02 Registration code APC GA30-55C/98/ 3 / 997 and APC G55-90C / 2000/ 3/ 999 Replaces 2933 5973 01 Registration code APC GA30-55C/98/ 3 / 996 and APC G55-90C / 2000/ 3/ 998

Stationary compressors: GA30-90C WorkPlace and WorkPlace Full-feature Description of product and of optional equipment

2003-09

Design objective
The GA 30-90C range is designed according to the workplace concept: all ancillaries like air and condensate treatment equipment can be integrated, which makes them unique all-in-one packages. Thanks to the extreme low noise levels (65-69 dB(A)), these units do not need conventional compressor rooms anymore and can be place next to the point of use. The customer will benefit from a very low installation cost: the required floor space is minimal and only one electrical supply is needed to power the complete air system. Expensive piping to connect ancillaries and to bring the compressed air to the point of use can be avoided. That why the GA 30-90C is labelled as WORKPLACE AIR SYSTEMS

Reliability & Energy efficiency


Compressor element The one-stage, oil-injected screw compressor elements used are: GA 30-55 C : GA 55-90C : C106 C146

The compressor element used in the new GA 30-55C is the C106 - screw element with Standard Atlas Copco Profile (SAP) - rotors. The C106 - screw has rotors of equal diameters and lower tip speeds close to optimal. The SAP can be ground, providing very narrow tolerances and consequently increased performance. Especially on higher pressure efficiency increased up to 15% thanks to a built-in pressure ratio optimised on 10 bar. The C146-screw element is specially developed to reach optimal performance on the very competition-sensitive GA 75-7.5 variant. An optimal bearing arrangement provides a long life time. Drive system The GA30 and 75 / 7.5 / 50Hz are the direct driven variants. All other units have a gearbox transmission. The direct drive or gearbox transmissions contribute to the best overall efficiency. The coupling used is of a special design to reduce torque peaks at start. The coupling housing is connecting the element directly to the motor for permanent alignment and optimal reliability of the drive system.

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Electric motors The Totally Enclosed Fan Cooled (TEFC) drive motor is of a high specification with high efficiency up to 94,8%, protection IP 55 and insulation class F. IP 55 means: 5 = dust can still penetrate but not in such a quantity that it disturbs 5 = protected against water jet Class F: the permissible temperature rise of the winding is 100C above ambient temperature. The high quality of the winding insulation is decisive for the service life of the motor. The separate fan motor is of the same high specification as the drive motor. Control/regulation system The GA 30-90C WorkPlace and WorkPlace Full Feature range is equipped with the user friendly Elektronikon. The Elektronikon features a clear alphanumeric display, continuously monitors the status of the compressor and automatically regulates the unit for economic and efficient operation. The Elektronikon regulates the compressor according to the energy efficient full load / no load system with Delayed Second Stop (DSS). The DSS-algorithm cuts energy consumption significantly by shutting off the motor as fast as possible when the unit switched to no load. At the same time it limits the amounts of motor starts to ensure a long motor service life. The Elektronikon provides a complete range of user friendly features: more than 20 different languages, a programmable time clock, different formats for temperature, pressure, time and date, easy access to all main data and regulation settings, etc. The Elektronikon provides full communication possibilities for remote monitoring and control. With the addition of optional communication modules the compressor can be integrated into existing plant management systems. Each Elektronikon can be configured as a Master controller in a multiple compressor installation to optimally control the compressed air system to minimze working pressure thus save energy. Add-on modules for extra digital and/or sensor inputs are available. The Elektronikon is also service friendly. It monitors all service intervals, generates service warning messages and displays the required level of service according to several Service Plans. In case of emergency it will shut down the compressor and keep all prevailing parameters in memory for easy diagnosis. Air intake system The air intake filter is of the heavy-duty type. The particle separation occurs in two stages, first by cyclone action, then by fine filtering. The efficiency of the filter is 99,9% for particle sizes greater or equal to 3 m. The air intake valve is of the mono-block type, integrating all pneumatic regulation functions of the compressor. The piston valve is of a simple design with only one moving part and is virtually maintenance-free. It contributes to the overall reliability of the compressor. This is opposite to conventional butterfly valves or turn-valves which have a higher degree of complexity and require careful maintenance.

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Oil- and after cooler The air and water coolers are of known and proven type used in all compressors of the GA-range. They contribute to the reliability and efficiency of the GA 30-90C compressors. Air cooled versions: The oil- and after coolers used in GA 30-90C are compact (combi-coolers for GA 30-55C, separate coolers for GA 55-90C) block coolers of aluminium for optimal heat transfer, low pressure drop and low weight. The after cooler reduces the temperature of the outlet air to approx. 10C above ambient temperature. Water cooled versions: The water cooled versions use compact and efficient tube/shell water coolers. Water separator The water separator used is the WSD 80 (in GA 30-55C) and WSD250 (in GA 55-90C) which has both an automatic float type drain and a manual drain to remove the condensate water. Please note the outlet pressure is measured at the outlet valve taking the pressure drop in the after cooler and water separator into consideration.

