Ga30 55c Instruc Eii

Instruction book
Atlas Copco Stationary Air Compressors
GA30 - GA37 - GA45 - GA55C

GA30 W - GA37 W - GA45 W - GA55C W
With Elektronikon I and Elektronikon II regulator
Instruction book
Important
1. From following serial number onwards: AII-380 000
2. This book must be used together with the "User manual for Elektronikon I and II regulators", Printed
Matter No. 2920 1461 0x.
Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium.

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.
No. 2920 1460 03
(Replaces 2920 1460 02)
Registration code: APC G30-55C / 38 / 978
2004-03 www.atlascopco.com
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Instruction book
This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency
and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and proper
maintenance from the beginning. The maintenance schedule comprises measures for keeping the
machine in good condition.
Keep the book available for the operator and make sure that the machine is operated and that
maintenance is carried out according to the instructions. Record all operating data, maintenance
performed, etc. in an operator's logbook available from Atlas Copco. Follow all relevant safety
precautions, including those mentioned on the cover of this book.
Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further
information.
In all correspondence always mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal
data".
The company reserves the right to make changes without prior notice.
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Instruction book
Contents
Page
1 LEADING PARTICULARS......................................................................................................................... 5
1.1 General description.............................................................................................................................. 5
1.1.1 Compressor variants ..................................................................................................................... 5
1.1.2 Air flow (Figs. 1.6 up to 1.8) .......................................................................................................... 8
1.1.3 Oil system (Figs. 1.6 up to 1.8) ..................................................................................................... 8
1.1.4 Cooling system (Figs. 1.6 up to 1.8) ............................................................................................. 8
1.1.5 Condensate drain system (Fig. 1.9) .............................................................................................. 8
1.2 Unloading/loading system.................................................................................................................... 8
1.2.1 Unloading (Fig. 1.6)....................................................................................................................... 8
1.2.2 Loading (Figs. 1.7 and 1.8) ......................................................................................................... 13
1.3 Elektronikon II regulator ..................................................................................................................... 14
1.3.1 Main functions ............................................................................................................................. 15
1.3.2 Control panel (Fig. 1.11) ............................................................................................................. 17
1.3.3 Display......................................................................................................................................... 18
1.3.4 Calling up other menus ............................................................................................................... 18
1.4 Elektronikon I regulator ...................................................................................................................... 23
1.4.1 Main functions ............................................................................................................................. 23
1.4.2 Control panel (Fig. 1.17) ............................................................................................................. 24
1.4.3 Display......................................................................................................................................... 25
1.4.4 Scrolling through all screens ....................................................................................................... 25
1.4.5 Pictographs used on the screen.................................................................................................. 25
1.5 Air dryer ............................................................................................................................................. 29
1.5.1 GA Pack FF and GA Workplace FF with IFD (Fig. 1.6) .............................................................. 29
1.5.2 GA Workplace FF with ICD (Fig. 1.7).......................................................................................... 29
2 INSTALLATION ....................................................................................................................................... 30
2.1 Dimension drawings (Figs. 2.1 and 2.2) ............................................................................................ 30
2.2 Installation proposals (Figs. 2.3 up to 2.5)......................................................................................... 32
2.3 Electrical connections ........................................................................................................................ 36
2.4 Cooling water requirements............................................................................................................... 37
2.5 Pictographs (Fig. 2.6)......................................................................................................................... 37
3 OPERATING INSTRUCTIONS ................................................................................................................ 39
3.1 Before initial start-up .......................................................................................................................... 39
3.1.1 Safety .......................................................................................................................................... 39
3.1.2 User manual ................................................................................................................................ 39
3.1.3 Outdoor/altitude operation........................................................................................................... 39
3.1.4 Moving/lifting ............................................................................................................................... 39
3.2 External compressor status indication/remote control (Elektronikon II) ............................................ 39
3.2.1 External compressor status indication ........................................................................................ 39
3.2.2 Remote control ............................................................................................................................ 40
3.3 Remote starting/stopping (Elektronikon I).......................................................................................... 40
3.4 Initial start-up ..................................................................................................................................... 41
3.5 Before starting.................................................................................................................................... 42
3.6 Operating GA Workplace/Workplace FF ........................................................................................... 45
3.6.1 Starting ........................................................................................................................................ 46
3.6.2 During operation.......................................................................................................................... 46
3.6.3 Checking the display ................................................................................................................... 46
3.6.4 Manual control (Fig. 3.6) ............................................................................................................. 48
3.6.5 Stopping (Fig. 3.6)....................................................................................................................... 49
3.7 Operating GA Pack/Pack FF ............................................................................................................. 49
3.7.1 Starting (Fig. 3.9)......................................................................................................................... 50
3.7.2 During operation.......................................................................................................................... 50
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3.7.3 Checking the display ................................................................................................................... 50

3.7.4 Stopping ...................................................................................................................................... 51
3.8 Taking out of operation at end of compressor service life ................................................................. 51
4 MAINTENANCE ....................................................................................................................................... 52
4.1 Drive motor (M1- Fig. 1.3).................................................................................................................. 52
4.2 Service actions for GA Pack/Pack FF................................................................................................ 52
4.3 Service plans for GA Workplace/Workplace FF ................................................................................ 53
4.4 Preventive maintenance schedule 1)................................................................................................. 53
4.5 Oil specifications ................................................................................................................................ 54
4.5.1 Atlas Copco Roto-injectfluid ........................................................................................................ 54
4.5.2 Mineral oil .................................................................................................................................... 55
4.6 Oil change.......................................................................................................................................... 55
4.7 Oil filter change .................................................................................................................................. 55
4.8 Storage after installation .................................................................................................................... 55
4.9 Service kits......................................................................................................................................... 56
5 ADJUSTMENTS AND SERVICING PROCEDURES .............................................................................. 57
5.1 Air filter (AF-Fig. 5.1).......................................................................................................................... 57
5.2 Coolers............................................................................................................................................... 57
5.3 Safety valve (SV-Fig. 5.1).................................................................................................................. 58
6 PROBLEM SOLVING .............................................................................................................................. 59
7 PRINCIPAL DATA ................................................................................................................................... 62
7.1 Readings on display (Figs. 1.11/1.17) ............................................................................................... 62
7.2 Electric cable size .............................................................................................................................. 62
7.3 Motor overload relay (F21) and fuses................................................................................................ 63
7.4 Fan motor circuit breaker (Q15) (air-cooled compressors)................................................................ 63
7.5 Dryer switches (Pack FF/Workplace FF with IFD)............................................................................. 63
7.6 Compressor specifications................................................................................................................. 64
7.6.1 Reference conditions .................................................................................................................. 64
7.6.2 Limitations ................................................................................................................................... 64
7.6.3 GA30 / GA30 W Pack/Workplace 2) .......................................................................................... 64
7.6.4 GA30 / GA30 W Pack FF/Workplace FF with IFD 2) ................................................................. 65
7.6.5 GA37 / GA37 W Pack/Workplace 2) ........................................................................................... 66
7.6.7 GA45 / GA45 W Pack/Workplace 2) ........................................................................................... 67
7.6.9 GA55C / GA55C W Pack/Workplace 2) ...................................................................................... 68
7.6.10 GA55C / GA55C W Pack FF/Workplace FF with IFD 2).......................................................... 69
7.7 Specifications of ICD dryer 2) ............................................................................................................ 69
7.7.1 Pressure dewpoint –40°C variant................................................................................................ 69
7.7.2 Pressure dewpoint –70°C variant................................................................................................ 70
7.8 Conversion list of SI units into US/British units.................................................................................. 70
8 INSTRUCTIONS FOR USE OF AIR RECEIVER..................................................................................... 72
9 PED .......................................................................................................................................................... 72
9.1 Components subject to 97/23/EC Pressure Equipment Directive ..................................................... 72
9.2 Overall rating...................................................................................................................................... 72
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1 LEADING PARTICULARS
1.1 General description
GA are stationary, single-stage, oil-injected screw compressors driven by an electric motor. GA30-GA37-
GA45-GA55C are air-cooled, whereas GA30 W-GA37 W-GA45 W-GA55C W are water-cooled.
1.1.1 Compressor variants

GA Pack
GA Pack are enclosed in a sound-insulated bodywork. The compressors are controlled by the Atlas
Copco Elektronikon® I regulator (Fig. 1.1). The electronic control module is fitted to the door at the front
side. An electric cabinet comprising the motor starter is located behind this panel.
GA Pack FF
GA Pack FF (Full-Feature) are also controlled by the Atlas Copco Elektronikon® I regulator (Fig. 1.1).
They are additionally provided with an air dryer integrated in the sound-insulated bodywork. The dryer
removes condensate from the compressed air by cooling the air to near freezing point and automatically
draining the condensate. See section 1.5.
GA Workplace
GA Workplace are enclosed in a sound-insulated bodywork. The compressors are controlled by the Atlas
Copco Elektronikon® II regulator (Fig. 1.2). The electronic control module is fitted to the door at the front
side. An electric cabinet comprising the motor starter is located behind this panel. A condensate trap with
automatic drain system is provided.
GA Workplace FF
GA Workplace FF (Full-Feature) are also controlled by the Atlas Copco Elektronikon® II regulator (Fig.
1.2). They are additionally provided with an IFD or ICD air dryer. The condensate is automatically
drained. See section 1.5.
On GA Workplace FF with IFD, the dryer is integrated in the sound-insulated bodywork and removes
condensate from the compressed air by cooling the air to near freezing point.
On GA Workplace FF with ICD, the dryer is integrated in the sound-insulated bodywork. However, the
dryer and compressor module are shipped separately and must be installed at the site. Condensate from
the compressed air is removed by the adsorption process of the ICD.
Fig. 1.1 Elektronikon I regulator Fig. 1.2 Elektronikon II regulator
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Fig. 1.3 Front view of GA37 Workplace Full-Feature with IFD
Fig. 1.4 Front view of GA37 Workplace Full-Feature with ICD
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Instruction book
Fig. 1.5 Rear view of GA37 Workplace Full-Feature with IFD
AF Air filter ER II Elektronikon II regulator

AR Air receiver/oil separator FN Fan
AV Air outlet valve M1 Drive motor
AV1 Dryer by-pass valve M2 Fan motor
Ca Air cooler OF Oil filter
Co Oil cooler S3 Emergency stop button
CV Check valve UA Unloader
Da Automatic condensate drain VP Oil cooler vent plug
Dm Condensate drain valve Vs Oil stop valve
E Compressor element 1 Dryer
Figs. 1.3 up to 1.5 GA37 Workplace Full-Feature
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Instruction book
1.1.2 Air flow (Figs. 1.6 up to 1.8)

Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed.
Compressed air and oil flow into air receiver/oil separator (AR) via check valve (CV). The air is
discharged through outlet valve (AV) via minimum pressure valve (Vp), air cooler (Ca) and condensate
trap (MT) (a condensate trap is not provided on GA Pack).
Check valve (CV) prevents blow-back of compressed air when the compressor is stopped. Minimum
pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure.
1.1.3 Oil system (Figs. 1.6 up to 1.8)

In air receiver/oil separator (AR), most of the oil is removed from the air/oil mixture centrifugally. The
balance is removed by oil separator element (OS). The oil collects in the lower part of air receiver/oil
separator (AR), which serves as oil tank.
The oil system is provided with a by-pass valve (BV). When the oil temperature is below 40 degrees
Celsius (65 degrees Celsius for 13 bar and 175 psi compressors), by-pass valve (BV) shuts off the oil
supply from oil cooler (Co). Air pressure forces the oil from air receiver/oil separator (AR) through oil filter
(OF) and oil stop valve (Vs) to compressor element (E) and the lubrication points. Oil cooler (Co) is by-
passed.
By-pass valve (BV) starts opening the oil supply from cooler (Co) when the oil temperature has increased
to the above-mentioned value. At approx. 55 degrees Celsius (80 degrees Celsius for 13 bar and 175 psi
compressors), 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.
1.1.4 Cooling system (Figs. 1.6 up to 1.8)

The cooling system comprises air cooler (Ca) and oil cooler (Co). On air-cooled compressors, the cooling
air is generated by fan (FN2). Water-cooled compressors are provided with a cooling water system.
1.1.5 Condensate drain system (Fig. 1.9)

All variants except for GA Pack are provided with a condensate trap in the air outlet system. The trap is
equipped with a valve for automatic condensate draining during operation (Da) and a manually operated
valve for draining after stopping the compressor (Dm).
1.2 Unloading/loading system

1.2.1 Unloading (Fig. 1.6)
If the air consumption is less than the air output of the compressor, the net pressure increases. When the
net pressure reaches the unloading pressure, solenoid valve (Y1) is de-energized. The plunger of the
valve returns by spring force:
1. The control pressure present in the chambers of loading plunger (LP) and unloading valve (UV) is
vented to atmosphere via solenoid valve (Y1).
2. Loading plunger (LP) moves upwards and causes inlet valve (IV) to close the air inlet opening.
3. Unloading valve (UV) is opened by receiver pressure. The pressure from air receiver (AR) is released
towards unloader (UA).
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Instruction book
4. The pressure is stabilized at a low value. A small amount of air is kept drawn in and is blown to the
unloader.
(1) AIR-COOLED
Air output is stopped (0 %), the compressor runs unloaded. WORKPLACE FULL-
FEATURE
(2) AIR INLET
(3) COMPRESSED AIR
(4) OIL
(5) REFRIGERANT LIQUID
(6) REFRIGERANT GAS
Fig. 1.6 GA Workplace Full-Feature with IFD during unloading
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Instruction book
Fig. 1.7 GA Workplace Full-Feature with ICD during loading
(2) AIR INLET

