Atlas Copco GA 11+ User manual

INSTRUCTION BOOK
OIL-INJECTED ROTARY SCREW COMPRESSORS
GA 11+, GA 15+, GA 18+, GA 22+, GA 26+, GA 30

Atlas Copco
Oil-injected rotary screw compressors
GA 11+, GA 15+, GA 18+, GA 22+, GA 26+, GA 30
Instruction book
Original instructions
COPYRIGHT NOTICE
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2021 - 06
No. 2920 7118 31
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................6
1.1 SAFETY ICONS...................................................................................................................................6
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................7
1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................8
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 9
1.6 DISMANTLING AND DISPOSAL...............................................................................................................11
2 General description......................................................................................................12
2.1 INTRODUCTION.................................................................................................................................12
2.2 FLOW DIAGRAM................................................................................................................................15
2.3 CONDENSATE SYSTEM.......................................................................................................................16
2.4 REGULATING SYSTEM........................................................................................................................20
2.5 ELECTRICAL SYSTEM.........................................................................................................................21
2.6 AIR DRYER......................................................................................................................................22
3 Elektronikon™ Swipe controller................................................................................. 24
3.1 CONTROLLER...................................................................................................................................24
3.2 CONTROL PANEL.............................................................................................................................. 26
3.3 ICONS USED.................................................................................................................................... 27
3.4 MENU............................................................................................................................................ 28
3.5 MAIN SCREEN..................................................................................................................................30
3.6 MACHINE SETTINGS MENU..................................................................................................................33
3.7 AUXILIARY EQUIPMENT PARAMETERS MENU............................................................................................35
3.8 DATA MENU.....................................................................................................................................36
3.9 SERVICE MENU................................................................................................................................ 37
3.10 CONTROLLER SETTINGS MENU.............................................................................................................39
3.11 INFORMATION MENU.......................................................................................................................... 41
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4 Elektronikon™ Touch controller................................................................................. 43
4.1 CONTROLLER...................................................................................................................................43
4.2 CONTROL PANEL.............................................................................................................................. 45
4.3 ICONS USED.................................................................................................................................... 46
4.4 MAIN SCREEN..................................................................................................................................50
4.5 QUICK ACCESS SCREEN.....................................................................................................................51
4.6 MENU SCREEN.................................................................................................................................52
4.7 DATA MENU.....................................................................................................................................54
4.8 SERVICE MENU................................................................................................................................ 56
4.9 WEEK TIMER MENU...........................................................................................................................58
4.10 EVENT HISTORY MENU.......................................................................................................................59
4.11 MACHINE SETTINGS MENU..................................................................................................................60
4.12 CONTROLLER SETTINGS MENU.............................................................................................................63
4.13 ACCESS LEVEL.................................................................................................................................66
5 Installation.....................................................................................................................68
5.1 DIMENSION DRAWINGS.......................................................................................................................68
5.2 INSTALLATION PROPOSAL................................................................................................................... 68
5.3 ELECTRICAL CONNECTIONS.................................................................................................................76
5.4 PICTOGRAPHS................................................................................................................................. 79
6 Options.......................................................................................................................... 81
6.1 ENERGY RECOVERY..........................................................................................................................81
6.2 MAIN SWITCH.................................................................................................................................. 93
6.3 DRYER BYPASS................................................................................................................................93
6.4 FREEZE PROTECTION........................................................................................................................ 94
6.5 HEAVY DUTY FILTER..........................................................................................................................96
6.6 PREFILTER......................................................................................................................................96
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7 Operating instructions................................................................................................. 98
7.1 INITIAL START-UP..............................................................................................................................98
7.2 BEFORE STARTING..........................................................................................................................100
7.3 STARTING ....................................................................................................................................101
7.4 DURING OPERATION........................................................................................................................102
7.5 CHECKING THE DISPLAY...................................................................................................................104
7.6 STOPPING ....................................................................................................................................107
7.7 TAKING OUT OF OPERATION..............................................................................................................108
8 Maintenance................................................................................................................109
8.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................109
8.2 OIL SPECIFICATIONS........................................................................................................................113
8.3 DRIVE MOTOR ...............................................................................................................................114
8.4 AIR FILTER....................................................................................................................................115
8.5 OIL AND OIL FILTER CHANGE.............................................................................................................115
8.6 COOLERS..................................................................................................................................... 117
8.7 DRYER MAINTENANCE INSTRUCTIONS..................................................................................................118
8.8 SAFETY VALVES............................................................................................................................. 119
8.9 SERVICE INTERVALS FILTERS............................................................................................................ 119
8.10 SERVICE KITS................................................................................................................................ 120
8.11 STORAGE AFTER INSTALLATION......................................................................................................... 120
9 Problem solving..........................................................................................................121
10 Technical data.............................................................................................................125
10.1 READINGS ON DISPLAY.................................................................................................................... 125
10.2 ELECTRIC CABLE SIZE AND FUSES......................................................................................................126
10.3 REFERENCE CONDITIONS AND LIMITATIONS.......................................................................................... 135
10.4 COMPRESSOR DATA........................................................................................................................136
10.5 TECHNICAL DATA CONTROLLER..........................................................................................................144
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11 Instructions for use.................................................................................................... 145
12 Guidelines for inspection...........................................................................................146
13 Pressure equipment directives................................................................................. 147
14 Declaration of conformity.......................................................................................... 148
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 Safety precautions, general
General precautions
1. The operator must employ safe working practices and observe all related work safety
requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter
of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to the
applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the voltage and depressurize the
compressor. In addition, the power isolating switch must be opened and locked.
