Instruction book for

stationary compressors

GA50 (W) VSD and

GA90 (W) VSD

Important: This book must be used together with the "User manual for Elektronikon®
regulator for GA50 VSD and GA90 VSD compressors"

Registration code This instruction book meets the requirements for instructions specified by the
Collection: APC G VSD
Tab: 38 machinery directive 89/392/EEC and is valid for CE as well as non-CE labelled
Sequence: 980 machines

Replaces
No. 2920 1190 04

No. 2920 1190 05

Industrial Air Division - B-2610 Wilrijk - Belgium
1997-06

*2920119005*
 Industrial Air Division Instruction book

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life.

Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the
beginning. The maintenance schedule comprises measures for keeping the machine in good condition.

Keep the book available for the operator and make sure that the machine is operated and that maintenance is carried out according
to the instructions. Record all operating data, maintenance performed, etc. in an operator's logbook available from Atlas Copco.
Follow all relevant safety precautions, including those mentioned on the cover of this book.

Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further information.

In all correspondence always mention the type and the serial number, shown on the data plate.

For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data".

The company reserves the right to make changes without prior notice.

Contents
Page Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.2.1 GA50 (W) VSD . . . . . . . . . . . . . . . . . . . . . 26
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.2.2 GA90 (W) VSD . . . . . . . . . . . . . . . . . . . . . 26
1.1.1 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.3 Oil and oil filter change interval . . . . . . . . . . . . . . 27
1.1.2 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.4 Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1.3 Cooling and condensate drain systems . . . . 5 4.4.1 Atlas Copco Roto-injectfluid . . . . . . . . . . 27
1.2 Regulating system . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.4.2 Mineral oil . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.5 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Elektronikon control module . . . . . . . . . . . . . . . . . 5 4.6 Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4.1 Elektronikon regulator . . . . . . . . . . . . . . . . 10 4.7 Oil separator change . . . . . . . . . . . . . . . . . . . . . . . 28
1.4.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . 10 4.8 Storage after installation . . . . . . . . . . . . . . . . . . . . 29
1.5 Electric cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.9 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5 Adjustments and servicing procedures. . . . . . . . . . . 29

2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . 14 5.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.1.1 Recommendations . . . . . . . . . . . . . . . . . . . 29
2.3 Installation proposal . . . . . . . . . . . . . . . . . . . . . . . 19 5.1.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . 20 5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5 Cooling water requirements . . . . . . . . . . . . . . . . . 20 5.3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 21 6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 7.1 Readings on display . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . 23 7.2 Settings of safety valve . . . . . . . . . . . . . . . . . . . . . 31
3.4.1 Checking the display . . . . . . . . . . . . . . . . . 23 7.3 Settings of circuit breakers . . . . . . . . . . . . . . . . . . 31
3.5 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 7.3.1 GA50 (W) VSD . . . . . . . . . . . . . . . . . . . . . 31
3.6 Taking out of operation . . . . . . . . . . . . . . . . . . . . . 24 7.3.2 GA90 (W) VSD . . . . . . . . . . . . . . . . . . . . . 31
7.4 Compressor specifications . . . . . . . . . . . . . . . . . . 31
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 7.4.1 Reference conditions . . . . . . . . . . . . . . . . . 31
4.1 Preventive maintenance schedule for the 7.4.2 Specific data of GA50 (W) VSD . . . . . . . 32
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 7.4.3 Specific data of GA90 (W) VSD . . . . . . . 32
4.2 Compressor motor . . . . . . . . . . . . . . . . . . . . . . . . 26 7.5 Conversion list of SI units into British units . . . . 32

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Instruction book Industrial Air Division

1 Leading particulars

1.1 General description 1.1.1 Air flow (Figs. 2)

GA50 (W) VSD and GA90 (W) VSD (Variable Speed Drive Air drawn through filter (AF) and check valve (CV) into
motor) are stationary, single-stage, oil-injected screw compressor element (E) is compressed. Compressed air and
compressors driven by an electric motor. oil flow into air receiver/oil separator (AR). The air is
discharged through outlet valve (AV) via minimum pressure
The compressors are enclosed in a sound-insulated bodywork. valve (Vp), air cooler (Ca) and moisture trap (MT).
The front panel comprises an Elektronikon control module
including the start and stop buttons. An isolator switch is also Minimum pressure valve (Vp) prevents the receiver pressure
provided. An electric cabinet comprising the motor start and from dropping below a minimum pressure.
speed control system is located behind this panel.

E1 SO AV

F007

AV. Air outlet valve

E1. Elektronikon control module
S0. Isolator switch

Fig. 1. General view of GA90 VSD

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Fig. 2a. Flow diagram of air-cooled GA VSD compressor, compressor stopped and isolator switch switched off

Fig. 2b. Flow diagram of water-cooled GA VSD compressor, compressor running

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Instruction book Industrial Air Division

AF. Air filter DP2. Oil drain plug, oil stop valve PDT1. Differential pressure sensor, oil
AR. Air receiver/oil separator DP3. Oil drain plug, compressor separator
AV. Air outlet valve element PT20. Pressure sensor, air outlet
BV. Oil cooler by-pass valve E. Compressor element Rf1. Nozzle, only for GA50 VSD
Ca. Air cooler E1. Elektronikon control module Rf2. Restrictor
Co. Oil cooler FC. Oil filler plug SV. Safety valve
CV. Check valve FN2. Fan, compressor coolers TT11. Temperature sensor, compres-
CV1. Check valve Gl. Oil level gauge sor element outlet
Da. Automatic condensate drain, MT. Air cooler moisture trap Vp. Minimum pressure valve
air cooler moisture trap M1. Compressor motor Vs. Oil stop valve
Dm. Manual condensate drain, air M2. Fan motor, compressor coolers Y1. Solenoid valve, blow off
cooler moisture trap OF. Oil filter 1. Oil scavenging line
DP1. Oil drain plug, air receiver OS. Oil separator element 2. Blow-off air flexible

Figs. 2. Flow diagrams

1.1.2 Oil system (Figs. 2) 1.2 Regulating system

In air receiver/oil separator (AR), most of the oil is removed If the air consumption is less than the air output of the
from the air/oil mixture centrifugally. The balance is removed compressor, the net pressure increases. When the net pressure
by oil separator element (OS). The oil collects in the lower differs from the setpoint (desired net pressure), the regulator
part of air receiver/oil separator (AR), which serves as oil tank. will decrease the motor speed. If the net pressure keeps on
rising when the motor runs at minimum speed, the regulator
The oil system is provided with a by-pass valve (BV). When will stop the motor. If the motor is stopped automatically and
the oil temperature is below 60°C (140°F), by-pass valve (BV) the net pressure approaches the setpoint, the regulator will
shuts off the oil supply from oil cooler (Co). Air pressure forces restart the motor.
the oil from air receiver/oil separator (AR) through oil filter(s)
(OF) and oil stop valve (Vs) to compressor element (E) and its
lubrication points. Oil cooler (Co) is by-passed. 1.3 Electrical system
By-pass valve (BV) starts opening the oil supply from cooler The system comprises (Figs. 6):
(Co) when the oil temperature has increased to the above-
mentioned value. At approx. 75°C (167°F) all the oil flows 1. Compressor motor (M1) and fan motor (M2)
through the oil cooler. 2. Elektronikon control module (Fig. 7a)
3. Compressor start button (I) and stop button (O)
4. Isolator switch (S0)
1.1.3 Cooling and condensate drain systems 5. Electric cabinet (Figs. 8)
(Figs. 3 and 4) 6. Sensors for the compressor element outlet temperature
(TT11), for the pressure difference over the oil separator
The cooling system comprises air cooler (Ca) and oil cooler (PDT1) and for the air outlet pressure (PT20). Water-cooled
(Co). GA50 VSD and GA90 VSD are air-cooled compressors, compressors are also provided with a sensor for the cooling
the cooling air is generated by fan (FN). GA50 W VSD and water outlet temperature (TT51).
GA90 W VSD are water-cooled compressors.