Oil consumption
The air/oil separator design of the new GA 30-90C is of the proven classic type used in the previous models but made even more compact. The air/oil separation removes the oil from the compressed air in three stages. First by cyclone action, then by gravitation and change in direction and finally by fine filtration. The resulting oil content of the compressed air leaving the unit is less than 2 mg/m.

Noise level
One of the major achievements of the new GA 30-90C design are the extremely low noise levels of 65-69dB(A). These low noise levels were realised by reducing noise and vibration at the source: Gearbox & coupling housing between screw element and drive motor: vibro-acoustic geometry-optimisation by Finite Element Method (FEM) to avoid almost completely any vibration transmission from screw element to other compressor parts downsizing for optimal compactness and minimal vibration transmission Low noise cooling fan design: radial type fan of extra large dimensions low speeds of 920/1080rpm (50-60Hz) on a 6-pole fan motor generates a laminar, high volume, low speed cooling air flow through the coolers providing high cooling efficiency at extremely low noise level. Vibration dampers: on screw element: extremely rigid connection towards the base frame on oil separator: to avoid any vibration transmission from the oil separator vessel (resulting from pulsation in the compressed air flow) to the base frame Extra noise-baffling in front and around the drive motor

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Customisation - Compactness
The GA 30-90C can be customised to a very large extent. It is available in three main versions: Pack (only on GA 30-55C): Basic compressor with Atlas Copco quality & reliability Elektronikon MKIV-I regulator No water separator Limited range of optional equipment Pack Full Feature: Basic compressor with Atlas Copco quality & reliability Elektronikon MKIV-I regulator Integrated refrigeration dryer with water separator Limited range of optional equipment WorkPlace: Complete industrial compressor Elektronikon MKIV-II regulator Minimum noise level Including water separator Full range of optional equipment WorkPlace Full Feature: State of the art industrial compressor Elektronikon MKIV-II regulator Minimum noise level Including refrigeration or desiccant dryer Full range of optional equipment The basic versions are able to operate up to 40C ambient temperatures. High Ambient Versions (HAV) are available which can operate up to 50C (not in FF execution). The Integrated ReFrigerant Dryers (IFD) on the GA 30-90C Full Feature series are the IFD 90-270. All have the environmental friendly R404a refrigerant with zero Ozone Depletion Potential (ODP). All main components are oversized. This provides a correct dewpoint even in extreme conditions of temperature and humidity. The ID 90-270 have compact aluminium air-to-air and air-to-refrigerant heat-exchangers, an hermetically sealed refrigerant compressor and an integrated WSD80-250 water separator with automatic and manual drain. The dewpoint is monitored by the Elektronikon which will generate a warning message at deviating values. A dewpoint indication or reading is available on the Elektronikon-display. One of three desiccant dryers can be integrated with a GA Workplace compressor. For the GA30-55C the choice is between the ICD100, ICD140 or ICD170C, andGA55-90C can be integrated with either the ICD170, ICD230 or ICD280. The package is delivered in two pieces that are both installation ready. The package includes dewpoint dependant switching and a dryer bypass, plus pre and after filters. Such a unit can be ordered by adding the appropriate option number to the Workplace part number. All versions of the GA 30-90C have a very compact canopy. Further, a full range of 35 items of optional equipment is available on Pack and Full Feature versions. It allows to customize the GA 30-90C to meet the most diverse needs. Most of the optional equipment can be integrated inside the compact canopy (see further). The units are Pre-Delivery Inspected (PDI) and contain all operation and safety instructions required. All units are filled with Atlas Copco Roto-Inject Fluid lubrication oil and are fully tested. The outlet valve is included on all units together with drain connections and a can of extra oil.

Condensate water disposal


The OSD90 can be integrated as optional equipment. It will remove oil out of the condensate water which can be drained to the public sewer without any further treatment.

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Service friendliness
Service friendliness has been enhanced on the new GA 30-90C range. Several items illustrate this: The Elektronikon monitors all service intervals, generates service warning messages whenever necessary and displays the required service plan. All canopy doors can be removed for free access to all compressor parts. All parts subject to regular maintenance are gathered at the front side of the machine. The suction side of the coolers is easily accessible for cleaning. The cooling fan assembly is positioned behind full steel panels providing full protection against physical injury but also full access for service inspection once removed.

High quality perception


Customer satisfaction is determined by a mix of facts and perceptions. The main features and benefits have been mentioned above. As a finishing touch the compressor layout has been reviewed. All components used and the general technical execution emanate high quality.