VSD units are powered by a frequency converter, wait 10 minutes before starting any
electrical repair.
In a domestic environment, this product may cause radio interference in which case
supplementary mitigation measures are required.
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the unit or on its components.
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1.3 Safety precautions during installation
All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with the applicable
safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is
strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and
deceleration must be kept within safe limits. Wear a safety helmet when working in the area
of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must
be taken. Consult your supplier.
3. In case the device is a compressor, place the machine where the ambient air is as cool and
clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must
be taken to minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting
the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes,
vapors and particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by
people cannot be drawn in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to
expand under heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of
strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This
machine is remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the
electrical isolating switch is open, locked and labelled with a temporary warning before any
maintenance or repair. As a further safeguard, persons switching on or off remotely
controlled machines shall take adequate precautions to ensure that there is no one checking
or working on the machine. To this end, a suitable notice shall be affixed to the start
equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted air does not recirculate to the compressor air inlet or
cooling air inlet.
12. The electrical connections must correspond to the applicable codes. The machines must be
earthed and protected against short circuits by fuses in all phases. A lockable power
isolating switch must be installed near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after
voltage failure is activated, a sign stating "This machine may start without warning" must be
affixed near the instrument panel.
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14. In multiple compressor systems, manual valves must be installed to isolate each
compressor. Non-return valves (check valves) must not be relied upon for isolating pressure
systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure relieving device or devices as
required.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other
high temperature piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to
be protected by a safety device with set pressure according to the maximum cooling water
inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the
dryer, safety valves must be installed in the vessels of the dryer.
Also consult the following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation
All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during operation
1. Never touch any piping or components of the machine during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing
through a hose or air line, ensure that the open end is held securely. A free end will whip
and may cause injury. Make sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes,
vapors or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods
only, e.g. to carry out routine checks. Wear ear protectors when opening a door.
On machines without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or
exceeds 80 dB(A) shall wear ear protectors.
8. Periodically check that:
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• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not
rubbing
• No leaks occur
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in
good repair, free of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a
workroom, take precautions against air pollution and possible contamination of the breathing
air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must
be taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure shall be protected by a pressure relieving device or devices as
required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book
must be respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.5 Safety precautions during maintenance or repair
All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during maintenance or repair
1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes,
etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all
damage or injuries caused by the use of non-genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached
to the starting equipment.
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6. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting
or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all
sources of pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by
covering the parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be
completely purged, e.g. by steam cleaning, before carrying out such operations. Never weld
on, or in any way modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure
vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they
function properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating
pressures, temperatures and time settings are correct. Check that all control and shut-down
devices are fitted and that they function correctly. If removed, check that the coupling guard
of the compressor drive shaft has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of
the oil separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture
from entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on
the bodywork and in the air inlet and outlet systems of the compressor, is in good condition.
If damaged, replace it by genuine material from the manufacturer to prevent the sound
pressure level from increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate
bowls.
21. Only if applicable, the following safety precautions are stressed when handling
refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin
with water. If liquid refrigerant contacts the skin through clothing, never tear off or
remove the latter; flush abundantly with fresh water over the clothing until all refrigerant
is flushed away; then seek medical first aid.