A moisture trap (MT) is provided in the air outlet system. The

trap is equipped with a valve for automatic condensate draining
1.4 Elektronikon control module
during operation (Da-Fig. 5) and a manually operated valve
for draining after stopping the compressor (Dm-Fig. 5). The control module consists of an Elektronikon regulator and
a control panel.

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 Industrial Air Division Instruction book

AR. Air receiver/oil separator

AV. Air outlet valve
Ca. Air cooler
Co. Oil cooler
CV. Check valve
E. Compressor element
E1. Elektronikon control
module
FC. Oil filler plug
FN. Fan, compressor coolers
Gl. Oil level gauge
M1. Compressor motor
M2. Fan motor
OF. Oil filter
S0. Isolator switch
SV. Safety valve
VP. Venting plug, oil cooler
1. Cooler plate
2. Flexible, oil drain
3. Arrow, rotation direction
of fan motor

Figs. 3. Front views

Fig. 3a. Front view of GA50 VSD

Ca E1

CO

AV
1

FN SO

OF

CV

E M1

F002

Fig. 3b. Front view of GA90 VSD

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Instruction book Industrial Air Division

AF. Air filter

AF Ca VP Co AR. Air receiver/oil separator
BV. Oil cooler by-pass valve
Ca. Air cooler
Co. Oil cooler
DP1. Oil drain plug, air receiver
E. Compressor element
FC. Oil filler plug
MT FN. Fan, compressor coolers
1
Gl. Oil level gauge
MT. Air cooler moisture trap
VP. Venting plug, oil cooler
1. Cooler plate
FN
Fig. 4. Rear view of GA90 VSD

BV
AR

F001
DP1 GI FC

1 2

Da. Automatic condensate drain, air cooler moisture trap

Dm. Manual condensate drain, air cooler moisture trap
1. Pictograph, manual condensate drain
2. Pictograph, automatic condensate drain
Dm Da Fig. 5. Condensate outlets

F004

PDT1. Differential pressure sensor, ELECTRIC CABINET CONTROL MODULE (E1)

oil separator A1. R.F.I. filter (optional) I. Start button
PT20. Pressure sensor, air outlet E1. Elektronikon control module K01. Auxiliary relay, fan motor
TT11. Temperature sensor, E4. Communication module K02. Auxiliary relay
compressor element outlet F1/F4. Fuses K03. Auxiliary relay
TT51. Temperature sensor, cooling K15. Contactor, fan motor K04. Auxiliary relay, service
water outlet (only on water- K35. Thermistor relay, motor temperature K05. Auxiliary relay, invertor shut-
cooled compressors) L1. Inductor down
Y1. Solenoid valve, blow off Q15. Circuit breaker, fan motor K06. Auxiliary relay
Q16. Circuit breaker, invertor K07. Auxiliary relay, general warning
MOTORS S0. Isolator switch K08. Auxiliary relay, general shut-
M1. Compressor motor T1. Transformer down
M2. Fan motor, compressor U1. Invertor K10. Auxiliary relay
coolers 1X1. Terminal strip O. Stop button

Figs. 6. Electrical diagrams

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 Industrial Air Division Instruction book

Fig. 6a. Electrical diagram of GA50 VSD

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Fig. 6b. Electrical diagram of GA90 (W) VSD

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 Industrial Air Division Instruction book

1.4.1 Elektronikon regulator (E1-Figs. 6) Warning If activated and provided the module was in the
automatic operation mode, the compressor will
The regulator has following functions: automatically restart if the supply voltage to the
module is restored within a programmed time
Controlling the compressor period (this time period is called the power
The regulator matches the compressor output to the air recovery time).
consumption by speed regulation of the motor.
The power recovery time can be set between 1
The regulator stops the compressor whenever necessary: and 254 or to symbol 00!. If the power recovery
- Indirect stop: i.e. the compressor runs at minimum speed time is set to 00!, the compressor will always
and the net pressure rises to the indirect stop level restart after a voltage failure, no matter how long
- Direct stop: i.e. the compressor runs at a speed in between it takes to restore the voltage.
minimum and maximum and the net pressure rises above
the direct stop setpoint.
1.4.2 Control panel (Fig. 7a)
Both settings are programmable; consult the "User manual for
Elektronikon regulator", section "Modify settings submenu". To control the compressor and to read and modify
programmable parameters, the regulator is provided with a panel
Note: to prevent the safety valve from opening too frequently including:
on 13 bar compressors, the setting of the direct stop setpoint
should never be more than 1bar.
Ref. Designation Function
Protecting the compressor
If the compressor element outlet temperature exceeds the 1 Automatic Indicates that the regulator is
programmed shut-down level, the compressor will be stopped. operation LED automatically controlling the
This will be indicated on the control panel (Fig. 7a). The compressor.
compressor will also be stopped in case of overload of fan motor
(M2-Figs. 2). 2 Voltage on LED Indicates that the voltage is
switched on.
If the compressor element outlet temperature exceeds a
programmed value below the shut-down level, this will also be 3 General alarm LED Is normally out. Is alight or blinks
indicated to warn the operator before the shut-down level is in case of an abnormal condition.
reached. See below.
Protecting the motor 4 Display Indicates:
GA50 (W) VSD - the name of the sensor of which
If the motor temperature should rise above the setting of the the actual reading is displayed
regulator, the regulator will stop the motor. - the unit of measurement and
actual reading
GA90 (W) VSD - messages regarding the motor
If the motor temperature should rise above the warning setting speed, a sensor error, a service
of the regulator, the regulator will temporary reduce the motor need or a fault
speed until the temperature has decreased again. A warning
appears on the display. If the temperature should not drop below 5 Function keys Keys to control and program the
the warning level after the regulator has decreased the motor compressor. The actual function
speed, the regulator will stop the motor. of each key is abbreviated and
indicated on the bottom line. The
Monitoring components subject to service most common ones are listed
The regulator continuously monitors the oil, oil filter, oil below.
separator, air filter and motor regreasing. Each input is
compared to programmed time intervals. If these limits are 6 Scroll keys As long as an arrow is shown on
exceeded, a message will appear on display (4-Fig. 7a) to warn the right side of the display, the key
the operator to service the indicated component. with the same symbol can be used
to scroll through the display.
Automatic restart after voltage failure
For compressors leaving the factory, this function is made 7 Tabulator key Key to go to the next field of the
inactive. If desired, the function can be activated. Consult display.
Atlas Copco.

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Instruction book Industrial Air Division

Ref. Designation Function Delivery air

bar 7.0
rpm 2500
8 Start button Push button to start the Menu More
compressor. LED (1) lights up
indicating that the regulator is F1 F2 F3
operative (in automatic operation).
Fig. 7b. Example of the main display
9 Stop button Push button to stop the
compressor. LED (1) goes out.