(3) COMPRESSED AIR
(4) OIL
(7) CONTROL AIR
(8) PURGE AIR
(9) AIR-COOLED WORKPLACE FULL-FEATURE WITH ICD
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Instruction book
WATER-COOLED PACK (1)
COMPRESSED AIR OUT (2) OIL (5)
AIR INLET (3) WATER (6)
COMPRESSED AIR (4) CONTROL AIR (7)
PT20
Ca Co
AV
ER I
Elektronikon I
Vp
OF
LP Y1 Rf2
VI 2
UV SV
AF BV
UA 3 OS
IV
1 M1
AR
FC
TT11
E Gl
CV
DP1
DP3 Vs
55442D
DP2
Fig. 1.8 GA Pack during loading
(1) WATER-COOLED PACK

(2) COMPRESSED AIR OUT
(3) AIR INLET
(4) COMPRESSED AIR
(5) OIL
(6) WATER
(7) CONTROL AIR
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Instruction book
AF Air filter LP Loading plunger

AR Air receiver/oil separator MT Air cooler condensate trap
AV Air outlet valve M1 Drive motor
BV Oil cooler by-pass valve M2 Motor, compressor fan
Ca Air cooler OF Oil filter
Co Oil cooler OS Oil separator element
CV Check valve PT20 Pressure sensor, air outlet
Da Automatic drain outlet, air cooler Rf2 Restrictor
condensate trap and integrated
prefilter
Dm Manual drain valve, air cooler SV Safety valve
condensate trap
DP1 Oil drain plug, air receiver TT11 Temperature sensor, compressor
element outlet
DP2 Oil drain plug, oil stop valve UA Unloader
DP3 Oil drain plug, check valve UV Unloading valve
E Compressor element VI Air filter service indicator
ER I Elektronikon I regulator Vp Minimum pressure valve
ER II Elektronikon II regulator Vs Oil stop valve
FC Oil filler plug Y1 Loading solenoid valve
FN2 Fan, compressor coolers 1 Flexible, blow-off air or inlet air
Gl Oil level gauge 2 Flexible, blow-off air or control air
IV Inlet valve 3 Flexible, oil scavenge
On GA Pack FF and GA Workplace FF with IFD also

FN2 Fan, condenser 8 Hot-gas by-pass valve
M1 Refrigerant compressor 9 Capillary tube
M2 Motor, condenser fan 10 Condenser
TT90 Temperature sensor, dewpoint 11 Filter
5 Air/air heat exchanger 12 Condenser fan control switch
6 Air/refrigerant heat exchanger 13 High-pressure shut-down switch
(evaporator)
7 Liquid separator
On GA Workplace FF with ICD also

AV1 Air outlet valve, dryer by-passed Y2 Solenoid valve
CV1 Check valve Y3 Solenoid valve
CV2 Check valve 14 Dryer inlet valve
DDp DDp filter 15 3-way valve
IPD Integrated pre-filter 16 Pneumatic actuator
PDP Pressure dewpoint sensor 17 Exhaust valve
PR Pressure regulator (only on 13 bar 18 Silencer
compressors)
PT81 Pressure sensor, tower Ta 19 Exhaust valve
PT82 Pressure sensor, tower Tb 20 Silencer
Rf Restrictor 21 Air filter
Ta Tower A 22 Shut-off valve, control pressure
Tb Tower B 23 Shut-off valve, PDP sensor
TT81 Temperature sensor, dryer inlet
Figs. 1. 6 up to 1.8 Air-oil and unloading-loading systems
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Instruction book
Da Automatic condensate drain

Dm Condensate drain valve
1 Pictograph, manual condensate drain
2 Pictograph, automatic condensate drain
Fig. 1.9 Condensate outlets
1.2.2 Loading (Figs. 1.7 and 1.8)

When the net pressure decreases to the loading pressure, solenoid valve (Y1) is energized. The plunger
of solenoid valve (Y1) moves upwards against spring force:
1. Control pressure is fed from air receiver (AR) via solenoid valve (Y1) to loading plunger (LP) and
unloading valve (UV).
2. Unloading valve (UV) closes the air blow-off opening. Loading plunger (LP) moves downwards and
causes inlet valve (IV) to open fully.
Air output is resumed (100 %), the compressor runs loaded.
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Instruction book
AF Air filter ER II Elektronikon II regulator

AR Air receiver/oil separator M1 Drive motor
AV Air outlet valve OF Oil filter
Ca Air cooler SV Safety valve
Co Oil cooler
Fig. 1.10 Water-cooled GA30C Workplace FF
1.3 Elektronikon II regulator

GA Workplace and Workplace FF are provided with the Elektronikon II regulator (Fig. 1.11).
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Instruction book
1 Stop button 8 Automatic operation LED

2 Start button 9 Function keys
3 Display 10 Pictograph, alarm
4 Scroll keys 11 Pictograph, automatic operation
5 Tabulator key 12 Pictograph, voltage on
6 Voltage on LED S3 Emergency stop button
7 General alarm LED
Fig. 1.11 Control panel, Elektronikon II
1.3.1 Main functions

1.3.1.1 Automatic control of the compressor
The regulator maintains the net pressure between programmable limits by automatically loading and
unloading the compressor. A number of programmable settings, e.g. the unloading and loading
pressures, the minimum stop time and the maximum number of motor starts are taken into account.
The regulator stops the compressor whenever possible to reduce the power consumption and restarts it
automatically when the net pressure decreases. In case the expected unloading period is too short, the
compressor is kept running to prevent too-short standstill periods.
For GA Workplace FF with ICD, the regulator also maintains the pressure dewpoint of the dryer between
programmable settings by defining the switching time. A number of programmable settings are taken into
account.
Warning
A number of time-based automatic start/stop commands may be programmed (consult the User manual
for Elektronikon I and II regulators). Take into account that a start command will be executed (if
programmed and activated), even after manually stopping the compressor.
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Instruction book
1.3.1.2 Protecting the compressor

Shut-down
If the compressor element outlet temperature exceeds the programmed shut-down level, the compressor
will be stopped. This will be indicated on display (3). The compressor will also be stopped in case of
overload of the drive motor and, for air-cooled compressors, also the fan motor.
Shut-down warning
If the compressor element outlet temperature exceeds a programmed value below the shut-down level,
this will also be indicated to warn the operator before the shut-down level is reached.
Service warning
A number of service operations are grouped in plans (called Service plans A, B, C and D). Each Service
plan has a programmed time interval. If a time interval is exceeded, a message will appear on display (3)
to warn the operator to carry out the service actions belonging to that plan.
Warning
A warning message also appears if:
- On water-cooled compressors, the cooling water outlet temperature exceeds the warning level.
- On Full-Feature compressors, the dewpoint temperature exceeds the warning level.
- On GA Workplace FF with ICD, the inlet temperature of the compressed air into the dryer exceeds the
warning level.
- On GA Workplace FF with ICD, the pressure in the dryer vessels is lower than the minimum or higher
than the maximum limit.
1.3.1.3 Automatic restart after voltage failure

For compressors leaving the factory, this function is made inactive. If desired, the function can be
activated. Consult Atlas Copco.
Warning
If activated and provided the module was in the automatic operation mode, the compressor will
automatically restart if the supply voltage to the module is restored within a programmed time period.
The power recovery time (the period within which the voltage must be restored to have an automatic
restart) can be set between 10 and 600 seconds or to Infinite. If the power recovery time is set to Infinite,
the compressor will always restart after a voltage failure, no matter how long it takes to restore the
voltage. A restart delay can also be programmed, allowing e.g. two compressors to be restarted one after
the other.
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Instruction book
1.3.2 Control panel (Fig. 1.11)
Fig. 1.11 Control panel, GA Workplace / GA Workplace FF
Ref. Designation Function

1 Stop button Push button to stop the compressor. LED (8) goes out. The
compressor will stop after running in unloaded condition for
about 30 seconds.
2 Start button Push button to start the compressor. LED (8) lights up
indicating that the regulator is operative (in automatic
operation). The LED goes out after unloading the
compressor manually.
3 Display Indicates messages concerning the compressor operating
condition, a service need or a fault.
4 Scroll keys Keys to scroll through the display.
5 Tabulator key Key to select the parameter indicated by a horizontal arrow.
Only the parameters followed by an arrow pointing to the
right are accessible for modifying.
6 Voltage on LED Indicates that the voltage is switched on.
7 General alarm LED Is alight if a warning, service warning or shut-down warning
condition exists or if a sensor is out of order.
7 General alarm LED Blinks in case of shut-down, if a sensor with shut-down
function is out of order or after an emergency stop.
8 Automatic operation Indicates that the regulator is automatically controlling the
LED compressor: the compressor is loaded, unloaded, stopped
and restarted depending on the air consumption and the
limitations programmed in the regulator.
9 Function keys Keys to control and program the compressor. See below.
10 Pictograph Alarm
11 Pictograph Automatic operation
12 Pictograph Voltage on
S3 Emergency stop button Push button to stop the compressor immediately in case of
emergency. After remedying the trouble, unlock the button
by pulling it out.
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1.3.3 Display
Normally, the display shows the operation status of the compressor, the air outlet pressure and the
abbreviations of function keys F1, F2 and F3.
Fig. 1.12 Example of the main display
1.3.4 Calling up other menus

Starting from the Main display (Fig. 1.12):
- Use the ↓ key (4-Fig. 1.11) for a quick look at the actual compressor status
- Press the key Menu (F1); the option "Status data" will be followed by a horizontal arrow:
- either press the tabulator key (5-Fig. 1.11) to select this menu
- or use the ↓ key to scroll until the desired submenu is followed by a horizontal arrow and then
press the tabulator key (5) to select this menu.
For detailed instructions, consult the User manual for Elektronikon I and II regulators.
See Fig. 1.15 for denomination of components
Fig. 1.13 Electric cabinet, GA Workplace / Workplace FF with IFD (typical example)
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Instruction book
See Figs. 1.15 and 1.16 for denomination of components
Fig. 1.14 Electric cabinet, GA Workplace FF with ICD (typical example)
Text on Fig. 1.15
(1) Customer's installation

(2) Option
(3) Dryer option
(4) All other variants
(5) Delta connection: 200-220-230 V 50/60 Hz (see motor data plate for correct connection)
(6) All voltages (50 and 60 Hz) except 440-460 V 60 Hz
(7) Star connection: all other voltages
(8) Option ES100
(9) Option phase sequence relay
(10) Option thermistor protection
(11) Supply of dryer
(12) All other voltages
(13) Emergency stop
(14) Remote start/programmed stop
(15) Remote load/unload (closed=load)
(16) Remote pressure sensing (link=remote)
(17) Overload main/fan motor
(18) Fault EWD
(19) Pressure drop PD/DD filter
(20) Remote pressure set selection (open= pressure set 1, closed=pressure set 2)
(21) Cubicle heater
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Instruction book
Fig. 1.15 Electric diagram of GA Workplace and GA Workplace FF (typical example)
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Fig. 1.16 Electric diagram of ICD dryer (typical example)
SENSORS/SOLENOID VALVES/ELECTRONIC DRAIN

PT20 Pressure sensor, air outlet
TT11 Temperature sensor, compressor element outlet
TT51 Temperature sensor, cooling water inlet (water-cooled compressors)
TT52 Temperature sensor, cooling water outlet (water-cooled compressors)
TT53/54 Temperature sensor, energy recovery water inlet/outlet (water-cooled compressors)
TT90 Temperature sensor, dewpoint (Full-Feature with IFD)
Y1 Loading solenoid valve
MOTORS
M1 Drive motor
M2 Fan motor, compressor coolers (air-cooled compressors)
ELECTRIC CABINET
F1/F11 Fuses
F21 Overload relay, drive motor
K11 Auxiliary contactor for dryer (Full-Feature with IFD)
K21 Line contactor
K22 Star contactor
K23 Delta contactor
Q15 Circuit breaker, fan motor (air-cooled compressors)
T1/T2 Transformers
T3 Transformer, dryer (Full-Feature with IFD)
1X0/1X8 Terminal strips
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Instruction book
CONTROL MODULE (E1)