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Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.6 Dismantling and disposal
Dismantling
Once the end of life of the machine is reached, please follow next steps:
1. Stop the machine.
2. Check all safety precautions mentioned in the previous chapters to secure safe handling
(e.g. LOTO, cool-down, depressurize, discharge, ...).
3. Separate the harmful from the safe components (e.g. drain oil from oil containing parts).
4. Refer to the disposal topic mentioned below.
Disposal of electrical and electronic appliances (WEEE)
This equipment falls under the provisions of the European Directive 2012/19/EU on waste
electrical and electronic appliances (WEEE) and may not be disposed as unsorted waste.
The equipment is labelled in accordance with the European Directive 2012/19/EU with the
crossed-out wheelie bin symbol.
At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate
collection.
For more information check with your local waste authority, customer center or distributor.
Disposal of other used material
Used filters or any other used material (e.g. filter bags, filter media, desiccant, lubricants,
cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe
manner, and in line with the local recommendations and environmental legislation.
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2 General description
2.1 Introduction
Introduction
GA 11+ up to GA 30 are single-stage, oil-injected screw compressors driven by an electric motor.
GA 11+ up to GA 26+ are controlled by the ElektronikonTM Touch or Swipe controller based on
the voltage.
GA 30 is controlled by the ElektronikonTM Swipe controller.
The controller is fitted to the cubicle door. An electric cabinet comprising the motor starter is
located behind this panel.
The compressors are air-cooled and are enclosed in a sound-insulated bodywork.
There are 2 versions of the compressor: Workplace (without integrated dryer) and Full-Feature
(with integrated dryer).
GA, without integrated dryer
Front view
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Open side view
GA, with integrated dryer
The compressors have an air dryer which is integrated in the sound-insulated bodywork. The
dryer removes condensate from the compressed air by cooling the air to near freezing point.
Front view
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Open side view
Reference Name
AF Air filter
AR Air receiver
AV Air outlet
Ca Air cooler
Co Oil cooler
Da Automatic condensate outlet
Dm Manual condensate outlet
DR Refrigerant dryer
E Compressor element
ED Electronic water drain
ER ElektronikonTM Touch controller
FN Cooling fan
M1 Motor of the compressor
OF Oil filter
OS Oil separator
S3 Emergency stop button
1 Electric cabinet
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2.2 Flow diagram
GA 11+ up to GA 30, without integrated dryer
GA 11+ up to GA 30, with integrated dryer
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Reference Description
A Air inlet
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate
Air flow
Air comes in through filter (AF) and inlet valve (IV) and is compressed in the compressor element
(E).
A mixture of compressed air and oil flows into the air receiver/oil separator (AR), where oil and air
are separated.
The air flows through the minimum pressure valve (Vp), the air cooler (Ca) and the condensate
trap (MT) to the outlet valve (AV).
Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum
pressure and includes a check valve which prevents blow-back of compressed air from the net.
Units with integrated dryer have a dryer (DR) after the air cooler.
Oil circuit
The air receiver (AR) removes most of the oil from the air/oil mixture by centrifugal action. The oil
collects in the lower part of the air receiver (AR) which serves as oil tank.
The oil separator (OS) removes the remaining oil.
The oil circuit has a thermostatic bypass valve (BV) that prevents that the oil flows through the oil
cooler (Co) when the oil temperature is low.
Air pressure forces the oil from air receiver (AR) through the oil filter (OF).
The filtered oil flows back through the outlet housing and to the element.
Cooling on air-cooled compressors
The cooling system has an air cooler (Ca) and an oil cooler (Co) (see Flow diagram).
The fan (FN) blows air over the coolers. This fan is set on and off, depending on the operating
conditions, according to a specific algorithm.
2.3 Condensate system
Drain connections
The compressors have an electronic water drain (LD200).
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Location of the electronic water drain (without integrated dryer)
Location of the electronic water drain (with integrated dryer)
The condensate collects in the condensate trap (MT) of the air cooler.
On units with integrated dryer, the condensate formed in the dryer collects in the lower part of the
heat exchanger/ evaporator.
When the condensate in the electronic drain reaches a certain level, it is drained via the
automatic drain outlet (Da).
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Condensate drain connections, units without integrated dryer
Condensate drain connections, units with integrated dryer
Reference Designation
Da Automatic drain connection
Dm Manual drain connection
Electronic water drain (LD200)
The Test button (2) on top of the drain can be used in three different ways, according the
situation:
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