S0 Isolator switch Switch to isolate the compressor

from the mains or to stop the Status data
compressor immediately in case of
emergency. The compressor will Main Slct
be depressurized automatically
when the isolator switch is F1 F2 F3
switched off.
Fig. 7c. Example of a main menu

Figs. 7. Displays

1.4.2.1 General alarm LED (3-Fig. 7a) 1)

- The LED blinks in case of a shut-down (due to too high a

compressor element outlet temperature, too high a motor
temperature, too high a temperature of the start and speed
control unit, overload of the fan motor, etc.); at the same
time the shut-down screen appears. After eliminating the
cause of the trouble and when the abnormal condition has
disappeared, press function key (5) below Rset.
- The LED blinks and the compressor is shut down if the
sensor of the compressor element (TT11-Fig. 9b) is out of
11 1 2 12 4 6
order; at the same time the display will show a fault message.
Depressurize the compressor by switching off the isolator
switch, close the air outlet valve and open manual drain
valve. Check the sensor and its wiring.
- The LED also blinks in case of a system failure (due to
8 hardware, software or communication problems). Consult
the "User manual for Elektronikon regulator" section
3 "System failures".
13 9 - The LED is alight in case of a shut-down warning; at the
same time a warning message appears. Remedy; see section
5 7
6.

F029
1.4.2.2 Selecting a menu
1. LED, automatic 7. Tabulator key
To facilitate controlling the compressor, menu-driven programs
operation 8. Start button
are implemented in the Elektronikon module. Use the function
2. LED, voltage on 9. Stop button
keys (5) to select the menus in order to program and monitor
3. LED, general alarm 11. Pictograph, automatic
the compressor. The "User manual for Elektronikon regulator"
4. Display operation
deals elaborately with all regulator functions.
5. Function keys 12. Pictograph, voltage on
6. Scroll keys 13. Pictograph, alarm
1) Consult the "User manual for Elektronikon regulator", section
Fig. 7a. Control panel "Status data submenu".

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 Industrial Air Division Instruction book

Q15 K15 F1 F2 T1 3 T2 SO

U1

Fig. 8a. Electric cabinet of GA50 VSD

Q15 K15 Q16 F1 F2

F1/F4. Fuses 2
K15. Contactor, fan motor
L1. Inductor U1
Q15. Circuit breaker, fan motor
L1
Q16. Circuit breaker, invertor
S0. Isolator switch
T1. Transformer 1
T2. Transformer 1
U1. Invertor 2 2
1. Vibration damper
2. Nut (to be removed)
3. Cover

Figs. 8. Electric cabinets Fig. 8b. Electric cabinet of GA90 (W) VSD

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Instruction book Industrial Air Division

1.4.2.3 Function keys

Abbre- Desig- Function

viation nation

Add Add To add compressor start/stop commands (day/

hour)
Canc Cancel To cancel a programmed setting when
programming parameters
Del Delete To delete compressor start/stop commands
Lim Limits To show limits for a programmable setting
List List To list programmed start/stop commands
(day/hour)
Main Main To return from a menu to the main display
(Fig. 7b)
Fig. 9a. Transport bolts of GA50 VSD
Menu Menu Starting from the main display (Fig. 7b), to
initiate the main menu (Fig. 7c) which gives
access to submenus 1.5 Electric cabinet (Figs. 8)
Starting from a submenu, to return to the main
menu (Fig. 7c) The cabinet comprises electric components such as the start
Mod Modify To modify programmable settings and speed regulation unit of the motor (U1), a transformer (T1)
More More To have a quick look at the compressor status and fuses (F1/F4) as well as the start contactor (K15) for the
Prog Program To program modified settings fan motor. A fan motor circuit breaker (Q15) is also provided.
Rset Reset To reset a timer or message
Rtrn Return To return to a previously shown option or If it should be necessary to change the rotation direction of the
menu fan motor (M2-Figs. 2), switch off the voltage and reverse two
Slct Select To select a submenu or to read more details connections at the terminals of circuit breaker (Q15).
of a selection shown on display
The parameters of the start and speed regulation unit (U1) are
factory-set and need no adjustment. Changing parameters may
damage the compressor; consult Atlas Copco.

CV. Check valve

OF. Oil filter
TT11. Temperature sensor, compressor
element outlet
Vs. Oil stop valve
1. Studs and nuts (to be removed)
2. Vibration damper
3. Hose clip, air inlet hose F006
4. Studs and nuts (to be removed)

Figs. 9. Transport bolts Fig. 9b. Transport bolts of GA90 (W) VSD

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 Industrial Air Division Instruction book

2 Installation

2.1 Dimension drawings (Figs. 10)

Fig. 10a. Dimension drawing of GA50 VSD

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Fig. 10b. Dimension drawing of GA50 W VSD

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Fig. 10c. Dimension drawing of GA90 VSD

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Fig. 10d. Dimension drawing of GA90 W VSD

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 Industrial Air Division Instruction book

2.2 Electric cable size Compressor type GA50 (W) VSD GA90 (W) VSD

Attention
- Local regulations remain applicable if they are stricter than Voltage (V) . . . . . . . . . . . 380/460 400
the values proposed below. Frequency (Hz) . . . . . . . . 50/60 50/60
- The voltage drop shall not exceed 5% of the nominal Maximum line
voltage. It may be necessary to use cables with a larger current (A) . . . . . . . . . . . 160 200
size than those stated to comply with this requirement. Cable size (mm2/
- Use the original cable entrance. In case additional holes AWG size) . . . . . . . . . . . 50 95
must be provided in the cubicle, take care that nothing can
drop into the start and speed regulation unit (U1).
- A ground fault circuit interrupter must not be used to
connect GA VSD compressors.

Fig. 11a. Installation proposal of GA50 VSD

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Instruction book Industrial Air Division

2.3 Installation proposal (Figs. 11)

Ref. Description/recommendation Ref. Description/recommendation

1 Install the compressor on a level floor suitable for taking 3 The maximum total pipe length (including
the weight of the compressor. interconnecting piping between compressor and
receiver) can be calculated as follows:
2 Compressed air outlet valve.
∆P x d5 x P
_________________________
L =
450 x Qc1.85

Fig. 11b. Installation proposal of GA90 VSD

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 Industrial Air Division Instruction book

Ref. Description/recommendation 2.5 Cooling water requirements

Following requirements are given as a general rule to prevent

L = pipe length in m cooling water problems. If in any doubt, consult Atlas Copco.
∆P = maximum allowable pressure drop
(recommended 0.1 bar (1.45 psi)) Recommended maxima - mg/l Recirculating Open
d = inner diameter of pipe in mm system system
P = compressor outlet pressure in bar absolute
Qc = free air delivery of compressor in l/s
Chloride (Cl-) . . . . . . . . . . . . . . . . < 600 < 150
4 Ventilation: the inlet grids and ventilation fan should be Sulphate (SO4--) . . . . . . . . . . . . . . < 400 < 250
installed in such a way that any recirculation of cooling Total solids . . . . . . . . . . . . . . . . . . < 3000 < 750
air to the compressor is avoided. The air velocity to the Suspended solids (as SiO2) . . . . . . < 10 < 10
grids must be limited to 5 m/s. The maximum allowable Free chlorine (Cl2) . . . . . . . . . . . . < 4 < 2
pressure drop over the cooling air ducts (air-cooled Ammonia (NH4+) . . . . . . . . . . . . . < 0.5 < 0.5
compressors) depends on the ambient temperature, Copper . . . . . . . . . . . . . . . . . . . . . < 0.5 < 0.5
consult Atlas Copco. The maximum air temperature at Iron . . . . . . . . . . . . . . . . . . . . . . . . < 0.2 < 0.2
the compressor intake opening is 40°C (104°F) Manganese . . . . . . . . . . . . . . . . . . < 0.1 < 0.1
(minimum 0°C (32°F)). Oxygen . . . . . . . . . . . . . . . . . . . . . < 3 < 3
Carbonate hardness (as CaCO3) . . 50-1000 50-500
The required ventilation to limit the compressor room Organics (KMnO4 Consumption) . < 25 < 10
temperature can be calculated as follows:

For alternatives 1 and 3: Qv = 0.92 N/∆T Remarks

- No algae nor oil.
Qv = required ventilation capacity in m3/s - Chloride and sulphate are interactive. In open systems the
For air-cooled compressors: N = shaft input of sum of the squares of these values must not exceed 85,000.
compressor in kW For recirculating systems with proper controls and treatment,
For water-cooled compressors: N = 10 kW the sum of the squares may be up to 520,000. Note that the
∆T = temperature increase in compressor room sulphate value must include any sulphite present.

5 The drain pipes to the drain collector must not dip into
the water. For draining of pure condensate water, install
an oil/water separator. Consult Atlas Copco.

6 Control module with monitoring panel.

7 Mains cables entry.

8 High-efficiency filter, type PD (optional). Filter traps

solid particles down to 0.01 micron with max. oil carry-
over of 0.01 mg/m3. A PD filter must be installed
downstream of a DD filter (optional).

If oil vapour and odours are undesirable, a filter of the

QD type (optional) should be installed downstream of
the PD filter.

2.4 Electrical connections

General
1. Check the fuses and the setting of the circuit breaker(s).
See section 7.3
2. Connect the power supply to terminals (L1, L2 and L3).
Connect the earth conductor to connector (PE). Consult
section 2.2.

20 2920 1190 05
Instruction book Industrial Air Division

3 Operating instructions 6. Check the oil level. The pointer of the level gauge (Gl-
Figs. 12) should register in the green or orange range. The
bottle delivered loose with the compressor is filled with
Safety precautions Atlas Copco Roto-injectfluid and can be used for topping
The operator must apply all relevant safety precautions, up.
including those mentioned in this book. 7. For GA90 VSD, a noise-damping kit is available as an
option, including a cooling air outlet duct and baffle plates.
Altitude operation 8. On water-cooled compressors: Close the cooling water
Consult Atlas Copco if operating above 1000 m. drain valve. Open the cooling water inlet valve and the
regulation valve.
Moving/lifting 9. A sticker dealing in short with the operating instructions
The compressor can be moved by a lift truck using the slots in and explaining the pictographs is delivered with the
the frame. Before lifting, reinstall the transport securing bolts literature set. Affix the sticker next to the control panel.
(see section 3.1). Make sure that the forks protrude from the Make yourself familiar with the instructions and pictographs
other side of the frame. The compressor can also be lifted explained.
after inserting beams in the slots. Make sure that the beams
cannot slide and that they protrude from the frame equally. The Stick labels on an obvious place near the control panel,
chains must be held parallel to the bodywork by chain spreaders warning the operator that:
in order not to damage the compressor. The lifting equipment - the compressor may automatically restart after voltage
must be placed in such a way that the compressor will be lifted failure (see section 1.4.1)
perpendicularly. Lift smoothly and avoid twisting. - the compressor is automatically started and stopped (see
section 1.2)
- the compressor may be remotely controlled (see section
3.2)
3.1 Initial start-up
10. On water-cooled compressors: Check the cooling water
Remarks quality (see section 2.5). A drain valve, a regulation valve
1. Read the "User manual for Elektronikon regulator" to and a shut-off valve should be installed by the customer in
familiarize yourself with all regulator functions. the cooling water piping.
2. Consult section 2 for the dimension drawings, electric cable 11. ON GA50 (W) VSD, switch on the voltage. Open the air
size and installation proposal. outlet valve and start the compressor. Check the rotation
direction of the fan motor, the correct rotation direction is
Start-up indicated by arrow (3-Fig. 3a). If the rotation direction is
1. The compressor element and motor are secured to the frame, wrong, reverse two incoming connections on the terminals
immobilizing the vibration dampers (2-Figs. 9) during of circuit breaker (Q15-Fig. 8a). The compressor motor
transport. will always rotate in the correct direction.
On GA50 (W) VSD, remove the stud, support and nuts (4- On GA90 (W) VSD, switch on the voltage. Open the air
Fig. 9a) on both sides of the motor support. Remove the outlet valve and start the compressor. The start and speed
transport supports from the compressor support. regulation unit prevents the compressor motor from rotating
On GA90 (W) VSD, remove the stud and nuts (1-Figs. 9) in the wrong direction. In case of wrong direction of rotation
of both compressor element supports, the start and speed following error code will appear on the display: Convertor
control unit is secured to the rear panel of the regulator failure error 56 0 1. If the compressor motor should not
cabinet, immobilizing vibration dampers (1-Fig. 8b). start and the fan motor rotates in the wrong direction, (the
Remove nuts (2-Fig. 8b). correct rotation direction is indicated on the fan housing)
2. Check that the electrical connections correspond to the local switch off the voltage and reverse two incoming electric
codes and that all wires are clamped tight to their terminals. lines. If the compressor motor starts and the fan motor
The installation must be earthed and protected against short rotates in the wrong direction, reverse two incoming
circuits by fuses of the inert type in all phases. An isolator connections on the terminals of circuit breaker (Q15-Fig.
switch must be installed near the compressor. 8b). Reset the regulator as described in the "User manual
3. Check the voltage selecting wires at the primary side of for Elektronikon regulator" section "Shut-down reset".
transformer (T1-Figs. 8) and the setting of fan motor circuit 12. Check the programmed settings. 1)
breaker (Q15-Figs. 8). Check that the switch on the circuit 13. Start and run the compressor for a few minutes. Check that
breaker is in position "I". the compressor operates normally.
On GA50 (W) VSD, remove cover (3-Fig. 8a) and check
the voltage selecting wires at the primary side of transformer
(T2-Fig. 8a); correct as necessary.
4. Fit air outlet valve (AV-Fig. 1) to the air outlet pipe. Close
the valve. Connect the air net to the valve. 1) Consult the "User manual for Elektronikon regulator", sections
5. Connect the manual and automatic condensate drain outlet regarding the submenus "Measured data", "Service", "Modify
to a drain collector as described in section 2.3. settings", "Timer" and "Programmable settings".

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 Industrial Air Division Instruction book

3.2 Before starting Check the oil level (Gl-Figs. 12). The pointer should be in
the upper field of the green range or in the HIGH range. If
If the compressor has not run for the past 6 months: the pointer registers in the LOW range, depressurize the oil
- Special precautions must be taken in order not to system by switching off the isolator switch, close the air
damage the convertor. Consult Atlas Copco. outlet valve and open manual drain valve (Dm-Fig. 5).
- Improve the lubrication of the compressor element at Wait until the compressor has depressurized. Unscrew
starting: loosen hose clip (3-Figs. 9b and 13) and lift the oil filler plug (FC-Figs. 12) only one turn to permit any
inlet hose. Open the check valve manually and pour 3/4 l pressure in the system to escape. Remove the filler cap
of oil into the compressor element. Reinstall the inlet and add oil until the level reaches the filler neck (adapter
hose. part included). Tighten the plug.