I Start button
K01 Blocking relay
K02 Auxiliary relay, star contactor
K03 Auxiliary relay, delta contactor
K04 Auxiliary relay, loading/unloading
K05 Auxiliary relay, air pressure high/low
K06 Auxiliary relay, dryer
K07 Auxiliary relay, manual/automatic operation
K08 Auxiliary relay, warning
K09 Auxiliary relay, shut-down
O Stop button
S3 Emergency stop button
OPTIONAL EQUIPMENT
AIE1 Expansion module, analog input
A1 Dryer (Full-Feature with IFD)
B1 Electronic water drain (EWD)
K25 Phase sequence protection
M3 Fan motor, electric cabinet (high ambient temperature)
R1/K34 Drive motor thermistor protection, shut-down
R2 Drive motor thermistor protection, warning
R3/R4 Heaters, freeze protection
R5 Heater, electronic water drain
R6 Heater, OSD
R7 Heater, cubicle
R96 Anti-condensation heater
S10 Main power isolating switch
TSLL91 Thermostat, cubicle freeze protection
Y2 Solenoid valve, modulating control
Y51 Water shut-off valve (water-cooled versions)
ICD DRYER
E11 Emix module
F90/F91 Fuses
PDS81 Differential switch, DDp filter
PT81 Pressure sensor, drying tower A
PT82 Pressure sensor, drying tower B
TT81 Temperature sensor, dryer inlet
TT82 Pressure dewpoint temperature sensor
T1 Transformer
Y1 Solenoid valve 1
Y2 Solenoid valve 2
1X0 Terminal strip, power supply
1X2 Terminal strip, dryer
1X3 Terminal strip, earth
1X5 Terminal strip, 24 V AC
Figs. 1.15 and 1.16 Electrical diagrams, GA Workplace / Workplace FF - 50 Hz with star-delta starter
(typical example)
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Instruction book
1.4 Elektronikon I regulator
GA Pack and Pack FF are provided with the Elektronikon I regulator (Fig. 1.17).
1 Stop button 8 General alarm LED

2 Start button 9 Pictograph, alarm
3 Display 10 Automatic operation LED
4 Reset key 11 Pictograph, automatic operation
5 Enter key 12 Downwards scroll key
6 Voltage on LED 13 Upwards scroll key
7 Pictograph, voltage on S3 Emergency stop button
Fig. 1.17 Control panel, Elektronikon I
1.4.1 Main functions

1.4.1.1 Automatic control of the compressor
The regulator maintains the net pressure between programmable limits by automatically loading and
unloading the compressor. A number of programmable settings, e.g. the unloading and loading
pressures, the minimum stop time and the maximum number of motor starts are taken into account.
The regulator stops the compressor whenever possible to reduce the power consumption and restarts it
automatically when the net pressure decreases.
1.4.1.2 Protecting the compressor

Shut-down
If the compressor element outlet temperature exceeds the programmed shut-down level, the compressor
will be stopped. This will be indicated on display (3). The compressor will also be stopped in case of
overload of the drive motor (M1) and, for air-cooled compressors, also the fan motor (M2).
2920 1460 03 - 23 -
Instruction book
Shut-down warning
If the compressor element outlet temperature or dewpoint temperature (Full-Feature) exceeds a
programmed value below the shut-down level, this will also be indicated to warn the operator before the
shut-down level is reached.
Service warning
If the service timer exceeds a programmed value, this will be indicated to warn the operator to carry out
some service actions.
1.4.1.3 Automatic restart after voltage failure

For compressors leaving the factory, this function is made inactive. If desired, the function can be
activated. Consult Atlas Copco.
Warning
If activated and provided the module was in the automatic operation mode, the compressor will
automatically restart if the supply voltage to the module is restored within a programmed time period.
1.4.2 Control panel (Fig. 1.17)

Ref. Designation Function
1 Stop button Push button to stop the compressor. LED (10) goes out. The
compressor will stop after running in unloaded condition for
about 30 seconds.
2 Start button Push button to start the compressor. LED (10) lights up
indicating that the regulator is operative (in automatic
operation).
3 Display Indicates the compressor operating condition, actually
measured values and programmed parameters.
4 Reset key Key to reset the service timer, a shut-down condition, etc.
5 Enter key Key to select or validate a parameter, to open a sub-display or
to return to a previous display.
6 Voltage on LED Indicates that the voltage is switched on.
7 Pictograph Voltage on
8 General alarm LED Is alight if a warning condition exists.
8 General alarm LED Blinks in case of a shut-down or emergency stop condition.
9 Pictograph Alarm
10 Automatic operation LED Indicates that the regulator is automatically controlling the
compressor: the compressor is loaded, unloaded, stopped and
restarted depending on the air consumption and the limitations
programmed in the regulator.
11 Pictograph Automatic operation
12 Downwards scroll key Key to scroll downwards through the screens or to decrease a
setting.
13 Upwards scroll key Key to scroll upwards through the screens or to increase a
setting.
S3 Emergency stop button Push button to stop the compressor immediately in case of
emergency. After remedying the trouble, unlock the button by
pulling it out and press reset key 4.
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Instruction book
1.4.3 Display
Normally, the display shows the operation status of the compressor by means of pictographs and the air
outlet pressure:
bar
6.6
Fig. 1.18 Main screen, typical example
1.4.4 Scrolling through all screens

It is possible to scroll downwards and upwards through a number of screens by means of the
upwards/downwards arrow keys (12 and 13-Fig. 1.17) on the control panel.
1.4.5 Pictographs used on the screen
Pictograph Explanation
Compressor status LOAD (during loaded running, the horizontal arrow blinks)
Compressor status UNLOAD
Running hours
Element outlet temperature
Dewpoint temperature
Motor or motor overload
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Instruction book
See Fig. 1.20 for denomination of components
Fig. 1.19 Electric cabinet, GA Pack / Pack FF (typical example)
Text on Fig. 1.20
(1) Customer's installation

(2) Option
(3) Dryer option
(4) All other variants
(5) Delta connection: 200-220-230 V 50/60 Hz (see motor data plate for correct connection)
(6) All voltages (50 and 60 Hz) except 440-460 V 60 Hz
(7) Star connection: all other voltages
(8) Remote emergency stop
(9) Option phase sequence relay
(10) Option thermistor protection
(11) Supply of dryer
(12) All other voltages
2920 1460 03 - 26 -
(9) (10)
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(1)
Instruction book
(8)
(2)
(3)
(4)
(6)
(7)
9820 3547 51/02

55439D
(11)
(12)
(5)
(2)
- 27 -
Instruction book
SENSORS/SOLENOID VALVES/ELECTRONIC DRAIN/HEATER

PT20 Pressure sensor, air outlet
Rs Crankcase heater, dryer (Full-Feature)
TT11 Temperature sensor, compressor element outlet
TT90 Temperature sensor, dewpoint (Full-Feature)
MOTORS
M1 Drive motor
M2 Fan motor, compressor coolers (air-cooled compressors)
ELECTRIC CABINET
F1/F11 Fuses
F21 Overload relay, drive motor
K11 Auxiliary contactor for dryer (Full-Feature)
K21 Line contactor
K22 Star contactor
K23 Delta contactor
Q15 Circuit breaker, fan motor (air-cooled compressors)
T1/T2 Transformers
T3 Transformer, dryer
1X0/8 Terminal strips
CONTROL MODULE (E1)

I Start button
K01 Blocking relay
K02 Auxiliary relay, star contactor
K03 Auxiliary relay, delta contactor
K04 Auxiliary relay, load/unload
K05 Auxiliary relay, dryer
K06 Auxiliary relay, shut-down
0 Stop button
MOTORS
M1 Drive motor
M2 Fan motor
OPTIONAL EQUIPMENT
A1 Dryer (Full-Feature)
B1 Electronic water drain (EWD)
K25 Phase sequence protection
M3 Fan motor, electric cabinet (high ambient temperature)
PDS11 Pressure switch, DD/PD filter
R1/K34 Drive motor thermistor protection, shut-down
R2 Drive motor thermistor protection, warning
R3/R4 Heaters, freeze protection
R5 Heater, electronic water drain
R6 Heater, OSD
R7 Heater, cubicle
R96 Anti-condensation heater
S10 Main power isolating switch
TSLL91 Thermostat, cubicle freeze protection
Y2 Solenoid valve, modulating control
Y51 Water shut-off valve (water-cooled versions)
Fig. 1.20 Electrical diagram, GA Pack/Pack FF-50 Hz with star-delta starter (typical example)
2920 1460 03 - 28 -
Instruction book
1.5 Air dryer

GA Pack FF, GA Workplace FF with IFD and GA Workplace FF with ICD are provided with a dryer which
removes condensate from compressed air.
1.5.1 GA Pack FF and GA Workplace FF with IFD (Fig. 1.6)

Compressed air circuit
Compressed air enters heat exchanger (5) and is cooled by the outgoing, dried air. Moisture in the
incoming air starts to condense. The air then flows through heat exchanger (6) where the refrigerant
evaporates withdrawing heat from the air. This cools the air to close to the evaporating temperature of the
refrigerant. More water in the air condenses. The cold air then flows through condensate trap (MT) which
separates condensate from the air. The condensate is automatically drained through outlet (Da). The
cold, dried air then flows through heat exchanger (5), where it is warmed up by the incoming air.
Refrigerant circuit
Compressor (M1) delivers high-pressure refrigerant gas which flows through condenser (10) where most
of the refrigerant condenses. The liquid flows through filter (11) to capillary tube (9). The refrigerant
leaves the capillary tube at evaporating pressure.
The refrigerant enters evaporator (6) where it withdraws heat from the compressed air by further
evaporation. The heated refrigerant leaves the evaporator and is sucked in by compressor (M1).
1.5.2 GA Workplace FF with ICD (Fig. 1.7)

The dryer has two towers containing desiccant. This desiccant is a very porous grain material that can
adsorb large amounts of water vapour. While the desiccant of one tower is drying the compressed air, the
desiccant of the other tower is being regenerated and vice versa. Regeneration of the desiccant is
achieved by means of purge air from the drying tower. The operation cycle of the dryer is repetitive and is
controlled by the compressor regulator and PDP sensor.
Compressed air circuit

The compressed air entering the dryer is led to one of the towers by means of 3-way valve (15). This 3-
way valve is controlled by pneumatic actuator (16). As the air flows upwards through the tower, the
desiccant adsorbs the water vapours and the compressed air is dried. The dry compressed air leaves the
dryer via the non-return valve (CV1 or CV2) on top of the drying tower.
Regeneration circuit
A small quantity of dried air is branched off from the dryer outlet and expanded to atmospheric pressure.
This purge air flows downwards through the desiccant bed of the regenerating tower. As the vapour
pressure of the purge air is much lower than that of the desiccant, the moisture is forced out of the
desiccant. The wet purge air is discharged to atmosphere via exhaust valve (17 or 19) and silencer (18 or
20).
Control air circuit

A second small portion of dried air flows via control air valve (22), air filter (21) and on 13 bar units
pressure regulator (PR) to solenoid valves (Y2 and Y3). When one of the solenoid valves is energized, the
control air is fed to pneumatic actuator (16) and exhaust valve (17 or 19).
PDP sensor (PDP) measures the pressure dewpoint of the compressed air leaving the drying tower. As
soon as the pressure dewpoint exceeds the setpoint, the Elektronikon regulator will shift towers, i.e. the
regenerated tower starts drying the compressed air and the other tower will be regenerated.
2920 1460 03 - 29 -
Instruction book
2 INSTALLATION
2.1 Dimension drawings (Figs. 2.1 and 2.2)
(1) Bypass (dryer version)

(2) Compressor cooling air outlet
(3) Dryer cooling air outlet

(4) Compressed air outlet
(5) Dryer cooling air inlet
(6) Compressor cooling air inlet
(7) Water cooled water outlet
(8) Water cooled water inlet
(9) Energy recovery water outlet
(10) Energy recovery water inlet
(11) Passage for OSD (option)
(12) Automatic drain (option)
(13) Manual drain (option)
(14) Electric cable passage
(15) Pack
(16) Workplace
(17) 4 holes diameter 15 in bottom of
forklift slots
(18) Weight
(19) With dryer
(20) Without dryer
(21) Centre of gravity
(22) Compressed air outlet
(23) Important remark: Never lift the
compressor and ICD when mounted
together
(24) Compressor unit
(25) Dryer unit
Fig. 2.1 Dimension drawing, GA Pack (FF) and GA Workplace (FF with IFD)
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Instruction book
Fig. 2.2 Dimension drawing, GA Workplace FF with ICD
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Instruction book
2.2 Installation proposals (Figs. 2.3 up to 2.5)
Ref. Description/recommendation
1 Install the compressor package on a solid, level floor suitable for taking the weight.
2 Position of the compressed air outlet valve.
3 The pressure drop over the delivery pipe can be calculated as follows:
dp = (L x 450 x Qc1.85) / (d5 x P)
dp = pressure drop (recommended maximum = 0.1 bar)

L = length of delivery pipe in m
d = inner diameter of the delivery pipe in mm
P = absolute pressure at the compressor outlet in bar(a)
Qc = free air delivery of the compressor in l/s
It is recommended that the connection of the compressor air delivery pipe is made on top of the
main air net pipe to minimize carry-over of possible remainder of condensate.
4 Ventilation: the inlet grids and ventilation fan should be installed in such a way that any recirculation
of cooling air to the compressor or dryer is avoided. The air velocity to the grids must be limited to 5
m/s. The maximum allowable pressure drop over the cooling air ducts is 30 Pa. If exceeding this
value, a fan is needed at the outlet of the ducts. Consult Atlas Copco.
For air-cooled compressors (Figs. 2.3 and 2.5):
- For alternatives 1 and 3, the required ventilation capacity to limit the compressor room
temperature can be calculated as follows:
Qv = 1.06 N / dT for GA Pack/Workplace/Workplace FF with ICD

