Atlas Copco GA 37+ User manual

GA 37+, GA 45+, GA 55, GA 75
Instruction book
Atlas Copco
Oil-injected rotary screw compressors

Atlas Copco
Oil-injected rotary screw compressors
2009 - 12
No. 9096 3321 00
www.atlascopco.com
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 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
Instruction book
GA 37+, GA 45+, GA 55, GA 75
From serial No. PNA923150

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Table of contents
1 Safetyprecautions ................................................................................................8
1.1 SAFETY ICONS ............................................................................................................8
1.2 SAFETY PRECAUTIONS DURING INSTALLATION .....................................................................8
1.3 SAFETY PRECAUTIONS DURING OPERATION.....................................................................10
1.4 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR.................................................... 11
2 Generaldescription............................................................................................. 13
2.1 INTRODUCTION ......................................................................................................... 13
2.2 AIR FLOW................................................................................................................ 17
2.3 OIL SYSTEM ............................................................................................................. 19
2.4 COOLING SYSTEM...................................................................................................... 20
2.5 CONDENSATE SYSTEM ................................................................................................ 22
2.6 REGULATING SYSTEM .................................................................................................. 23
2.7 ELECTRICAL SYSTEM .................................................................................................. 24
2.8 ELECTRICAL DIAGRAMS ............................................................................................... 26
2.9 AIR DRYER .............................................................................................................. 30
3 ElektronikonGraphiccontroller ......................................................................... 32
3.1 ELEKTRONIKON GRAPHIC REGULATOR ........................................................................... 32
3.2 CONTROL PANEL ...................................................................................................... 34
3.3 ICON USED ............................................................................................................. 35
3.4 MAIN SCREEN MENU .................................................................................................. 38
3.5 CALLING UP MENUS................................................................................................... 40
3.6 INPUTS MENU .......................................................................................................... 41
3.7 OUTPUTS MENU......................................................................................................43
3.8 COUNTERS .............................................................................................................. 45
3.9 SETTINGS MENU ....................................................................................................... 47
3.10 SERVICE MENU ......................................................................................................... 48
3.11 SETPOINT MENU ....................................................................................................... 52

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3.12 EVENT HISTORY MENU ................................................................................................ 55
3.13 MODIFYING GENERAL SETTINGS ................................................................................... 56
3.14 INFO MENU .............................................................................................................. 58
3.15 WEEK TIMER MENU ................................................................................................... 59
3.16 TEST MENU.............................................................................................................. 63
3.17 USER PASSWORD MENU .............................................................................................. 64
3.18 PROGRAMMABLE SETTINGS .......................................................................................... 65
4 OSCi(optional)....................................................................................................69
4.1 INTRODUCTION ......................................................................................................... 69
4.2 OPERATION .............................................................................................................. 70
4.3 PUTTING INTO OPERATION (COMMISSIONING) ................................................................... 75
4.4 PICTOGRAPHS .......................................................................................................... 76
4.5 ELEKTRONIKON DISPLAY AND WARNIGS ........................................................................... 76
4.6 DATA DISPLAYED DURING NORMAL OPERATION .................................................................. 77
4.7 WARNING ............................................................................................................... 78
4.8 MAINTENANCE .......................................................................................................... 80
4.9 SERVICES KITS ......................................................................................................... 83
4.10 PROBLEM SOLVING .................................................................................................... 83
5 Energyrecovery(optional) ................................................................................. 86
5.1 ENERGY RECOVERY UNIT ............................................................................................ 86
5.2 ENERGY RECOVERY SYSTEMS ....................................................................................... 87
5.3 OPERATION .............................................................................................................. 88
5.4 MAINTENANCE .......................................................................................................... 91
5.5 ENERGY RECOVERY DATA ............................................................................................ 92
6 Installation ........................................................................................................... 94
6.1 DIMENSION DRAWINGS................................................................................................ 94
6.2 INSTALLATION PROPOSAL ............................................................................................. 96
6.3 ELECTRICAL CONNECTIONS ......................................................................................... 98
6.4 COOLING WATER REQUIREMENTS...............................................................................100