OF

Vp

AR

AR

FC FC

GI

GI

F005
DP1

Fig. 12a. Oil system components of GA50 VSD Fig. 12b. Oil system components of GA90 (W) VSD

AR. Air receiver/oil separator OF. Oil filter

DP1. Oil drain plug, air receiver Vp. Minimum pressure valve
FC. Oil filler plug 1. Flexible, oil drain
Gl. Oil level gauge

Figs. 12. Oil system components

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Instruction book Industrial Air Division

Remark filler plug (FC-Figs. 12) only one turn to permit any
It is possible to remotely control following functions: pressure in the system to escape. Remove the filler plug
and add oil until the level reaches the filler neck (adapter
part included). Tighten the plug.
Function Action (see strip 1X1-Figs. 6)
2. If automatic operation LED (1) is alight, the regulator is
automatically controlling the compressor, i.e. matching the
Remote start/ Connect a remote start button compressor speed to the net pressure, starting and stopping
programmed stop (pulse command of minimum 500 the compressor whenever necessary.
ms) between terminals 30 and 31.
Connect a remote stop button Warning When the motors are stopped and LED (1) is
between terminals 30 and 32. alight, the motors may start automatically.
Open switch CMS1 and close
switch CMS2. The start and stop
buttons (8 and 9-Fig. 7a) are made 3.4.1 Checking the display 1) (Fig. 7a)
inactive.
1. Regularly check the display for readings and messages.
Normally the main display (Fig. 7b) is shown, indicating
Warning After connecting as described above, the the compressor outlet pressure, the motor speed and the
compressor is remotely controlled. abbreviations of the functions of the keys below the display.
See section 1.4.
2. Always check the display (4) and remedy the trouble if alarm
3.3 Starting (Fig. 7a) LED (3) is alight or blinks. See section 1.4.2.1.
3. The display (4) will show a service message if one of the
1. Switch on the voltage. Check that voltage on LED (2) lights monitored components is to be serviced; reset the relevant
up. The message compressor off appears. timer after servicing.
2. Open air outlet valve (AV-Fig. 1). Notes:
3. Close condensate drain valve (Dm-Fig. 5). - Whenever a shut-down, shut-down warning, service
4. On water-cooled compressors: request, sensor error or fan motor overload message is
- Check that the cooling water drain valve is closed and displayed, the free spaces on the display between the
open the cooling water inlet valve. function keys (5) are filled with blinking indicators (**).
- Open the water flow regulation valve; this step can be - When more than one message needs to be displayed (e.g.
overlooked if, after previous operation, the setting of both warning and service), the messages are
this valve has not been disturbed. continuously displayed for 3 seconds each.
5. Press start button I (8). The compressor starts running and
automatic operation LED (1) lights up. 4. Regularly press the function key (5) below More 2) to call
6. On water-cooled compressors: regulate the cooling water up information about the actual compressor condition:
flow with the compressor running in normal operating - the status of controlling the compressor (local or remote)
conditions. Adjust the water flow to obtain the most suitable - the status of the compressor start/stop timer (on or
air temperature at the element outlet, i.e. between 2°C and off) 3)
5°C above the relevant temperature in Fig. 15. Consult the - the outlet pressure
example below Fig. 15. - the compressor element outlet temperature
- the status of the fan motor overload protection (normal
For optimum operation, the cooling water outlet temperature or not)
must never exceed the value specified in section 7.4. - the total running hours
- the cooling water outlet temperature

3.4 During operation (Fig. 7a)

In order to ensure sufficient motor cooling, the doors must be

closed during operation and may be opened for short periods
only to carry out checks.
1) Consult the "User manual for Elektronikon regulator", sections
"Status data submenu" and "Service submenu".
1. Check the oil level during operation: the pointer of the 2) If the More function is not indicated on the bottom line of display
level indicator (Gl-Figs. 12) must register in the green range; (4-Fig. 7a), press function key (5) below Menu until function
if not, press button O (9), switch off the isolator switch Main appears above key (F1), then press the function key below
(S0-Figs. 1 and 3a), close air outlet valve (AV-Figs. 1 Main.
and 3b), open manual drain valve (Dm-Fig. 5) and wait 3) The compressor is automatically started and stopped if these start/
until the compressor has depressurized. Unscrew oil stop commands are programmed and activated; consult the "User
manual for Elektronikon regulator", section "Timer submenu".

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 Industrial Air Division Instruction book

3.5 Stopping (Fig. 7a) 4 Maintenance

1. Press stop button O (9). LED (1) goes out. The compressor Attention: Before starting any maintenance, press stop button
stops and the message Programmed stop appears on the O (9-Fig. 7a), switch off the isolator switch (S0-Figs. 1 and
screen. Five seconds later, the message changes from 3a), close air outlet valve (AV-Fig. 1), open manual drain (Dm-
Programmed stop to Compressor stopped Fig. 5) and switch off the voltage.
2. To stop the compressor in case of emergency, switch off
isolator switch (S0-Figs. 1 and 3a). The air outlet valve can be locked as follows:
3. Close air outlet valve (AV-Fig. 1) and switch off the voltage. - Close the valve.
4. Open condensate drain valve (Dm-Fig. 5). - Remove the bolt fixing the handle to the valve.
5. On water-cooled compressors, close the cooling water - Lift the handle and turn it until the slot fits over the blocking
inlet valve (customer's installation). If freezing edge.
temperatures can be expected, drain the cooling system - Fix the handle to the valve using the special bolt and wrench
completely. delivered loose with the compressor.

Mechanical maintenance
3.6 Taking out of operation Open drain valve (Dm-Fig. 5) and wait for at least 2 minutes
(time needed for the compressor to depressurize) before
At the end of the life cycle of the compressor, proceed as starting maintenance.
follows:
Electrical maintenance
1. Stop the compressor and close the air outlet valve. Wait for at least 6 minutes before starting maintenance as
2. Switch off the voltage and disconnect the compressor from hazardous high voltage remains on the condensers of the
the mains. start and speed regulation unit for 6 minutes after switching
3. Wait until the compressor has depressurized. Unscrew plug off the voltage.
(FC-Figs. 12) only one turn to permit any pressure in the
system to escape. Open drain valve (Dm-Fig. 5). Apply all relevant safety precautions, including those mentioned
4. Shut off and depressurize the part of the air net which is in this book.
connected to the outlet valve. Disconnect the compressor
air outlet pipe from the air net.
5. Isolate the compressor water system (only on water-cooled
compressors) from the cooling water net.
6. Drain the oil, water and condensate circuits.
7. Disconnect the compressor condensate piping from the
condensate drain net.

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Instruction book Industrial Air Division

4.1 Preventive maintenance schedule for the compressor 1)

Attention:
For overhauling or carrying out preventive maintenance, service kits are available. See section 4.9.
Atlas Copco also offers several types of Service contracts, relieving you of all preventive maintenance work. For more details,
consult your nearest Atlas Copco representative.
The schedule comprises a summary of the maintenance instructions. Read the respective section before taking maintenance
measures.
When servicing, replace all disengaged packings, e.g. gaskets, O-rings, washers.
The "longer interval" checks must also include the "shorter interval" checks.