Qv = (1.06 N + 4) / dT for GA Pack FF/Workplace FF with IFD
Qv = required ventilation capacity in m³/s

N = nominal motor power of compressor in kW
dT = temperature increase in compressor room in °C
- For alternatives 2 and 4: the fan capacity should match the compressor fan capacity at a
pressure head equal to the pressure drop over the air ducts.
For water-cooled compressors (Fig. 2.4), the required ventilation capacity to limit the compressor
room temperature can be calculated as follows:
Qv = 0.13 N / dT for GA Pack/Workplace

Qv = (0.13 N + 4) / dT for GA Pack FF/Workplace FF with IFD
Qv = required ventilation capacity in m³/s

N = nominal motor power of compressor in kW
dT = temperature increase in compressor room
5 The drain pipes to the drain collector must not dip into the water of the drain collector. Atlas Copco
has oil/water separators (type OSD) to separate the major part of the oil from the condensate to
ensure that the condensate meets the requirements of the environmental codes.
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Instruction book
6 Position of the control panel.
7 Position of the mains cable.
8 Provision for the inlet and outlet of the optional energy recovery system.
9 On GA Pack, GA Pack FF, GA Workplace and GA Workplace FF with IFD

Filter, type DD, for general purpose filtration (optional). The filter traps solid particles down to 1
micron with a max. oil carry-over of 0.5 mg/m³. A high-efficiency filter, type PD (optional), may be
installed downstream of a DD filter. This filter traps solid particles down to 0.01 micron with a max.
oil carry-over of 0.01 mg/m³. If oil vapour and odours are undesirable, a filter of the QD type
(optional) should be installed downstream of the PD filter.
It is recommended to provide by-pass pipes and valves over the filters to isolate the filters during
maintenance without disturbing the compressor.
On GA Workplace FF with ICD

Filters with regard to filtration of oil and particles are included in the package. If oil vapour and
odours are undesirable, a filter of the QD type (optional) should be installed downstream of the
dryer.
It is recommended to provide by-pass pipes and valves over the filter to isolate the filter during
maintenance without disturbing the compressor.
10 The air receiver (optional) should be installed in a frost-free room on a solid, level floor.
For normal air consumption, the volume of the air net (receiver and piping) can be calculated as
follows:
V = (0.25 x Qc x P1 x To) / (fmax x dP x T1)
V = volume of air net in l

Qc = free air delivery of compressor in l/s
P1 = compressor air inlet pressure in bar absolute
fmax = cycle frequency = 1 cycle/30 s
dP = Punload - Pload in bar
T1 = compressor air inlet temperature in K
To = air receiver temperature in K
11 On GA Pack FF, GA Workplace and GA Workplace FF with IFD

Optional dryer by-pass pipe.
On GA Workplace FF with ICD

Dryer by-pass pipe.
12 On GA Pack FF and GA Workplace FF with IFD, an optional condensate trap by-passing the
dryer is available.
13 For water-cooled compressors (Fig. 2.4): position of cooling water pipes.
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Instruction book
Fig. 2.3 Installation proposal for air-cooled GA Pack (FF) and GA Workplace (FF with IFD) compressors
Text on Fig. 2.3
(1) Compressor
(2) Ventilation proposals
(3) Minimum free area
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Instruction book
Fig. 2.4 Installation proposal for water-cooled GA Pack (FF) and GA Workplace (FF with IFD)
compressors
Text on Fig. 2.4
(1) Compressor
(2) Cooling systems
(3) Minimum free area
2920 1460 03 - 35 -
Instruction book
Text on Fig. 2.5
(2) Ventilation proposals

(3) Minimum free area to be reserved for the
compressor installation
Fig. 2.5 Installation proposal for air-cooled GA Workplace FF with ICD compressors
2.3 Electrical connections

General
- Provide an isolating switch.
- Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals.
- Check the fuses and the setting of the overload relay. See section 7.
- Connect the power supply cables to terminals (L1, L2 and L3-Figs. 1.13, 1.14 and 1.20)
- Connect the earth conductor to earth bolt (PE-Figs. 1.13, 1.14 and 1.19) and the neutral conductor to
connector (N).
2920 1460 03 - 36 -
Instruction book
On GA Pack FF/Workplace FF with IFD (Figs. 1.15 and 1.20):

The voltage supply to the dryer must be 230 V single-phase. The voltage to the dryer is supplied over the
contacts of relay (K11), which close when the compressor is started. For compressor supply voltages
different from 3 x 400 V plus neutral or 3 x 230 V, the power to the dryer is supplied by a transformer.
On GA Workplace FF with ICD (Figs. 1.15/1.16):

The power supply of the dryer is derived from the main voltage supply of the compressor. A multi-voltage
transformer is installed in the dryer cubicle, check that the setting at the primary side of this transformer
corresponds to the supply voltage of the compressor.
2.4 Cooling water requirements

Following requirements are given as a general rule to prevent cooling water problems. If in any doubt,
consult Atlas Copco.
Recommended maxima Recirculating system Pass-through system

Chloride (Cl-) lower than 600 mg/l lower than 150 mg/l
Sulphate (SO4--) lower than 400 mg/l lower than 250 mg/l
Total solids lower than 3000 mg/l lower than 750 mg/l
Suspended solids (as SiO2) lower than 10 mg/l lower than 10 mg/l
Free chlorine (Cl2) lower than 4 mg/l lower than 2 mg/l
Ammonia (NH4+) lower than 0.5 mg/l lower than 0.5 mg/l
Copper lower than 0.5 mg/l lower than 0.5 mg/l
Iron lower than 0.2 mg/l lower than 0.2 mg/l
Manganese lower than 0.1 mg/l lower than 0.1 mg/l
Oxygen lower than 3 mg/l lower than 3 mg/l
Carbonate hardness (as CaCO3) 50-1000 mg/l 50-500 mg/l
Organics (KMnO4 Consumption) lower than 25 mg/l lower than 10 mg/l
No algae
No oil
Remark
Chloride and sulphate are interactive. In pass-through systems the sum of the squares must not exceed
85,000. For recirculating systems with proper controls and treatment, the sum of the squares may be up
to 520,000. Note that the sulphate value must include any sulphite present.
2.5 Pictographs (Fig. 2.6)

Read the warnings attentively and act accordingly.
2920 1460 03 - 37 -
Instruction book
1 Water outlet
2 Manual condensate drain
3 Water inlet
4 Automatic condensate drain
5 Warning: before connecting compressor electrically, consult Instruction book for motor
rotation direction
6 Warning: switch off voltage and depressurize compressor before repairing
7 Torques for steel (Fe) or brass (CuZn) bolts
8 Lightly oil gasket of oil filter, screw it on and tighten by hand (approx. half a turn)
9 Consult Instruction book before greasing
10 Warning: switch off voltage before removing protecting cover inside electric cubicle
11 Consult Instruction book before carrying out maintenance
12 Warning: stop compressor before repairing fans
13 Warning: voltage
14 Warning: potential risk of sudden releasing of spring underneath cover of unloader during
disassembling, have possible repairs carried out by Atlas Copco
Fig. 2.6 Pictographs (typical examples)
Note
For compressors equipped with an Elektronikon I regulator, also consult section 1.4.5.
2920 1460 03 - 38 -
Instruction book
3 OPERATING INSTRUCTIONS
3.1 Before initial start-up
3.1.1 Safety
The operator must apply all relevant safety precautions, including those mentioned in this book.
3.1.2 User manual

Read the related "User manual for Elektronikon I and II regulators" as mentioned on the first page of this
book to familiarize yourself with all regulator functions.
3.1.3 Outdoor/altitude operation

If the compressor is installed outdoors or if the air inlet temperature can be below 0 degrees Celsius,
precautions must be taken. In this case, and also if operating at high altitude, consult Atlas Copco.
3.1.4 Moving/lifting
The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks
protrude from the other side of the frame. The compressor can also be lifted after inserting beams in the
slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The chains
must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. The
lifting equipment must be placed in such a way that the compressor will be lifted perpendicularly. Lift
smoothly and avoid twisting.
Warning
Never lift a GA Workplace FF with ICD package; compressor module and ICD module must be lifted
separately.
3.2 External compressor status indication/remote control (Elektronikon II)
GA Workplace and Workplace FF are provided with the Elektronikon II regulator (Fig. 1.11). These
regulators allow:
- external indication of the compressor status
- remote control of the compressor
3.2.1 External compressor status indication

Auxiliary contacts (K07, K08 and K09) are provided at the back of the electronic module (Fig. 1.11) for
external indication of:
- manual load/unload or automatic operation (K07)
- warning condition (K08)
- shut-down condition (K09)
Maximum load for these contacts: 1 A / 250 V AC.
Attention
Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas
Copco.
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Instruction book
3.2.2 Remote control

Consult the User manual for Elektronikon I and II regulators (Part 2, section 14.1) if it is desired to switch
to another control mode.
Attention
Have the modifications checked by Atlas Copco. Stop the compressor and switch off the voltage before
connecting external equipment. Only voltage-free contacts are allowed.
Following control modes can be selected:
3.2.2.1 Local control

The compressor will react to commands entered by the buttons on the control panel. Compressor
start/stop commands via function “Clock function” are active, if programmed.
3.2.2.2 Remote control

The compressor will react to commands from external switches. Emergency stop button (S3-Fig. 1.11)
remains active. Compressor start/stop commands via function “Clock function” are still possible.
For remote starting and stopping: Connect a start/programmed stop button between terminals 30 and 33
of terminal strip (1X6-Fig. 1.15).
Bridge terminals 30 and 34: In this mode, the outlet pressure is still sensed by pressure transducer
(PT20), resulting in loading and unloading of the compressor at the pressures programmed in the
electronic regulator. If terminals 30 and 34 are not bridged, the compressor is switched out of automatic
load/unload operation and remains running unloaded.
For remote loading/unloading (via external pressure switch): Bridge terminals 30 and 35 and connect a
load/unload switch between terminals 30 and 34. This results in loading and unloading of the compressor
at the closing and opening pressures of the external pressure switch respectively.
3.2.2.3 LAN control

The compressor can be controlled via a LAN (local area network). Consult Atlas Copco.
3.3 Remote starting/stopping (Elektronikon I)

GA Pack and Pack FF are provided with the Elektronikon I regulator (Fig. 1.17). These regulators allow
remote starting and stopping.
Attention
Stop the compressor and switch off the voltage before connecting external equipment. Only voltage-free
contacts are allowed. Have the modifications checked by Atlas Copco.
Remote starting and stopping: connect a start/programmed stop button between terminals 30 and 33 of
terminal strip (1X6-Fig. 1.20).
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Instruction book
1 Transport bolt, to be removed AF Air filter

2 Transport support, to be removed AR Air receiver/oil separator
3 Vibration damper DP1 Oil drain plug
FC Oil filler plug
Gl Oil level gauge
OF Oil filter
SV Safety valve
1 Transport spacer, to be removed
2 Vibration damper
Fig. 3.1 Transport fixations, motor side Fig. 3.2 Oil system components and transport
fixations
3.4 Initial start-up