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6.5 PICTOGRAPHS......................................................................................................103
7 Operating instructions....................................................................................105
7.1 BEFORE INITIAL START-UP........................................................................................105
7.2 INITIAL START-UP...................................................................................................106
7.3 BEFORE STARTING.................................................................................................109
7.4 STARTING............................................................................................................110
7.5 DURING OPERATION...............................................................................................112
7.6 CHECKING THE DISPLAY..........................................................................................114
7.7 STOPPING...........................................................................................................115
7.8 TAKING OUT OF OPERATION......................................................................................115
8 Maintenance....................................................................................................117
8.1 PREVENTIVE MAINTENANCE SCHEDULE........................................................................117
8.2 DRIVE MOTOR .....................................................................................................119
8.3 OIL SPECIFICATIONS..............................................................................................120
8.4 OIL AND OIL FILTER CHANGE....................................................................................120
8.5 DISPOSAL OF USED MATERIAL...................................................................................122
8.6 STORAGE AFTER INSTALLATION..................................................................................122
8.7 SERVICE KITS......................................................................................................123
9 Adjustments and servicing procedures...........................................................124
9.1 AIR FILTER..........................................................................................................124
9.2 COOLERS ..........................................................................................................125
9.3 SAFETY VALVES.....................................................................................................126
10 Problem solving...............................................................................................127
10.1 PROBLEM SOLVING.................................................................................................127
11 Technical data.................................................................................................130
11.1 READINGS ON DISPLAY............................................................................................130
11.2 ELECTRIC CABLE SIZE AND MAIN FUSES......................................................................131
11.3 SETTINGS OF FAN MOTOR CIRCUIT BREAKER................................................................132
11.4 SETTINGS FOR MOTOR OVERLOAD RELAY.....................................................................132
11.5 DRYER SWITCHES................................................................................................133
11.6 REFERENCE CONDITIONS AND LIMITATIONS..................................................................133
11.7 COMPRESSOR DATA..............................................................................................134

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11.8 TECHNICAL DATA ELEKTRONIKON CONTROLLER.............................................................144
12 Instructions for use of air receiver..................................................................145
12.1 INSTRUCTIONS FOR USE.........................................................................................145
13 Guidelines for inspection.................................................................................146
13.1 GUIDELINES FOR INSPECTION...................................................................................146

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1 Safety precautions
1.1 Safety icons
Explanation
1.2 Safetyprecautionsduringinstallation
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
shallapply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained,
specialised 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 depressurise the compressor. In addition,
the power isolating switch must be opened and locked.
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.
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.
Danger for life
Warning
Important note

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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. 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 minimise the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. 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.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead
to internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. 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.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
9. 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 that the isolating switch is open and locked
before any maintenance or repair. As a further safeguard, 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 start equipment.
10. 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.
11. The electrical connections must correspond to the applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases.Alockable power isolating switch must be installed
near the compressor.
12. 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.
13. 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.
14. 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.
15. Pipework or other parts with a temperature in excess of 800C and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high-temperature pipework
must be clearly marked.
16. 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.
17. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
Also consult following safety precautions: Safety precautions during operation and Safety
precautionsduringmaintenance.
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
includedherein.
Some precautions are general and cover several machine types and equipment; hence some statements
may not apply to your machine.

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1.3 Safety precautions during operation
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
shallapply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained,
specialised 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 depressurise the compressor. In addition,
the power isolating switch must be opened and locked.
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.
Precautions during operation
1. 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. Afree end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
2. 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.
3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or
particles.
4. Never operate the machine below or in excess of its limit ratings.
5. 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.
6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
7. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• 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
8. 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.
9. Do not remove any of, or tamper with, the sound-damping material.
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.

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10. 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.
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.
1.4 Safety precautions during maintenance or repair
General precautions
1. The operator must employ safe working practices and observe all related local work safety
requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two
shallapply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained,
specialised 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 local 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 depressurise the compressor. In addition,
the power isolating switch must be opened and locked.
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.
Precautions during maintenance or repair
1. Always wear safety glasses.
2. Use only the correct tools for maintenance and repair work.
3. Use only 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.
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 before connecting or disconnecting a pipe.
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.

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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 vapours 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 vapour 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.The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. 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.
22. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
Also consult following safety precautions: Safety precautions during installation and
Safetyprecautions 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.