Period 2) Running See See Service Operation

hours 2) section note Kit
Daily -- 3.2/3.4 -- Check oil level
" 8 3.4/7.1 -- Check readings on display
" 8 -- 10 Check that condensate is discharged during operation (Da)
" -- 3.5 10 Drain condensate (Dm)

Monthly -- -- -- Clean compressor

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

" -- -- 8 Carry out a LED/display test
" -- -- -- Check for oil leaks
" 500 -- 1 Clean cooling air openings of electric cabinet
" 500 5.2 1 Inspect coolers (Ca/Co); clean if necessary
" 500 -- 1/7 Remove air filter element (AF), inspect
" 500 -- 4 Check pressure difference over Atlas Copco prefilters or
afterfilters (optional)

Yearly -- 5.3 -- Test safety valve (SV)

" -- -- -- Have operation of electrical components tested
" -- -- 9 Test temperature shut-down protection
" 1,000 4.4/4.5/4.6 2/6 If mineral oil is used, change oil and oil filter (OF)
" 1,000 -- -- If mineral oil is used, inspect restrictor (Rf2) for cleanness
" 2,000 5.1 6 X Replace air filter element (AF)
" 2,000 -- -- X Remove, dismantle and clean float valve of moisture trap (MT)
" 2,000 -- -- If Roto-injectfluid is used, inspect restrictor (Rf2) for cleanness
" 2,000 4.6 2/6 X If Roto-injectfluid is used, replace oil filters (OF)
" 2,000 or 4.4/4.5 3/5/6 X If Roto-injectfluid is used, change oil
4,000
-- 4,000 4.2 -- X On GA50 VSD, regrease compressor motor bearings (M1)
-- 6,000 4.7 6 X Replace oil separator (OS)

3-yearly 1,800,000 m³ 4.2 -- X On GA90 (W) VSD 10 bar, regrease compressor motor
bearings (M1)
" 1,300,000 m³ 4.2 -- X On GA90 (W) VSD 13 bar, regrease compressor motor
bearings (M1)

1) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by
Warranty or Product Liability.
2) Whichever interval comes first. The local Sales Company may overrule the maintenance schedule, especially the service
intervals, depending on the environmental and working conditions of the compressor.

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 Industrial Air Division Instruction book

Remark: For overhauling valves or carrying out preventive maintenance, service kits are available. Consult the Parts list for the
contents of the kits.

Notes
1. More frequently when operating in a dusty atmosphere.
2. Use only (an) oil filter(s) as specified in the Parts list. The part number is marked on the filter.
3. Special Atlas Copco oil for screw compressors keeping the compressor in excellent condition.
4. If the pressure drop reaches 0.5 bar, it is strongly recommended to change the filter element as its efficiency is decreasing.
The filter element must be changed when the pressure drop reaches 1 bar.
5. It is strongly recommended to use Atlas Copco Roto-injectfluid. The change interval for this oil is 4,000 running hours or
yearly if operating continuously at a compressor element outlet temperature below 100°C and 2,000 running hours or yearly
if operating continuously close to or above 100°C.
6. Consult the "User manual for Elektronikon regulator" for resetting the service timer.
7. Replace the filter if damaged.
8. Consult the "User manual for Elektronikon regulator", section "Display test".
9. Consult the "User manual for Elektronikon regulator", section "Modify settings submenu" before modifying the temperature
protection settings.
Decrease the shut-down warning level and shut-down level for the compressor element outlet temperature to the minimum
settings. Run the compressor: when reaching the setting, the compressor must shut down. Afterwards, reset the warning and
shut-down levels to their original values.
10. Atlas Copco has oil separators to separate the major part of the oil from the condensate to ensure that the separated water
meets the requirements of the environmental codes.

4.2 Compressor motor (M1-Figs. 3) on the regulator. During this program the compressor will run
at a speed of 1200 rpm and the compressed air is blown off via
Tubes with the correct type of grease can be ordered from solenoid valve (Y1-Figs. 2). When the regreasing program
Atlas Copco (see section 4.9). has finished, the compressor can be put into operation again by
pressing the start button. Reset the regulator as described in
the "User manual for Elektronikon regulator" section "Service
4.2.1 GA50 VSD reset".

The bearings must be regreased with KLÜBER - ASONIC HQ

72 - 102. Quantity: 5 g (0.18 oz) per bearing. After regreasing
the bearings, loosen wing nut (1-Fig. 13), lift nozzle (2-Fig.
13) and turn it 90° clockwise (automatic operation pictograph
covered and grease pump pictograph visible); tighten the wing
nut. Run the Regreasing program from the Test submenu on
the regulator. During this program the compressor will run at a
speed of 1200 rpm and the compressed air is blown off via
solenoid valve (Y1-Fig. 13). When the regreasing program
has finished, loosen the wing nut, lift the nozzle and turn it
back into its original position (grease pump pictograph covered
and automatic operation pictograph visible). The compressor
can be put into operation again by pressing the start button. 2
Reset the regulator as described in the "User manual for
Elektronikon regulator" section "Service reset".
If the compressor should shut-down on "Over pressure" after
regreasing the motor bearings, check that the nozzle is in the
correct position.

4.2.2 GA90 (W) VSD

Y1. Solenoid valve
The bearings must be regreased with KLÜBER - ASONIC HQ 1. Wing nut
72 - 102. Quantity: 10 g (0.35 oz) per bearing. The regreasing 2. Blow-off nozzle
interval depends on the operating conditions of the compressor. 3. Hose clip, air inlet hose
The parameter to determine the regreasing interval is indicated 4. Air inlet hose
by the regulator. Every time the bearings have been regreased,
the Regreasing program must be run from the Test submenu Fig. 13. Blow-off nozzle of GA50 VSD

26 2920 1190 05
Instruction book Industrial Air Division

4.3 Oil and oil filter change interval

Consult section 4.1 for the change intervals and section 4.4 for
the oil specifications.

4.4 Oil specifications

4.4.1 Atlas Copco Roto-injectfluid

It is strongly recommended to use Atlas Copco Roto-

injectfluid. This is special oil for screw compressors which
keeps the compressor in excellent condition.

Atlas Copco Roto-injectfluid can be ordered in following

quantities:

Quantity Ordering number

14. Switch off the voltage and depressurize the compressor
15-litre can 2901 0086 01
before starting maintenance or repairs
25-litre can 2901 0001 01
15. Consult instruction book before greasing
209-litre drum 2901 0045 01
16. Manual condensate drain
17. Automatic condensate drain
The oil change interval depends on the working
18. Torques for steel (Fe) or brass (CuZn) bolts
temperature. See note 5 below the maintenance schedule.
19. Compressor remains pressurized for 30 seconds after
switching off the voltage
20. Keep the doors closed during operation
4.4.2 Mineral oil
21. Cooling water inlet
22. Cooling water outlet
Although Roto-injectfluid is recommended, a high-quality
23. Nozzle position, regreasing or automatic operation
mineral oil with oxidation inhibitors and anti-foam and anti-
24. Warning, voltage
wear properties can also be used after taking some precautions.
25. Switch off the voltage and wait for at least 6 minutes
The oil system should first be drained and flushed. The viscosity
before removing the screen
grade must correspond to the ambient temperature and ISO
3448, as follows:
Fig. 14. Pictographs