1. For GA Workplace FF with ICD, build the compressor and dryer together as described in the
assembly instruction 2920 1515 00
2. Following transport fixations, painted red, must be removed:
- spacers (3-Fig. 3.2) from both gear casing supports
- spacers (1-Fig. 3.2) from both air receiver supports
- support (2-Fig. 3.1)
On GA Pack FF and GA Workplace FF with IFD compressors, if a transformer (T3-Figs. 1.15/1.20)
is provided, also remove the spacers underneath this transformer.
3. Check that the electrical connections correspond to the local codes and that all wires are clamped
tight to their terminals. The installation must be earthed and protected against short circuits by
fuses of the inert type in all phases. An isolating switch must be installed near the compressor.
4. Check transformer (T1-Figs. 1.13, 1.14 and 1.19) for correct connection, the settings of drive motor
overload relay (F21) and, on air-cooled compressors, fan motor circuit breaker (Q15) (on water-
2920 1460 03 - 41 -
Instruction book
cooled compressors, circuit breaker (Q15) is installed but not in operation; check that the switch on
the circuit breaker is in position "I"). Also check that overload relay (F21) is set for automatic
resetting.
5. Fit air outlet valve (AV-Figs. 3.3, 3.4 and 3.8). Close the valve. On compressors with dryer by-
pass, fit valve (AV1). Connect the air net to the valve(s).
6. Connect the manual condensate drain valve (Dm-Figs. 3.3, 3.4 and 3.8) (not provided on GA Pack).
Close the valve. Connect the valve to a drain collector.
7. Connect the automatic drain outlet (Da-Figs. 3.3, 3.4 and 3.8) (not provided on GA Pack) to a drain
collector.
8. On water-cooled compressors, drain valves, shut-off valves and a regulating valve should be fitted
by the customer in the cooling water piping.
9. Check the oil level. The pointer of level gauge (Gl-Fig. 3.2) should register in the green or orange
range.
10. Provide labels, warning the operator that:
- the compressor may automatically restart after voltage failure (if activated, consult Atlas Copco)
- the compressor is automatically controlled and may be restarted
11. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of
the drive motor (M1-Fig. 1.3) and fan motor (M2-Fig. 1.3) (on air-cooled compressors) while the
motor is coasting to a stop.
The correct rotation direction of the drive motor is indicated by an arrow provided on the gear
casing. If the rotation direction is wrong, switch off the voltage and reverse two incoming electric
lines.
Rotation arrows, visible through the grating in the roof, are provided on the plate below the fan to
indicate the correct rotation direction of the fan motor. If necessary, switch off the voltage and
reverse two incoming electric connections at the terminals of circuit breaker (Q15-Figs. 1.13, 1.14
and 1.19).
12. Check the programmed settings. Consult the User manual for the Elektronikon I and II regulators.
13. On GA Workplace FF with ICD:
- Open the dryer by-pass valve (AV1-Fig. 3.4)
- Close the dryer inlet valve (1-Fig. 3.5)
- Close the dryer outlet valve (AV-Fig. 3.4)
- Close the air supply valve towards the PDP sensor (23-Fig. 1.7)
14. Start and run the compressor for a few minutes. Check that the compressor operates normally.
15. On GA Workplace FF with ICD:
- Slowly open the dryer inlet valve (1-Fig. 3.5)
- Check the dryer connections for air leaks
- Let the dryer operate for several hours with the dryer outlet valve closed
- Gradually open the dryer outlet valve and close the by-pass valve.
- Open the air supply valve towards the PDP sensor
3.5 Before starting

Attention
- If the compressor has not run for the past 6 months, it is strongly recommended to improve the
lubrication of the compressor element at starting: Remove bolts (2-Fig. 5.2), lift unloader (UA) and
pour 3/4 l of oil into the compressor element. Reinstall the unloader. Make sure that all connections
are tight.
- For Workplace FF with IFD and Pack FF, switch on the voltage 4 hours before starting to energize the
crankcase heater of the refrigerant compressor of the dryer.
- For Workplace FF with ICD, if the compressor has not been used for 3 months, refer to steps 13 up to
15 of chapter 3.4 (Initial start-up).
1. Check the oil level (Gl-Fig. 3.2). The pointer should register in the upper field of the green range or in
the orange range. If the pointer registers in the red range (low range), stop the compressor and
2920 1460 03 - 42 -
Instruction book
switch off the voltage. Depressurize the oil system by unscrewing oil filler plug (FC) one turn. Remove
the plug and add oil until the level reaches the filler opening. Fit and tighten the plug.
2. If necessary, empty the dust trap of air filter (AF-Fig. 3.2).
3. If the coloured part of service indicator (VI-Fig. 5.2) shows full out, replace air filter element (AF).
Reset the service indicator by pushing the knob in the extremity of the body.
On water-cooled compressors also:

4. Check that the cooling water drain valves in the inlet and outlet pipes are closed.
5. Open the cooling water inlet valve.
6. Open the water flow regulating valve. This step can be overlooked if, after previous operation, the
setting of this valve has not been disturbed.
On GA Workplace FF with ICD also:

7. Close the dryer inlet valve (1-Fig. 3.5).
8. Close the air supply valve towards the PDP sensor (23-Fig. 1.7).
9. Close the dryer outlet valve (AV-Fig. 3.4).
AV Air outlet valve

Fig. 3.3 GA37 Workplace FF with IFD
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AV Air outlet valve, dry compressed air

AV1 Air outlet valve, dryer by-passed
Fig. 3.4 GA37 Workplace FF with ICD
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Instruction book
1 Shut off valve, dryer inlet
Fig. 3.5 View of ICD dryer
3.6 Operating GA Workplace/Workplace FF

1 Stop button
2 Start button
3 Display
4 Scroll keys
5 Tabulator key
6 Voltage on LED
7 General alarm LED
8 Automatic operation LED
9 Function keys
10 Pictograph, alarm
11 Pictograph, automatic operation
12 Pictograph, voltage on
Fig. 3.6 Control panel, Elektronikon II
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Instruction book
3.6.1 Starting
1. Switch on the voltage. Check that voltage on LED (6-Fig. 3.6) lights up.
2. On GA Workplace and GA Workplace FF with IFD, open air outlet valve (AV-Fig. 3.3).
3. Close condensate drain valve (Dm-Figs. 3.3 and 3.4).
4. Press start button (2-Fig. 3.6). The compressor starts running and automatic operation LED (8) lights
up. Ten seconds (programmable) after starting, the drive motor switches over from star to delta. At
the same time (programmable), the compressor starts running loaded. The message on display (3)
changes from "Auto unloaded" to "Auto loaded".
For water-cooled compressors also:

5. If necessary, regulate the cooling water flow during loaded running to obtain the most suitable
temperature at the outlet of the compressor element, i.e. between 2 and 7 degrees Celsius above the
relevant temperature in Fig. 3.7. For optimum operation, the cooling water outlet temperature must
never exceed the value specified in section 7.6. Consult Atlas Copco if condensate should be formed
during frequent unloading periods.

6. Slowly open the dryer inlet valve (1-Fig. 3.5).
7. Gradually open the dryer outlet valve (AV-Fig. 3.4).
8. Close the by-pass valve (AV1-Fig. 3.4).
9. Open the shut-off valve towards the PDP sensor (23-Fig. 1.7).
Note
The dryer is sensitive to high air flow velocities because this can damage the desiccant. High-speed flow
occurs when a compressor starts against an empty air net. Therefore, the air net must be filled by slowly
opening the dryer outlet valve (AV-Fig. 3.4).
3.6.2 During operation

1. Check the oil level during loaded operation: the pointer of level gauge (Gl-Fig. 3.2) must register in the
green range; if not, press stop button (1-Fig. 3.6), wait until the compressor has stopped. Switch off
the voltage and depressurize the oil system (by unscrewing oil filler plug FC-Fig. 3.2 one turn) and
wait a few minutes. Remove the plug and add oil until the level reaches the filler opening. Fit and
tighten the plug.
2. If the coloured part of service indicator (VI-Fig. 5.2) shows full out, stop the compressor and replace
air filter element (AF-Fig. 3.2). Reset the service indicator by pushing the knob in the extremity of the
body.
3. When automatic operation LED (8-Fig. 3.6) is alight, the regulator is automatically controlling the
compressor, i.e. loading, unloading, stopping of the motors and restarting.
3.6.3 Checking the display

1. Regularly check display (3-Fig. 3.6) for readings and messages. Normally, the display shows the
compressor outlet pressure, the status of the compressor and the abbreviations of the functions of the
keys below the display.
2. Always check display (3-Fig. 3.6) and remedy the trouble if alarm LED (7) is alight or blinks. Consult
the User manual for Elektronikon I and II regulators, Part 2, sections 5 and 15.
3. The display (3) will show a service message if a service plan interval has been exceeded or if a
service level for a monitored component has been exceeded. Carry out the service actions of the
indicated plans or replace the component and reset the relevant timer.
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Warning
Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop
button (S3-Fig. 3.3 and 3.4)), switch off the voltage and depressurize the compressor.
Notes
- Whenever a warning, service request, sensor error or motor overload message is displayed, the free
spaces on the display between function keys (9-Fig. 3.6) are filled with blinking indicators (**).
- When more than one message needs to be displayed (e.g. both warning and service), the messages
will be displayed one after the other for 3 seconds.
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Instruction book
Example:
If operating at a pressure of 10 bar(e) in an ambient temperature of 20 degrees Celsius and at a relative
air humidity of 100 %, the minimum temperature to prevent condensate from forming is 68 degrees
Celsius. Regulate the cooling water flow during loaded operation to obtain a temperature between 70 and
approx. 75 degrees Celsius at the outlet of the compressor element.
Fig. 3.7 Minimum compressor element outlet temperature for water-cooled compressors
3.6.4 Manual control (Fig. 3.6)

Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops
and restarts the compressor automatically. LED (8) is then alight.
Manually unloading
Press key "Unld" (F3). LED (8) goes out. The message "Manual Unload" appears on the display. The
compressor remains running unloaded unless it is loaded again manually.
Manually loading
Press the key "Load" (F3). LED (8) lights up. The command will switch the compressor to automatic
operation again: the compressor will be loaded if the air net pressure drops below the programmed level.
Manually starting
In automatic operation, the regulator limits the number of motor starts. If the compressor is stopped
manually, it must not be restarted manually within 5 minutes after the last stop.
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Instruction book
Note
If the "Load" or "Unld" (unload) function is not indicated on the bottom line of display (3), press key "Menu"
(9) until the function "Main" appears above key (F1), then press the key "Main".
3.6.5 Stopping (Fig. 3.6)

1. Press stop button (1). LED (8) goes out. The message "Programmed stop" appears. The
compressor runs unloaded for 30 seconds and then stops. On GA Workplace FF with ICD, the dryer
towers will be depressurised automatically.
2. To stop the compressor in case of emergency, press button (S3-Fig. 3.3). Alarm LED (7) blinks.
After remedying the fault, unlock the button by pulling it out and press key "Rset" (9) before restarting.
The message "All conditions are OK" appears. Press keys "Menu" and "Main".
3. Close air outlet valve (AV- Figs. 3.3 and 3.4) and switch off the voltage.
4. Open condensate drain valve (Dm-Figs. 3.3 and 3.4).
On water-cooled compressors only

5. Close the cooling water inlet valve.
6. If freezing temperatures may be expected, drain the cooling system completely.
AV Air outlet valve

Fig. 3.8 GA30 Pack FF
3.7 Operating GA Pack/Pack FF

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Instruction book
1 Stop button
2 Start button
3 Display
4 Reset key
5 Enter key
6 Voltage on LED
7 Pictograph, voltage on
8 General alarm LED
9 Pictograph, alarm
10 Automatic operation LED
11 Pictograph, automatic operation
12 Downwards scroll key
13 Upwards scroll key
3.7.1 Starting (Fig. 3.9)

1. Switch on the voltage. Check that voltage on LED (6) lights up.
2. Open air outlet valve (AV-Fig. 3.8).
3. On GA Pack FF, close condensate drain valve (Dm-Fig. 3.8).
4. Press start button (2). The compressor starts running and automatic operation LED (10) lights up.
Ten seconds after starting, the drive motor switches over from star to delta and the compressor starts
running loaded.
For water-cooled compressors also:

5. If necessary, regulate the cooling water flow during loaded running to obtain the most suitable
temperature at the outlet of the compressor element, i.e. between 2 and 7 degrees Celsius above the
relevant temperature in Fig. 3.7. For optimum operation, the cooling water outlet temperature must
never exceed the value specified in section 7.6. Consult Atlas Copco if condensate should be formed
during frequent unloading periods.
3.7.2 During operation

1. Check the oil level during loaded operation: the pointer of level gauge (Gl-Fig. 3.2) must register in
the green range; if not, press stop button (1-Fig. 3.9), wait until the compressor has stopped,
depressurize the oil system (by unscrewing oil filler plug FC-Fig. 3.2 one turn) and wait a few minutes.
Remove the plug and add oil until the level reaches the filler opening. Fit and tighten the plug.
2. If the coloured part of service indicator (VI-Fig. 5.2) shows full out, replace air filter element (AF-Fig.
3.2). Reset the service indicator by pushing the knob in the extremity of the body.
3. When automatic operation LED (10) is alight, the regulator is automatically controlling the compressor,
i.e. loading, unloading, stopping of the motors and restarting.
3.7.3 Checking the display

1. Regularly check display (3-Fig. 3.9): the compressor status is indicated by pictographs; see section
1.4.5.
2. Remedy the trouble if alarm LED (8) is alight or blinks. Consult the User manual for Elektronikon I
and II regulators, Part 1, sections 4 up to 7.
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Warning
Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop
button (S3-Fig. 3.8), switch off the voltage and depressurize the compressor.
3.7.4 Stopping
1. Press stop button (1-Fig. 3.9). LED (10) goes out. The compressor runs unloaded for 30 seconds
and then stops.
2. To stop the compressor in case of emergency, press button (S3-Fig. 3.8). Alarm LED (8) and a
pictograph representing the button blink. After remedying the fault, unlock the button by pulling it out
and press key (4) before restarting.
3. Close air outlet valve (AV- Fig. 3.8) and switch off the voltage.
4. On GA Pack FF, open condensate drain valve (Dm-Fig. 3.8).
On water-cooled compressors only

5. Close the cooling water inlet valve.
6. If freezing temperatures may be expected, drain the cooling system completely.
3.8 Taking out of operation at end of compressor service life

At the end of the service life of the compressor, proceed as follows:
1. Stop the compressor and close the air outlet valve.