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2 General description
2.1 Introduction
Introduction
GA37+ up to GA 75 are single-stage, oil-injected screw compressors driven by an electric motor. The
compressors are available in air-cooled and water-cooled version.
GA Workplace
GAWorkplace are enclosed in a sound-insulated bodywork. The compressors are controlled by the
Atlas Copco Elektronikon® regulator. The electronic control module is fitted to the door on the right
side. An electric cabinet comprising the motor starter is located behind this panel. A condensate trap
with Electronic Water Drain (EWD) is provided.
Front view, GA 37+ up to GA 75

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GA Workplace Full-Feature
GAWorkplace Full-Feature are enclosed in a sound-insulated bodywork. The compressors are controlled
by theAtlas Copco Elektronikon® regulator. The electronic control module is fitted to the door on the right
side.An electric cabinet comprising the motor starter is located behind this panel. They are provided with
an air dryer. The condensate is automatically drained.The dryer is integrated in the sound-insulated
body work. The dryer removes water from the compressed air by cooling the air to near freezing point.
Rear view, GA 37 + up to GA 75 Workplace
Reference Name
AV Air outlet valve
Ca Air cooler
Co Oil cooler
CV/Vs Check valve/oil stop valve
Da Automatic condensate outlet
E Compressor element
ER Elektronikon® Graphic controller
FN Cooling fan
HC Energy recovery system (optional)
M1 Drive motor
S3 Emergency stop button
UA Unloader
VP Vent plug

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Front view, GA 37+ up to GA 75 Full-Feature

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Rear view, GA 37+ up to GA 75 Workplace
Reference Name
1 Electric cubicle
AF Air filter
AR Air receiver (oil separator vessel)
AV Air outlet valve
Ca Air cooler
Co Oil cooler
CV/Vs Check valve/oil stop valve
Da Automatic condensate outlet, aftercooler
Da1 Automatic condensate outlet, dryer
DD DD filter (optional)
DR Dryer
E Compressor element
ER Elektronikon® Graphic controller
FN Cooling fan
HC Energy recovery system (optional)
M1 Drive motor
OF Oil filter
PD PD filter (optional)
S3 Emergency stop button
UA Unloader
VP Vent plug

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Coolers on water-cooled compressors
2.2 Air flow
Flow diagrams
Water-cooled air cooler and oil cooler
Reference Name
Ca Air cooler
Co Oil cooler
Flow diagram, GA workplace

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Note: The cooling fan is not provided on water-cooled compressors.
Description
Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed. A mix
of compressed air and oil flows into the air receiver/oil separator (AR) via check valve (CV). The air is
discharged through outlet valve (AV) via minimum pressure valve (Vp) and air cooler (Ca).
The air cooler is provided with a moisture trap (MT).
On Full-Feature compressors, the air flows through air dryer (DR) before it is discharged through outlet
valve(AV). Also see section Air dryer.
Reference Description
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
F Condensate
G Dry compressed air
Flow diagram, GA Workplace Full-Feature

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Note: The cooling fan is not provided on water-cooled compressors.
Description
In air receiver/oil separator (AR), most of the oil is removed from the air/oil mixture by centrifugal
action.The rest is removed by oil separator (OS). The oil collects in the lower part of air receiver/oil
separator (AR),which serves as an oil tank.
The oil system is provided with a thermostatic bypass valve (BV). When the oil temperature is below its
set point, bypass valve (BV) shuts off the supply to oil cooler (Co) and the oil cooler is bypassed.
Check valve (CV) prevents blow-back of compressed air when the compressor is stopped. Minimum
pressure valve (Vp) prevents the receiver pressure (AR) from dropping below a minimum pressure during
unloaded operation.
2.3 Oil system
Flow diagram
References Description
1 For Workplace units, compressed air flow to the air outlet valve
For Full-Feature units, compressed air flow to the air dryer
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
F Condensate
Oil system

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Air pressure forces the oil from air receiver/oil separator (AR) through oil filter (OF) and oil stop valve
(Vs)to compressor element (E).
Bypass valve (BV) starts opening the supply from cooler (Co) when the oil temperature has increased to
the set point.At approx. 15 °C above the set point, all the oil flows through the oil cooler.
Oil stop valve (Vs) prevents the compressor element from flooding with oil when the compressor is
stopped.The valve is opened by element outlet pressure when the compressor is started.
2.4 Cooling system
Flow diagram
Cooling system,air-cooled compressors