Conclusion
As a result the GA 30-90C range is pre-determined to satisfy the unexpressed desires and latent needs of existing customers and emerging needs of prospective customers. The GA 30-90C range are reliable and energy efficient compressors which can provide dry compressed air thanks to the Full Feature versions with integrated filters. More than 70% of the energy can be recovered. They are environment friendly with R404a zero Ozone Depletion Potential (ODP) refrigerant, with clean condensate water from the OSD and extremely low noise levels down to 65-69 dB(A). The GA 30-90C can be installed virtually everywhere thanks to its complete, integrated equipment, low noise level and clean operation. A dedicated compressor room is not necessary anymore. The GA 30-90C are WORKPLACE AIR SYSTEMS.

Product description optional equipment for GA 30-90C


The optional equipment for GA 30-90C units is available as factory version or sales version, unless otherwise stated. In factory version the equipment is built into the unit to the largest extent ex-Airpower. The factory versions for GA 30-90C have to be ordered with a 0000 000X XX product number together with the product number of the standard unit. In sales version all necessary equipment is gathered in a kit which allows proper mounting of the equipment locally. The sales versions have to be ordered separately with a 10-digit product number. For availability and relevant product numbers, dimension drawings & installation instructions: see tab 26, unless otherwise stated.

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Modulating control This alternative regulating system has been designed to match the air capacity of the compressor to the customers air consumption, maintaining the delivery pressure in a band as stable as possible. The air delivery of the compressor can be reduced to 50% of its nominal capacity. Relevant AML-data can be found under tab 17. For performance curves, operating and installation instructions: see dedicated instruction book for modulating control tab 38. Spare parts list is included in the spare parts book of the compressor (ASL in tab 39). Kit content: unloading valve, solenoid valve, mounting brackets, tubes and electrical cables. Important note: Modulation control is an older type of regulation providing varying capacity at a very poor efficiency. It is strongly recommended to investigate our state of the art GA 18-90VSD units as an alternative. They offer varying capacity from 15% to 100% at superior efficiency in a 0.2 bar regulating band at any delivery pressure between 4 bar and 13 bar. The price premium on the VSDs is justified by energy cost savings up to 35% and flexibility in use. Energy recovery The energy required in any compression process is transformed into heat. A major part of this heat is dissipated through the oil system. The energy recovery systems are designed to recover up to 70% of this heat to be used for hot water production without any adverse influence on the compressor performance. See tabs 18 & 40 for performance curves, operating and installation instructions. Spare parts list is included in the spare parts book of the compressor (ASL in tab 39). Kit content: oil/water heat exchanger, 4-way valve, thermostatic valve, mounting brackets, hose assemblies and pipes. Most of the components in the sales kit are pre-assembled. Electronic drain The electronic drain assures proper draining of condensate water and thus prevents water in the customers system. It generates a warning signal at any malfunction of the draining process. The warning message appears on the Elektronikon-display of the GA30-90C (not available on Pack units) The electronic drain takes over the drain-function of the WSD water separator. The floating ball from the WSD water separator is removed and the automatic drain is connected to the Electronic Drain. The condensate water is gathered in the electronic drain. At a certain level the water is drained during a certain time. Kit content: Electronic drain device, pipes, electric cables and drain tubes. Integrated OSD The oil separating device (OSD) separates the oil-residues from the condensate water. The clean water can be drained in the sewer without any further treatment. The separated oil is gathered in a can and can be disposed of according to prevailing regulations. The OSD can not be used in combination with the electronic drain. Spare parts list is included in the spare parts book of the compressor (ASL in tab 39). Kit content: OSD90, mounting brackets, tubes and connections. Class 2 filter kit (general purpose filter kit) On Full Feature units only! Integration of a DD into a GA 30-90C Full Feature unit will provide compressed air quality according to ISO 8573-1 class 2.4.2. Kit content: DD, electrical and drain connections.