Ambient temperature Viscosity Viscosity

grade index

2. Remove vent plug (VP-Figs. 3a and 4). Drain the oil by

Consistently above 25°C (77°F) . ISO VG 68 Minimum 95 removing drain plugs (DP1, DP2 and DP3-Figs. 2). Fit
Between 25°C (77°F) and and tighten all plugs after draining. Collect the oil in a
0°C (32°F) . . . . . . . . . . . . . . . . . . ISO VG 32 Minimum 95 collector and deliver it to the oil collection service.
or 46 3. Fill air receiver (AR) with oil until the level reaches the
filler neck. Take care that no dirt drops into the system.
Reinstall and tighten filler plug (FC).
Never mix oils of different brands or types. Use only non-
4. Run the compressor for a few minutes. Stop the
toxic oils where there is a risk of inhaling delivered air.
compressor and switch off the isolator switch to
depressurize the compressor. Wait a few minutes to allow
the oil to settle. Unscrew oil filler plug (FC) only one turn
4.5 Oil change (Figs. 12) to permit any pressure in the system to escape. Fill the air
receiver with oil until the level reaches the filler neck
1. Run the compressor until warm. Stop the compressor, (adapter part included). Tighten filler plug (FC).
switch off isolator switch (S0-Figs. 1 and 3a), close air 5. Reset the oil service warning. 1)
outlet valve (AV-Fig. 1), open manual drain valve (Dm-
Fig. 5) and wait until the compressor has depressurized.
Unscrew oil filler plug (FC) only one turn to permit any
pressure in the system to escape. 1) Consult the "User manual for Elektronikon regulator", section
"Service submenu".

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 Industrial Air Division 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 %, the minimum
temperature to prevent condensate from forming is 68°C. Regulate the cooling water flow during loaded operation to obtain a
temperature between 70°C and approx. 75°C at the outlet of the compressor element.

Fig. 15. Minimum allowable air temperature at outlet of compressor element (water-cooled compressors only)

4.6 Oil filter change (Figs. 12) 6. Tighten plug (FC). Tighten the plug in the oil filter housing
and vent plug (VP-Figs. 3a and 4).
1. Close the air outlet valve (AV-Fig. 1) and let the compressor 7. Reset the oil filter service warning. 1)
run at minimum speed for 3 minutes. Stop the compressor,
switch off isolator switch (S0-Figs. 1 and 3a) and open
manual drain valve (Dm-Fig. 5). Wait until the 4.7 Oil separator change
compressor has depressurized. Unscrew oil filler plug
(FC) only one turn to permit any pressure in the system 1. Stop the compressor, switch off the isolator switch, close
to escape. the air outlet valve (AV-Fig. 1) and open manual drain
2. Remove vent plug (VP-Figs. 3a and 4), wait 5 minutes, valve (Dm-Fig. 5). Wait until the compressor has
remove the drain plug in the oil filter housing and catch the depressurized. Unscrew oil filler plug (FC-Figs. 12) only
oil in a receptacle. one turn to permit any pressure in the system to escape.
3. Remove oil filter(s) (OF-Figs. 9b and 12a). 2. Disconnect the flexibles from the minimum pressure valve
4. Clean the filter seat(s) on the manifold. Oil the gaskets of (Vp-Fig. 12a) and air receiver cover.
the new elements. Screw the elements into place and tighten
them firmly by hand.
5. Fill the receiver (AR) with oil until the level reaches the
1) Consult the "User manual for Elektronikon regulator", section
filler neck (adapter part included).
"Service submenu".

28 2920 1190 05
Instruction book Industrial Air Division

3. Remove the air receiver cover with scavenging line. Take 5.1.2 Servicing
care not to distort the scavenging line.
4. Fit the new separator and cover using new O-rings which 5.1.2.1 GA50 (W) VSD
are included in the oil separator kit (see section 4.9).
5. Reconnect the flexibles. 1. Release the snap clips and remove the dust trap. Remove
6. Tighten filler plug (FC). the filter element and clean the filter chamber.
7. Reset the oil separator service warning. 1) 2. Install the new element and the dust trap.
3. Reset the air filter service indicator. Reset the air filter
service warning. 1)
4.8 Storage after installation

Run the compressor twice a week until warm. 5.1.2.2 GA90 (W) VSD (AF-Fig. 4)

If the compressor is stored without running from time to time, 1. Unscrew the wing nut of the filter cover. Remove the filter
protective measures must be taken. Consult Atlas Copco. element and clean the filter chamber.
2. Install the new element and the filter cover.
3. Reset the air filter service indicator. Reset the air filter
4.9 Service kits service warning. 1)

Service kits are available offering you the benefits of genuine

Atlas Copco parts while keeping the maintenance budget low. 5.2 Coolers
The kits comprise all parts needed for servicing.
Keep the coolers clean to maintain the cooling efficiency.

Compressor type GA50 (W) VSD GA90 (W) VSD Air-cooled compressors
Service kit for: Ordering Ordering To facilitate external cleaning of the coolers, side panels (1-
number number Figs. 3 and 4) can be removed.

Remove any dirt from the coolers with a fibre brush. Never
Oil filters and air filter: 2901 0326 00 2901 0050 00
use a wire brush or metal objects. Then clean by air jet in
Oil separator: 2901 0213 00 2901 0070 00
reverse direction of normal flow.
Motor regreasing: 2901 0338 00 2901 0338 00
Refit the side panels.

Water-cooled compressors
Consult Atlas Copco.

5.3 Safety valve

Operating
Operate the safety valve by unscrewing the cap one or two turns
and retightening it.

Testing
5 Adjustments and servicing The valve can be tested on a separate compressed air line. If
the valve does not open at the pressure specified in section 7.2,
procedures consult Atlas Copco. No adjustments are allowed.

5.1 Air filter

5.1.1 Recommendations

1. Never remove the element while the compressor is running.

2. For minimum compressor down-time, replace the dirty
element by a new one. 1) Consult the "User manual for Elektronikon regulator", section
3. Discard the element when damaged. "Service submenu".

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 Industrial Air Division Instruction book