2. Switch off the voltage and disconnect the compressor from the mains.
3. Depressurize the compressor by opening plug (FC-Fig. 3.2) one turn and by opening valve (Dm-Figs.
3.3, 3.4 and 3.8).
4. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the
compressor air outlet pipe from the air net.
5. If provided, isolate and disconnect the water system from the cooling water net.
6. Drain the oil, water (if provided) and condensate circuits.
7. Disconnect the condensate piping from the condensate net.
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4 MAINTENANCE
Attention
Apply all relevant safety precautions, including those mentioned in this book.
Before starting any maintenance or repairs:

1. Press the stop button (1-Figs. 3.6 and 3.9), wait until the compressor has stopped (approx. 30
seconds), press emergency stop button and switch off the voltage.
2. Close air outlet valve (AV-Figs. 3.3, 3.4 and 3.8) and depressurize by opening valve (Dm-Figs. 3.3,
3.4 and 3.8) (not provided on GA Pack) and by opening plug (FC-Fig. 3.2) one turn.
3. The air outlet valve (AV) can be locked during maintenance or repair as follows:
4. Close the valve.
- Remove the bolt fixing the handle.
- Lift the handle and turn it until the slot of the handle fits over the blocking edge on the valve body.
- Lock the handle using the special bolt and wrench delivered loose with the compressor.
4.1 Drive motor (M1- Fig. 1.3)

Attention
- Never mix greases of different brands or types.
- The bearings must be regreased each 4000 operating hours. The lubrication points are marked.
For GA30-45 / GA W 30-45

Recommended grease: Atlas Copco Roto-Glide (ordering number 2908 8513 00 for a 400 g grease
cartridge).
Quantity: 15 g (11 g for non-drive end side of GA30/GA W 30)
For GA55C with ABB motor

Recommended grease: Special high-quality ball bearing grease available from Atlas Copco (ordering
number 2901 0338 01 for a 400 g grease cartridge).
Quantity: 16 g
4.2 Service actions for GA Pack/Pack FF

Besides the daily and 3-monthly checks, the service operations are grouped in time intervals (running
hours); see section 4.4.
The regulator has a programmable service timer. When the timer reaches the programmed interval, LED
(8-Fig. 3.9) will light up. Press key (12-Fig. 3.9), “r000” appears. Press key (5-Fig. 3.9), “S” (S standing
for “Service”) appears. In this case, check the running hours. Carry out the service operations
corresponding to the running hours as specified in the schedule of section 4.4. Reset the service timer
after servicing. For detailed information, consult the User manual for Elektronikon I and II regulators, Part
1, section 6.
Important
If using mineral oil instead of Atlas Copco Roto-injectfluid, the service timer interval has to be decreased:
500 running hours for 13 bar (175 psi) units and 1000 running hours for 7.5-10 bar (100-150 psi) units.
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Instruction book
4.3 Service plans for GA Workplace/Workplace FF

Besides the daily and 3-monthly checks, the service operations are grouped in plans, called Service plans
A, B, C or D; see section 4.4. Each plan has a programmed time interval at which all service actions
belonging to that plan are to be carried out.
When reaching the interval, a message will appear on the screen indicating which Service plans are to be
carried out. After servicing, the intervals are to be reset. For detailed information, consult the User
manual for Elektronikon I and II regulators, Part 2, sections 5, 12 and 15.
Important
Always consult Atlas Copco in case any timer setting should be changed.
4.4 Preventive maintenance schedule 1)
Period See section See notes below table Service operation

Daily 3 - Check oil level
" 3 and 7 - Check readings on display
" -- - Check that condensate is discharged
during loading
" 3 - Check air filter service indicator
“ 3 - Check for cooling water flow (water-cooled
compressors)
“ 3 - Drain condensate
On GA Workplace FF with ICD also
Check the pressure dewpoint temperature
3-monthly 5 - Check coolers and condenser of dryer;

clean if necessary
" 5 1 Remove air filter element. Clean by air jet
and inspect
Service actions
Running See See notes Service plan Service operation

hours section below (GA
table Workplace)
4000 4 2/4 A If Atlas Copco Roto-injectfluid is used, change oil
and oil filter
For GA 13 bar (175 psi) compressors:
500 4 2/4/3 A If oil as specified in section 4.5.2 is used, change
oil and oil filter
For GA 7.5 - 10 bar (100 - 150 psi)
compressors:
1000 4 2/4/3 A If oil as specified in section 4.5.2 is used, change
oil and oil filter
4000 -- - B Check pressure and temperature readings

" -- - B Carry out a LED/display test
" -- 6 B Check for possible air, oil or water leakage
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Running See See notes Service plan Service operation

hours section below (GA
table Workplace)
" 4 and 5 2 B Replace air filter element
" -- - B Remove, dismantle and clean float valve of
condensate trap
“ 4 - B Re-grease bearings of drive motor as specified
" -- - B Test temperature shut-down function
“ 5 - B Test safety valve
For GA Workplace FF with ICD:
“ -- - B Replace the silencers of the dryer
“ -- - B Replace the elements of the IPD and DDp filters
8000 -- 5 C Replace oil separator

“ -- 7 C Exchange the dewpoint sensor

40000 -- 8 D Have the desiccant of the ICD dryer replaced
Notes
1. More frequently when operating in a dusty atmosphere. Replace damaged or heavily contaminated
elements.
2. Use genuine Atlas Copco filters.
3. For GA Workplace/Workplace FF, the interval for Service plan A is to be reduced to the mentioned
interval in case mineral oil is used instead of Roto-injectfluid.
4. Recommended oil: Atlas Copco Roto-injectfluid. For the change interval in extreme conditions of
temperature, humidity or cooling air, consult Atlas Copco.
5. Or when the pressure drop over the separator exceeds 1 bar. Check the pressure drop when the
compressor is running loaded and preferably with a stable working pressure.
6. Any leakage should be attended to immediately. Damaged flexibles or flexible joints must be
replaced.
7. The certificate is only one year valid; for updating consult your Atlas Copco customer centre.
8. At normal working conditions, the lifetime of the desiccant is approximately 5 years
4.5 Oil specifications

Attention
Never mix oils of different brands or types. Use only non-toxic oils.
4.5.1 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.
Roto-injectfluid can be ordered in following quantities:
Roto-injectfluid Ordering number

20 litre can 2901 0522 00
209 litre drum 2901 0045 01
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Instruction book
4.5.2 Mineral oil

Although Roto-injectfluid is recommended, mineral oil can be used after taking following precautions:
- the previously used oil should first be drained and the system flushed
- the oil filter should be replaced
- the oil must meet the requirements as specified below
High-quality, mineral oil with oxidation inhibitors and anti-foam and anti-wear properties. The viscosity
grade must correspond to the ambient temperature and ISO 3448, as follows:
Ambient temperature Viscosity grade Viscosity index
Consistently above 25 degrees Celsius ISO VG 68 Minimum 95

Between 25 and 0 degrees Celsius ISO VG 46 Minimum 95
4.6 Oil change

1. Run the compressor until warm. Stop the compressor and depressurize by unscrewing filler plug (FC-
Fig. 3.2) one turn to permit any pressure in the system to escape. Wait a few minutes and remove
plug (FC) and vent plug (VP-Fig. 1.3).
2. Drain the oil by removing drain plugs (DP1, DP2 and DP3- Figs. 3.2 and 5.2). Fit and tighten all drain
plugs as well as vent plug (VP). Deliver the oil to the local oil collection service.
3. Fill receiver (AR-Fig. 3.2) with oil until the level reaches the filler neck. Take care that no dirt drops
into the system. Fit and tighten plug (FC).
4. Run the compressor for a few minutes. Stop the compressor and wait a few minutes to allow the oil to
settle. Depressurize by unscrewing filler plug (FC-Fig. 3.2) one turn to permit any pressure in the
system to escape. Fill the receiver with oil until the level reaches the filler neck. Tighten plug (FC).
5. Reset the oil service warning. Consult the User manual for Elektronikon I and II regulators: Part 1,
section 7 for Elektronikon I or Part 2, section 15 for Elektronikon II.
4.7 Oil filter change

1. Run the compressor unloaded for 3 minutes.
2. Stop the compressor and depressurize by unscrewing filler plug (FC-Fig. 3.2) one turn to permit any
pressure in the system to escape.
3. Remove vent plug (VP-Fig. 1.3), wait 5 minutes, remove drain plug (DP2-Fig. 5.2) and catch the oil in
a receptacle.
4. Remove oil filter (OF-Fig. 3.2).
5. Clean the filter seat on the manifold. Oil the gasket of the new element. Screw the element into place
and tighten firmly by hand.
6. Remove plug (FC-Fig. 3.2) and fill with oil until the level reaches the filler opening.
7. Tighten plugs (FC-Fig. 3.2), (VP-Fig. 1.3) and (DP2-Fig. 5.2).
8. Reset the oil filter service warning. Consult the User manual for Elektronikon I and II regulators: Part
1, section 7 for Elektronikon I or Part 2, section 15 for Elektronikon II.
4.8 Storage after installation

Run the compressor twice a week until warm. Load and unload the compressor a few times. If the
compressor is stored without running from time to time, protective measures must be taken. Consult Atlas
Copco.
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4.9 Service kits

Service kits are available offering the benefits of genuine Atlas Copco parts while keeping the
maintenance budget low. The kits comprise all parts needed for servicing.
See sections 4.1 and 4.5.1 for the ordering numbers for the motor grease and Roto-injectfluid respectively.
Service kit for oil filters and air filters Ordering number
GA30 all versions 2901 0325 00
GA37 10-13 bar
GA37 125-150-175 psi
GA45/GA55C 13 bar
GA45/GA55C 175 psi
GA37 7.5-8 bar, GA37 100 psi 2901 0326 00

GA45/GA55C 7.5-8-10 bar, GA45/GA55C 100-125-150 psi
GA30/45/55C 2901 0566 00
Service kit for ICD dryers
Service plan B and C

ICD100 2901 1000 00
ICD140 2901 1002 00
ICD170 2901 1004 00
Service plan D
ICD100 2901 1001 00
ICD140 2901 1003 00
ICD170 2901 1005 00
Footnote chapter 4
1) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability. 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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5 ADJUSTMENTS AND SERVICING PROCEDURES

5.1 Air filter (AF-Fig. 5.1)
1. Stop the compressor. Switch off the voltage. Release the snap clips of the filter and remove the dust
trap and air filter element. Clean the trap. Discard the air filter element.
2. Fit the new element and the trap.
3. Reset service indicator (VI-Fig. 5.2) by pushing the knob in the extremity of the body.
4. Reset the air filter service warning. Consult the User manual for Elektronikon I and II regulators: Part
1, section 7 for Elektronikon I or Part 2, section 15 for Elektronikon II.
AF Air filter
AR Air receiver
SV Safety valve
Fig. 5.1 Air filter and receiver
5.2 Coolers
Keep the coolers clean to maintain the cooling efficiency.
On air-cooled compressors
Remove any dirt from the coolers with a fibre brush. Never use a wire brush or metal objects. Then clean
by air jet in reverse direction of normal flow while covering all compressor parts under the coolers. If it is
necessary to wash the coolers with a cleansing agent, consult Atlas Copco.
On water-cooled compressors
Consult Atlas Copco for cleaning.
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5.3 Safety valve (SV-Fig. 5.1)

Operate the safety valve, depending on the type of valve:
- by unscrewing the cap one or two turns and retightening it
- or by pulling the valve lifting lever
Testing
The valve can be tested on a separate compressed air line. If the valve does not open at the set pressure
stamped on the valve, consult Atlas Copco.
Warning
No adjustments are allowed. Never run the compressor without safety valve.
AF Air filter
BV Oil cooler by-pass valve
CV Check valve
DP2 Oil drain plug, oil stop valve
DP3 Oil drain plug, check valve
E Compressor element
UA Unloader
UV Unloading valve
VI Air filter service indicator
Vs Oil stop valve
1 Air inlet flexible
2 Bolt
3 Warning: potential risk of sudden
releasing of spring underneath cover
of unloader during disassembling,
have possible repair carried out by
Atlas Copco
4 Vibration damper
Fig. 5.2 Unloader and compressor element
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6 PROBLEM SOLVING
If alarm LED (7-Fig. 3.6) is alight or blinks, consult the User manual, Part 2, sections 5 and 15.
If alarm LED (8-Fig. 3.9) is alight or blinks, consult the User manual, Part 1, sections 4 up to 7.
Attention
Apply all relevant safety precautions, including those mentioned in this book.
Before starting any maintenance or repairs:

1. For GA Workplace/Workplace FF, press stop button (1-Fig. 3.6), wait until the compressor has
stopped (approx. 30 seconds), press emergency stop button (S3-Fig. 3.3 and 3.4) and switch off the
voltage.
For Pack/Pack FF, press stop button (1-Fig. 3.9), wait until the compressor has stopped (approx. 30
seconds), press emergency stop button (S3-Fig. 3.8) and switch off the voltage.
2. Close air outlet valve (AV-Figs. 3.3, 3.4 and 3.8) and depressurize by opening plug (FC-Fig. 3.2) one
turn and by opening valve (Dm-Figs. 3.3, 3.4 and 3.8) (not provided on GA Pack).
3. The air outlet valve (AV-Figs. 3.3, 3.4 and 3.8) can be locked during maintenance or repair as follows:
- Close the valve.
- Remove the bolt fixing the handle.
- Lift the handle and turn it until the slot of the handle fits over the blocking edge on the valve body.
- Lock the handle using the special bolt and wrench delivered loose with the compressor.
Mechanical faults and suggested remedies (Figs. 1.6, 1.7 and 1.8)
1 Compressor starts running, but does not load after a delay time
a Solenoid valve (Y1) out of order
a Replace valve
b Inlet valve (IV) stuck in closed position
b Have valve checked
c Leak in control air flexibles
c Replace leaking flexible
d Minimum pressure valve (Vp) leaking (when net is depressurized)
d Have valve checked
2 Compressor does not unload, safety valve blows

a Solenoid valve (Y1) out of order
a See 1a
b Inlet valve (IV) does not close
b See 1b
3 Condensate is not discharged from condensate trap during loading

a Discharge flexible clogged
a Check and correct as necessary
b Float valve malfunctioning
b Remove float valve assembly, clean and check
4 Compressor air output or pressure below normal

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 See 1a
d Leak in control air flexibles
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d See 1c
e Inlet valve (IV) does not fully open
e See 1b
f Oil separator element (OS) clogged
f Have element replaced
g Air leakage
g See 1c
h Safety valve (SV) leaking
h Replace valve
i Compressor element (E) out of order
i Consult Atlas Copco
5 Excessive oil flow through air inlet filter after stopping

a Check valve (CV) leaking or oil stop valve (Vs) jammed
a Replace defective parts. Replace air filter element (AF)
6 Safety valve (SV) blows after loading

a Inlet valve (IV) malfunctioning
a See 1b
b Minimum pressure valve (Vp) malfunctioning
b See 1d
c Oil separator element (OS) clogged
c See 4f
d Safety valve (SV) out of order
d See 4h
e On Full-Feature with IFD, dryer piping clogged because of ice formation
e Have refrigerant system checked by Atlas Copco
7 Element outlet or air outlet temperature above normal

a Insufficient cooling air or cooling air temperature too high
a Check for cooling air restriction or improve ventilation of compressor room. Avoid recirculation of
cooling air. If installed, check capacity of compressor room fan. On water-cooled compressors, check
cooling water flow; if necessary, have system cleaned
b Oil level too low
b Check and correct as necessary
c Oil cooler (Co) clogged
c Clean cooler
d By-pass valve (BV) malfunctioning
d Have valve tested
e Air cooler (Ca) clogged
e Clean cooler
f Compressor element (E) out of order
f See 4i
8 Pressure dewpoint temperature to high

a The dryer is not yet regenerated
a Close the dryer outlet valve and have the desiccant regenerated
b Free water in compressed air inlet
b Check that condensate separators and drains upstream of the dryer are operative
c Air flow through the dryer too high
c Correct as necessary
d Outlet pressure too low
d Check whether the compressor provides enough air for the application
e Compressed air temperature at dryer inlet too high
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e Check compressor aftercooler
9 The dryer produces a lot of noise

a Silencers defective or connected badly
a Check the silencers and their fixations
10 Insufficient air leaves the dryer

a Too much purge air flow
a Check the condition of solenoid valves, pneumatic valves and 3-way valve. Replace if defective.
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7 PRINCIPAL DATA
7.1 Readings on display (Figs. 1.11/1.17)
Ref. Reading
Air outlet pressure Modulates between programmed unloading and loading
pressures
Compressor element outlet temperature Approx. 60 degrees Celsius above cooling air temperature
or above cooling water inlet temperature
Pressure dewpoint temperature

GA Pack FF Approx. 4°C
GA Workplace FF with IFD Approx. 4°C
GA Workplace FF with ICD - 40 °C
GA Workplace FF with ICD (-70 °C variant) - 70°C
7.2 Electric cable size

Attention
- Local regulations remain applicable if they are stricter than the values proposed below.
- The voltage drop must not exceed 5 % of the nominal voltage. It may be necessary to use cables with
a larger section than those stated to comply with this requirement.
- The values below apply to Full-Feature compressors.
Frequency Voltage (V) GA30 Cable GA37 Cable GA45 Cable GA55C Cable
(Hz) size size size size
(mm²/AWG) (mm²/AWG) (mm²/AWG) (mm²/AWG)
IEC
50/60 230 70 95 120 120
50/60 380 35 50 50 -
50 400 35 35 50 70
50 500 25 25 35 50
CSA/UL
60 220/230 AWG000/2x 2x AWG1 2x AWG0 2x AWG00
AWG3
60 440/460 AWG3 AWG2 AWG00 AWG1
60 575 AWG4 AWG3 AWG2 AWG1
2920 1460 03 - 62 -
Instruction book
7.3 Motor overload relay (F21) and fuses
Frequency Voltage GA30 GA30 GA37 GA37 GA45 GA45 GA55C GA55C
(Hz) (V) F21 Fuses (A) F21 (A) Fuses (A) F21 Fuses (A) F21 (A) Fuses
(A) (A) (A)
IEC
50 230 67.2 160 79 200 97.3 200 118.9 250
50 400 38.8 100 45.6 100 56.1 125 68.2 160
50 500 31.1 80 36.1 80 44.9 100 54.7 125
60 220/230 68.2 160 81.7 200 100 250 121.6 300
60 440/460 34.1 80 40.9 100 50 125 60.8 125
60 380 40.9 100 48.3 125 59.1 125 - -
CSA/UL
60 220/230 68.2 200 (CSA) 81.7 225 100 250 (CSA) 121.6 300
2x 100 (CSA) 2x 2x 125 (CSA)
(UL) 110 (UL) (UL) 2x 150
(UL)
60 440/460 34.1 100 (CSA) 40.9 110 50.0 150 (CSA) 60.8 175
90 (UL) (CSA) 125 (UL) (CSA)
100 (UL) 150 (UL)
60 575 27.0 80 (CSA) 32.1 100 39.2 125 (CSA) 46.6 150
70 (UL) (CSA) 90 100 (UL) (CSA)
(UL) 125 (UL)
7.4 Fan motor circuit breaker (Q15) (air-cooled compressors)
GA30/45 GA55C
Q15 (A) Q15 (A)
IEC
50 230 4.7 8.0
50 400 2.7 4.7
50 500 2.2 3.8
60 220/230 4.2 9.7
60 440/460 2.4 5.6
CSA/UL
60 220/230 4.2 9.7
60 440/460 2.4 5.6
60 575 1.9 4.4
7.5 Dryer switches (Pack FF/Workplace FF with IFD)
Condenser fan control switch

- Cut-out pressure bar(e) 16.7
- Switch-on pressure bar(e) 18
Shut-down switch bar(e) 31
2920 1460 03 - 63 -
Instruction book
7.6 Compressor specifications

7.6.1 Reference conditions
Air inlet pressure (absolute) bar 1

Air inlet temperature Celsius 20
Relative humidity % 0
Working pressure bar(e) See nominal values below
On water-cooled units also:

Cooling water inlet temperature Celsius 20
7.6.2 Limitations
Maximum working pressure bar(e) See maximum values below

Minimum working pressure bar(e) 4
Maximum air inlet temperature Celsius 40
Minimum air inlet temperature Celsius 0
On water-cooled units also:

Max. cooling water outlet temperature Celsius 50
Max. cooling water inlet temperature Celsius 40
(GA30/45 W)
Max. cooling water inlet temperature Celsius 35
(GA55 C W)
Max. cooling water inlet pressure bar(e) 5
7.6.3 GA30 / GA30 W Pack/Workplace 2)
Compressor 7.5 bar 8 bar 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi
type
Frequency Hz 50 50 50 50 60 60 60 60
Maximum bar(e) 7.5 8 10 13 7.4 9.1 10.8 12.5
(unloading)
pressure
Nominal working bar(e) 7 8 9.5 12.5 6.9 8.6 10.3 12
pressure
Temperature of °C 29 29 29 29 29 29 29 29
air leaving outlet
valve, approx.
Drive motor, 1 LA 1 LA 1 LA 1 LA 1 LA 1 LA 1 LA 1 LA
SIEMENS 5189-2 5189-2 5189-2 5189-2 5189-2 5189-2 5189-2 5189-2
Motor shaft r/min 2955 2955 2955 2955 3555 3555 3555 3555
speed
Power input, GA kW 35.8 36.5 35.4 36.4 35.3 37.2 35 36
Power input, GA kW 34.7 35.3 34.2 35.2 34 36 33.8 34.8
W
Oil capacity, GA l 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.6
Oil capacity, GA l 17.9 17.9 17.9 17.9 17.9 17.9 17.9 17.9
W
2920 1460 03 - 64 -
Instruction book
type
Mean sound dB 65 65 65 64 65 65 65 64
pressure level 3)
Cooling water l/min 32 32 32 32 32 32 32 32
consumption,
GA W 4)
consumption,
GA W 5)
7.6.4 GA30 / GA30 W Pack FF/Workplace FF with IFD 2)
type
Frequency Hz 50 50 50 50 60 60 60 60
Maximum bar(e) 7.25 7.75 9.75 12.75 7.15 8.85 10.55 12.25
(unloading)
pressure
Nominal working bar(e) 7 7.75 9.5 12.5 6.9 8.6 10.3 12
pressure
Temperature of °C 25 25 25 25 25 25 25 25
air leaving outlet
valve, approx.
SIEMENS 5189-2 5189-2 5189-2 5189-2 5189-2 5189-2 5189-2 5189-2
Motor shaft r/min 2955 2955 2955 2955 3555 3555 3555 3555
speed
Power input, GA kW 38 38.1 37.6 38.5 37.8 39.9 37.7 38.3
Power input, GA kW 36.8 36.9 36.4 37.4 36.6 38.5 36.4 37.1
W
Oil capacity, GA l 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.6
Oil capacity, GA l 17.9 17.9 17.9 17.9 17.9 17.9 17.9 17.9
W
Mean sound dB 65 65 65 64 65 65 65 64
pressure level 3)
consumption,
GA W 4)
consumption,
GA W 5)
Refrigerant type R404a R404a R404a R404a R404a R404a R404a R404a
Refrigerant kg 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
charge
Pressure °C 4 4 4 4 4 4 4 4
dewpoint,
approx. 6)
2920 1460 03 - 65 -
Instruction book
type
Frequency Hz 50 50 50 50 60 60 60 60
Maximum bar(e) 7.5 8 10 13 7.4 9.1 10.8 12.5
(unloading)
pressure
pressure
Temperature of °C 29 29 29 29 29 29 29 29
air leaving outlet
valve, approx.
SIEMENS 5209-2 5209-2 5209-2 5209-2 5209-2 5209-2 5209-2 5209-2
Motor shaft r/min 2960 2960 2960 2960 3560 3560 3560 3560
speed
Power input, GA kW 44.9 45.5 44 44.2 45.3 44.7 45 44.2
Power input, GA kW 43.7 44.4 42.8 43.1 43.8 43.5 43.7 43
W
Oil capacity, GA l 16.3 16.3 16.3 16.3 16.3 16.3 16.3 16.3
Oil capacity, GA l 17.9 17.9 17.9 17.9 17.9 17.9 17.9 17.9
W
Mean sound dB 66 66 66 65 66 66 66 65
pressure level 3)
consumption,
GA W 4)
consumption,
GA W 5)
type
Frequency Hz 50 50 50 50 60 60 60 60
Maximum bar(e) 7.25 7.75 9.75 12.75 7.15 8.85 10.55 12.25
(unloading)
pressure
pressure
Temperature of °C 25 25 25 25 25 25 25 25
air leaving outlet
valve, approx.
SIEMENS 5209-2 5209-2 5209-2 5209-2 5209-2 5209-2 5209-2 5209-2
Motor shaft r/min 2960 2960 2960 2960 3560 3560 3560 3560
speed
Power input, GA kW 47.6 47.6 46.8 47 48.4 47.9 48 47.3
Power input, GA kW 46.5 46.5 45.6 45.8 47 46.7 46.8 46.1
W
2920 1460 03 - 66 -
Instruction book
type
Oil capacity, GA l 16.3 16.3 16.3 16.3 16.3 16.3 16.3 16.3
Oil capacity, GA l 17.9 17.9 17.9 17.9 17.9 17.9 17.9 17.9
W
Mean sound dB 66 66 66 65 66 66 66 65
pressure level 3)
consumption,
GA W 4)
consumption,
GA W 5)
Refrigerant kg 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3
charge
Pressure C 4 4 4 4 4 4 4 4
dewpoint,
approx. 6)
type
Frequency Hz 50 50 50 50 60 60 60 60
Maximum bar(e) 7.5 8 10 13 7.4 9.1 10.8 12.5
(unloading)
pressure
pressure
Temperature of °C 29 29 29 29 29 29 29 29
air leaving outlet
valve, approx.
Drive motor, 1 LA 9 1 LA 9 1 LA 9 1 LA 9 1 LA 9 1 LA 9 1 LA 9 1 LA 9
SIEMENS 209-2 209-2 209-2 209-2 209-2 209-2 209-2 209-2
Motor shaft r/min 2965 2965 2965 2965 3565 3565 3565 3565
speed
Power input, GA kW 53.1 51.1 53.8 54.8 54.4 53.8 53.8 53.9
Power input, GA kW 51.9 49.9 52.6 53.6 52.7 52.6 52.6 52.7
W
Oil capacity l 17.9 17.9 17.9 17.9 17.9 17.9 17.9 17.9
Mean sound dB 67 67 67 66 67 67 67 66
pressure level 3)
consumption,
GA W 4)
consumption,
GA W 5)
2920 1460 03 - 67 -
Instruction book
type
Frequency Hz 50 50 50 50 60 60 60 60
Maximum bar(e) 7.25 7.75 9.75 12.75 7.15 8.85 10.55 12.25
(unloading)
pressure
pressure
Temperature of °C 25 25 25 25 25 25 25 25
air leaving outlet
valve, approx.
SIEMENS 9209-2 9209-2 9209-2 9209-2 9209-2 9209-2 9209-2 9209-2
Motor shaft r/min 2965 2965 2965 2965 3565 3565 3565 3565
speed
Power input, GA kW 56.3 53.5 57 58.1 58.2 57.6 57.7 57.8
Power input, GA kW 55.2 52.3 55.8 56.9 56.5 56.3 56.4 56.5
W
Oil capacity l 17.9 17.9 17.9 17.9 17.9 17.9 17.9 17.9
Mean sound dB 67 67 67 66 67 67 67 66
pressure level 3)
consumption,
GA W 4)
consumption,
GA W 5)
Refrigerant kg 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4
charge
Pressure °C 4 4 4 4 4 4 4 4
dewpoint,
approx. 6)
7.6.9 GA55C / GA55C W Pack/Workplace 2)
Compressor type 7.5 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi
bar
Frequency Hz 50 50 50 60 60 60 60
Maximum (unloading) bar(e) 7.5 10 13 7.4 9.1 10.8 12.5
pressure
Nominal working bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
pressure
Temperature of air Celsius 30 30 30 30 30 30 30
leaving outlet valve,
approx.
Drive motor, ABB M3AA- M3AA- M3AA- M3AA- M3AA- M3AA- M3AA-
200 200 200 200 200 200 200
MLE-2 MLE-2 MLE-2 MLE-2 MLE-2 MLE-2 MLE-2
Motor shaft speed r/min 2975 2975 2975 3575 3575 3575 3575
2920 1460 03 - 68 -
Instruction book
Compressor type 7.5 10 bar 13 bar 100 psi 125 psi 150 psi 175 psi
bar
Power input kW 64.8 66.1 65.8 66.3 66 65.7 67.5
Oil capacity l 17.9 17.9 17.9 17.9 17.9 17.9 17.9
Mean sound pressure dB 73/70 73/70 73/70 75/74 75/74 75/74 75/74
level, Pack/Workplace 3)
Cooling water l/min 54.5 54.5 54.5 54.5 54.5 54.5 54.5
consumption, GA W 1)
7.6.10 GA55C / GA55C W Pack FF/Workplace FF with IFD 2)
Compressor type 7.5 10 bar 13 bar 100 psi 125 psi 150 psi 175
bar psi
Frequency Hz 50 50 50 60 60 60 60
Maximum (unloading) bar(e) 7.25 9.75 12.75 7.15 8.85 10.55 12.25
pressure
Nominal working bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
pressure
Temperature of air Celsius 25 25 25 25 25 25 25
leaving outlet valve,
approx.
Drive motor, ABB M3AA- M3AA- M3AA- M3AA- M3AA- M3AA- M3AA-
200 200 200 200 200 200 200
MLE-2 MLE-2 MLE-2 MLE-2 MLE-2 MLE-2 MLE-2
Motor shaft speed r/min 2975 2975 2975 3575 3575 3575 3575
Power input kW 68.2 69.5 69.2 70.6 69.4 70 71.8
Oil capacity l 17.9 17.9 17.9 17.9 17.9 17.9 17.9
Mean sound pressure dB 73/70 73/70 73/70 75/74 75/74 75/74 75/74
level, Pack
FF/Workplace FF 3)
Refrigerant type R404a R404a R404a R404a R404a R404a R404a
Refrigerant charge kg 1.4 1.4 1.4 1.4 1.4 1.4 1.4
Pressure dewpoint, Celsius 4 4 4 4 4 4 4
approx. 6)
Cooling water l/min 54.5 54.5 54.5 54.5 54.5 54.5 54.5
consumption, GA W 1)
7.7 Specifications of ICD dryer 2)