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Class 1 filter kit (fine filter kit) On Full Feature units of GA 55-90C only! Integration of a DD/PD combination into a GA 55-90C Full Feature unit will provide compressed air quality according to ISO 8573-1 class 1.4.1. Kit content: DD/PD filter, electrical and drain connections. Transformer kit FF Transformer kits required to provide single power supply - connection for FF-units working on following systems: 50Hz: 400V when no neutral line is available This transformer eliminates the need for an extra power supply line for the integrated dryers in the above mentioned case. Not applicable on GA 55-90C: Thanks to the availability of 3-phase refrigerant compressors, all required voltagefrequency combinations will be available as standard. ID-bypass kit This kit allows the user to bypass the ID in case of a failure. By switching the electrical connection of the pressure transducers and changing the direction of the airflow through the three way valve, the ID will be bypassed. The time to dismount the ID is reduced to an absolute minimum thanks to two design features: - there is no need to dismount the bypass pipe itself because internally the bypass is lead behind the ID and can remain fixed whilst removing the ID. - the frame of the ID is adapted in width to slide the ID out of the unit and has forklift slots to remove it by forklift. Note that, when using the bypass, also the WSD inside the machine will be bypassed. Therefore an additional WSD80-250 is included in the kit. This WSD must be installed in the bypass line, outside of the unit. Kit contents : three way valve, piping, pressure transducer, WSD80-250, ball valve and drain tubes. WSD kit Pack Units WSD water separator to be included inside the Pack - versions. Only optional equipment available on the Pack range. Kit content: WSD 80, piping and drain tubes. Not applicable GA 55-90C as there is no Pack version. Lifting Device The Lifting Device allows the customer to lift the compressor by means of e.g. a crane. It is AIB and CE-approved, and hence complies to all safety standards applicable for this kind of equipment. Only available as factory version. Freeze Protection The Freeze Protection allows the unit to start up in ambient temperatures down to -20C. The unit can run continuously at -10C. Typical application are compressors installed in non-heated rooms outside the main factory building. After start-up, the room will heat up by the compressor cooling air flow. Heat-tracing cable is wrapped around the oil separator vessel and water separator and there is extra heating in the electrical cubicle. Kit content: heat-tracing and cable terminals.

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Rain Protection The Rain Protection prevents rain from entering the machine. At the same time it protects the display of the Elektronikon-module against sun and rain. It is composed of several baffles and covers mounted on the compressor. Kit content: metal rain protection panels, mounting brackets Main Power Isolator Switch This switch can be used to isolate the compressor from the main power supply without having to disconnect the electrical wiring. The switch has a lockable handle. Kit content: main power isolator switch and cables. Phase sequence relay A special relay controlling the correct sense of rotation will prevent the motor from starting when the 3 phases of the main supply are not connected correctly. Kit content: relay, cabling, mounting brackets Oil Containing Frame This additional collector-frame to be installed under the standard machine will collect oil from occasional leakage and avoid oil to spread over the floor. Kit content: frame. Dryer kit In case an Integrated Dryer (ID) should be retrofitted on a unit, ID-dryer kits are available (as long as the production of the compressor is taking place). Kit content: ID-dryer, relay, electrical cables (included glands and sockets). As a matter of fact only available as sales version since a factory version is the standard FF-unit. Special colour The machine canopy can be painted in colour different from the standard colours. Only available as factory version. Tropical Thermostat In areas with tropical climate (high temperature, high humidity) there is a risk for condensation of water in the compressor-oil. To avoid this, a thermostatic valve of a higher setting (75C) can be introduced in the oil circuit of the unit. As a result the unit will run at artificially high temperatures and thus avoid condensation. Performance of the compressor will be affected slightly. Relevant AML-data can be found under tab 17. Kit content: thermostatic valve Relays for ES 100 - sequence selector Extra relays to connect the GA 30-90C to the ES 100 - sequence selector. These optional relays provide a very simple connection to ES 100 if no extra communication possibilities are required.

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Russian GOST-stamp For import into Russia, GOST-stamps (on the dataplate and on all sides of the packing) are available which refer to the registration number of the certifying body that issues the Gosstandart-certificate. The Gosstandart-certificate is compulsory for import into Russia and has to be requested at the AC Sales Company in Moscow, Russia. Contact the Division for further information. Only available as factory version PAO oil Synthetic poly-alpha olefin oil for applications where the mineral Roto-injectfluid is not suitable. Typical application is Membrane Air and Gas-separation. Only available as factory version Food-Grade oil Food-grade oil for applications where the mineral Roto-injectfluid is not suitable. Only available as factory version HD-Rotofluid oil Synthetic 8000 hrs oil Only available as factory option Drive Motor anti-condensation and thermistor Protection Additional anti-condensation heaters on the drive motor. Typical application: intermittent operation with prolonged standstill periods in humid conditions. Additional thermistor-monitoring of the drive motor winding temperature providing warning signals and eventually shutdown of the compressor. Only available as factory version Water Shutoff Valve On water cooled units only! The water shutoff valve will open or close the cooling water flow in parallel with the start-stop condition of the unit. Kit content: Water Shutoff Valve, wiring, mounting brackets

Integrated Desiccant Dryer (ICD) This option turns a Workplace unit into a Workplace Full Feature with integrated desiccant dryer. There are 6 option numbers available per compressor range. The option numbers correspond to the ICD module and the type of desiccant required there are three units possible per compressor range, each with the choice of two desiccants. If the application is situated In a hot ambient condition or if a PDP of 70C/-94F is required, the option including molecular sieve desiccant should be used, otherwise activated alumina should be used. This option can be ordered as both a factory or sales version. See the features and options database for part numbers.

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