6 Problem solving 3. Safety valve (SV) blows

a. Minimum pressure valve (Vp) malfunctioning
- Before starting repairs, press stop button O (9-Fig. 7a), wait a. Remove and check. Replace defective parts
until the compressor has stopped, switch off isolator switch b. Oil separator element (OS) clogged
(S0-Figs. 1 and 3a) and switch off the voltage. Close air b. Replace element
outlet valve (AV-Fig. 1), the air outlet valve can be locked c. Safety valve (SV) out of order
as described in section 4. Open manual drain valve (Dm- c. Remove and check. Replace if not airtight after
Fig. 5) and wait for at least 2 minutes (time needed for reinstalling
the compressor to depressurize) before starting any
mechanical repairs. Wait at least 6 minutes before 4. Element outlet 1) or air outlet temperature above normal
starting any electrical repairs as hazardous high voltage a. On air-cooled compressors: insufficient cooling air or
remains on the condensers of the start and speed cooling air temperature too high
regulation unit for 6 minutes after switching off the a. Check for cooling air restriction or improve ventilation
voltage. Furthermore, apply all relevant safety precautions, of compressor room. Avoid recirculation of cooling air.
including those mentioned in this book. If installed, check capacity of compressor room fan
b. On water-cooled compressors: insufficient cooling
- The chart helps to solve mechanical problems. An electrical water flow or cooling water temperature too high
fault must be traced by an electrician. Check that the wires b. Decrease temperature, if possible, or increase water flow
are not damaged and that they are clamped tight to their c. Oil level too low
terminals. c. Check and correct as necessary
d. Oil cooler (Co) clogged
- Consult the "User manual for Elektronikon regulator" if a d. Clean cooler
service message or fault message appears on the display e. By-pass valve (BV) malfunctioning
(4-Fig. 7a) or when alarm LED (3-Fig. 7a) is alight or blinks. e. Remove and test valve
f. Air cooler (Ca) clogged
f. Clean cooler
Mechanical faults and suggested remedies (Figs. 2) g. On water-cooled compressors: restriction of cooling
Explanation of the table below: water system due to dirt or formation of scale
- Conditions of the compressor, always preceded by a number, g. Consult Atlas Copco
are printed in bold. h. Compressor element (E) out of order
- Each possible fault is followed by its relevant suggested h. Consult Atlas Copco
remedy and both are preceded by the same letter.
5. Motor temperature above normal
1. Condensate is not discharged from moisture trap during a. Insufficient cooling air or cooling air temperature too
operation high
a. Discharge flexible clogged a. Check for cooling air restriction or improve ventilation
a. Check and correct as necessary of compressor room. Avoid recirculation of cooling air.
b. Float valve malfunctioning If installed, check capacity of compressor room fan
b. Remove float valve assembly, clean and check b. Insufficient sealing of door panels
b. Check that all doors are closed, check seals of door
2. Compressor air output or pressure below normal panels.
a. Air consumption exceeds air output of compressor
a. Check equipment connected
b. Choked air inlet filter element (AF)
b. Replace filter element
c. Solenoid valve (Y1) malfunctioning
c. Remove and check valve, replace if necessary
d. Oil separator element (OS) clogged
d. Replace element
e. Air leakage
e. Check and correct as necessary
f. Safety valve (SV) leaking
f. Remove and check. Replace if not airtight after
reinstalling
g. Compressor element (E) out of order
g. Consult Atlas Copco
Only on GA50 VSD:
h. Nozzle (Rf1) in wrong position
h. Correct the position of the restrictor, consult section 4.2.1 1) A warning message will appear on display (4-Fig. 7a).

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Instruction book Industrial Air Division

7 Principal data 7.3.2 GA90 (W) VSD

Circuit breaker Supply Fre- Maximum

7.1 Readings on display (4-Fig. 7a) 1) voltage quency setting

Ref.: Air outlet pressure

Reading: Depends on the setpoint (desired net pressure) Fan motor (Q15-Fig. 8b)
Shown: On main display (Fig. 7b), when: - Air-cooled compressors . 400 V 50 Hz 10 A
- switching on voltage - Water-cooled
- selecting main display with function keys (5) compressors . . . . . . . . . . . 400 V 50 Hz 1.2 A
below Menu and Main
- keys of module are not used for four minutes Invertor (Q16-Fig. 8b) . . . . 400 V 50 Hz Minimum
Sensor: PT20-Figs. 2 setting of
circuit
Ref.: Compressor element outlet temperature breaker
Reading: Approx. 60°C/108°F above cooling air
temperature (cooling water temperature on water-
cooled compressors)
Shown: When using the function key (5) below More on
the main display (Fig. 7b)
Sensor: TT11-Fig. 9b

Ref.: Cooling water outlet temperature (water 7.4 Compressor specifications

cooled compressors)
Reading: Below 50°C
Shown: When using the function key (5) below More on 7.4.1 Reference conditions
the main display (Fig. 7b)
Sensor: TT51-Figs. 6 Air inlet pressure (absolute) . . . . . . . . . . . . . bar 1
Air inlet temperature . . . . . . . . . . . . . . . . . . °C 20
Relative humidity . . . . . . . . . . . . . . . . . . . . . % 0
For water-cooled compressors also:
Cooling water inlet temperature . . . . . . . . . . °C 20

7.2 Settings of safety valve

GA50 (W) VSD 14.5 bar(e)

GA90 (W) VSD 14.5 bar(e)

7.3 Settings of circuit breakers

7.3.1 GA50 (W) VSD

Circuit breaker Supply Fre- Maximum

voltage quency setting

1) See "User manual for Elektronikon regulator for GA90 VSD

Fan motor (Q15-Fig. 8a) . 400 V 50 Hz 4.2 A
compressors", sections "Modify settings submenu" and "More
function"

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 Industrial Air Division Instruction book

7.4.2 Specific data of GA50 (W)VSD 1)

Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7 9.5 12.5

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hz 50/60 50/60 50/60
Number of compression stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1
Maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 4800 4260 3615
Minimum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 4 4 4
Maximum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 40 40 40
Minimum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 0 0 0
Maximum cooling water outlet temperature 6) . . . . . . . . . . . . . . . . . . °C 50 50 50
Maximum cooling water inlet pressure 6) . . . . . . . . . . . . . . . . . . . . . . bar(e) 5 5 5
Recommended cooling water flow 6)
- cooling water inlet temperature below 25°C 7) . . . . . . . . . . . . . . . . . l/min 50 50 50
- cooling water inlet temperature between 25°C and 40°C 8) . . . . . . . l/min 75 75 75
Temperature of air leaving air outlet valve, approx. . . . . . . . . . . . . . . °C 34 33 32
Electric power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW 63.2 63.0 60.0
Oil capacity, approx.
- air cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 18 18 18
- water cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 17 17 17
Sound pressure level 3) 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 75 75 75

7.4.3 Specific data of GA90 (W) VSD 1)

Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7 9.5 12.5

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hz 50/60 50/60 50/60
Number of compression stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1
Maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 4820 4230 3600
Minimum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 4 4 4
Maximum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 40 40 40
Minimum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 0 0 0
Maximum cooling water outlet temperature 6) . . . . . . . . . . . . . . . . . . °C 50 50 50
Maximum cooling water inlet pressure 6) . . . . . . . . . . . . . . . . . . . . . . bar(e) 5 5 5
Recommended cooling water flow 6)
- cooling water inlet temperature below 25°C 7) . . . . . . . . . . . . . . . . . l/s 1.5 1.5 1.5
- cooling water inlet temperature between 25°C and 40°C . . . . . . . . . l/s 2.2 2.2 2.2
Temperature of air leaving air outlet valve, approx. . . . . . . . . . . . . . . °C 30 30 30
Oil capacity, approx. 5)
- air cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 28 28 28
- water cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 22 22 22
Electric power input
- air cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW 105.5 105 102
- water cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW 102 101.1 98.5
Sound pressure level 3) 4)
- air cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 85 85 85
- water cooled compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 78 78 78
Sound pressure level 2) 3) 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 76 76 76

7.5 Conversion list of SI units into British units

1 bar = 14.504 psi 1 kW = 1.341 hp (UK and US) 1 m = 3.281 ft 1 N = 0.225 lbf
1 g = 0.035 oz 1 l = 0.264 US gal 1 mm = 0.039 in 1 Nm = 0.738 lbf.ft
1 kg = 2.205 lb 1 l = 0.220 Imp gal (UK) 1 m3/min = 35.315 cfm x°C = (32 + 1.8x) °F
1 km/h = 0.621 mile/h 1 l = 0.035 cu.ft 1 mbar = 0.401 in wc ∆t 1°C = ∆t 1.8 °F

1) At reference conditions 4) Free field conditions 7) ∆t=15°C

2) With silencing kit and outlet duct (optional) 5) Air-cooled compressors 8) ∆t=10°C
3) According to PNEUROP/CAGI PN8NTC2 6) Water-cooled compressors

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