7.7.1 Pressure dewpoint –40°C variant
7.7.1.1 For compressors with a working pressure up to 10 bar
Dryer type ICD100 ICD140 ICD170C
Volume flow at dryer inlet l/s
- 7 bar 100 140 170
- 8 bar 110 154 187
- 9 bar 120 168 204
- 10 bar 130 182 221
Pressure drop over the dryer bar 0.2 0.2 0.2
Regeneration air consumption % 18 18 18
Amount of desiccant per vessel kg 50 70 85
2920 1460 03 - 69 -
Instruction book
7.7.1.2 For compressors with a working pressure of 13 bar

Volume flow at dryer inlet l/s 124 176 215
7.7.2 Pressure dewpoint –70°C variant

7.7.2.1 For compressors with a working pressure up to 10 bar
Volume flow at dryer inlet l/s
- 7 bar 80 112 136
- 8 bar 88 123 149
- 9 bar 96 134 163
- 10 bar 104 145 176
7.7.2.2 For compressors with a working pressure of 13 bar

Volume flow at dryer inlet l/s 99 141 172
7.8 Conversion list of SI units into US/British units

1 bar = 14.504 psi
1 g = 0.035 oz
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 l/s = 2.117 cfm
1 mm = 0.039 in
1 mbar = 0.401 in water column
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x degrees Celsius = (32 + 1.8 x) degrees Fahrenheit 7)
Footnotes chapter 7
1) Maximum cooling water inlet temperature (35 degrees Celsius) and temperature rise of 15 degrees
Celsius.
2) At reference conditions.
3) According to PNEUROP PN8NTC2.2.
4) At water inlet temperature below 25 degrees Celsius and temperature rise of 15 degrees Celsius.
5) At water inlet temperature between 25 and 40 degrees Celsius and temperature rise of 10 degrees
Celsius.
2920 1460 03 - 70 -
Instruction book
6) At 20 degrees Celsius / 100% relative humidity.

7) A temperature difference of 1 degree Celsius = a temperature difference of 1.8 degrees Fahrenheit.
2920 1460 03 - 71 -
Instruction book
8 INSTRUCTIONS FOR USE OF AIR RECEIVER
1. This vessel can contain pressurized air; be aware of its potential danger in case of misuse.
2. This vessel shall only be used as compressed air/oil separator and be operated within the specified
limits as mentioned on the data plate.
3. No alterations shall be made to this vessel by welding, drilling or other methods of mechanical work
without written permission of the manufacturer.
4. Original bolts have to be used after opening for inspection. The maximum torque has to be taken into
consideration: for M12 bolts 73 Nm (+/- 18), for M16 bolts 185 Nm (+/- 45).
5. Pressure and temperature of this vessel must be clearly indicated.
6. The safety valve must correspond with pressure surges of 1.1 times the maximum allowable operating
pressure. It should guarantee that the pressure will not permanently exceed the maximum allowable
operating pressure of the vessel.
7. Use only oil as specified by the manufacturer.
8. This vessel has been designed and built to guarantee an operational lifetime in excess of 20 years
and an infinite number of pressure load cycles. Therefore, there is no intrinsic need for in service
inspection of the vessel when used within the design limits and in its intended application. However,
national legislation may require in service inspection.
9 PED
9.1 Components subject to 97/23/EC Pressure Equipment Directive
Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to Category II
Part number Description PED Class

0832 1000 74 Safety valve IV
1613 9665 99 Vessel II
9.2 Overall rating

The compressors are conform to PED category II.
2920 1460 03 - 72 -
O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................
SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations 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.
In addition to normal safety rules which should be observed with stationary If necessary, install a suction duct. Never obstruct the air inlet. Care
air compressors and equipment, the following safety directions and shall be taken to minimize the entry of moisture with the inlet air.
precautions are of special importance.
4. The aspirated air shall be free from flammable fumes or vapours,
When operating this unit, the operator must employ safe working practices e.g. paint solvents, that can lead to internal fire or explosion.
and observe all related local work safety requirements and ordinances.
5. Air-cooled units shall be installed in such a way that an adequate
The owner is responsible for maintaining the unit in a safe operating flow of cooling air is available and that the exhausted air does not
condition. Parts and accessories shall be replaced if unsuitable for safe recirculate to the inlet.
operation.
6. Arrange the air intake so that loose clothing of people cannot be
Installation, operation, maintenance and repair shall only be performed sucked in.
by authorized, trained, competent personnel.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
Normal ratings (pressures, temperatures, time settings, etc.) shall be air dryer or air net is free to expand under heat and that it is not in
durably marked. contact with or close to flammable material.
Any modification on the compressor or air dryer shall only be performed
8. No external force may be exerted on the air outlet valve; the connected
in agreement with Atlas Copco and under supervision of authorized,
pipe must be free of strain.
competent personnel.
If any statement in this book, especially with regard to safety, does not 9. If remote control is installed, the unit shall bear an obvious sign
comply with local legislation, the stricter of the two shall apply. reading:
These precautions are general and cover several machine types and DANGER: This machine is remotely controlled and may start
equipment; hence some statements may not apply to the unit(s) described without warning.
in this book.
As a further safeguard, persons switching on remotely controlled
units shall take adequate precautions to ensure that there is no one
Installation checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed: 10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
1. A compressor or air dryer shall be lifted only with adequate equipment instrument panel.
in conformity with local safety rules.
11. In multiple compressor systems manual valves shall be installed to
Loose or pivoting parts shall be securely fastened before lifting. It is isolate each compressor. Non-return valves (check valves) shall not
strictly forbidden to dwell or stay in the risk zone under a lifted load. be relied upon for isolating pressure systems.
Lifting acceleration and retardation shall be kept within safe limits.
12. Never remove or tamper with the safety devices, guards or insulations
W ear a safety helmet when working in the area of overhead or lifting
fitted on the unit. Every pressure vessel or auxiliary installed outside
equipment.
the unit to contain air above atmospheric pressure shall be protected
2. Any blanking flanges, plugs, caps and desiccant bags shall be by a pressure-relieving device or devices as required.
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working 13. Pipework or other parts with a temperature in excess of 80 degrees
pressure. celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
3. Place the unit where the ambient air is as cool and clean as possible. pipework shall be clearly marked.
2920 1377 03 1/2 (continued on inside of cover)

SAFETY PRECA UTIONS (continued)
14. If the ground is not level or can be subject to variable inclination, 5. Never use flammable solvents or carbon tetrachloride for cleaning
consult Atlas Copco. parts. Take safety precautions against toxic vapours of cleaning
liquids.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses. 6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
Operation clean cloth, paper or tape.
1. Air hoses shall be of correct size and suitable for the working pressure. 7. Never weld or perform any operation involving heat near the oil
Never use frayed, damaged or deteriorated hoses. Use only the correct system. Oil tanks must be completely purged, e.g. by steam-cleaning,
type and size of hose end fittings and connections. When blowing before carrying out such operations.
through a hose or air line, ensure that the open end is held securely.
A free end will whip and may cause injury. Make sure that a hose is Never weld on, or in any way modify, pressure vessels.
fully depressurized before disconnecting it.
Whenever there is an indication or any suspicion that an internal
Never play with compressed air. Do not apply it to your skin or part of a machine is overheated, the machine shall be stopped but no
direct an air stream at people. Never use it to clean dirt from your inspection covers shall be opened before sufficient cooling time
clothes. When using it to clean equipment, do so with extreme caution has elapsed; this to avoid the risk of spontaneous ignition of the oil
and use eye protection. vapour when air is admitted.
2. The compressor is not considered as capable of producing air of Never use a light source with open flame for inspecting the interior
breathing quality. For breathing air quality, the compressed air must of a machine, pressure vessel, etc.
be adequately purified according to local legislation and standards.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes. 9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
4. Never operate the units at pressures below or in excess of their limit and that the control and shut-down devices function correctly. If
ratings as indicated on the Principal Data sheet. removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear 10. Every time the separator element is renewed, examine the discharge
protectors when opening a door. pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors. 11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
7. Periodically check that:
a. All guards are in place and securely fastened 12. Make sure that all sound-damping material, e.g. on the bodywork
b. All hoses and/or pipes inside the unit are in good condition, secure and in the air inlet and outlet systems of the compressor, is in good
and not rubbing condition. If damaged, replace it by genuine Atlas Copco material
c. There are no leaks to prevent the sound pressure level from increasing.
d. All fasteners are tight
e. All electrical leads are secure and in good order 13. Never use caustic solvents which can damage materials of the air
.
f Safety valves and other pressure-relief devices are not obstructed net, e.g. polycarbonate bowls.
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, 14. The following safety precautions are stressed when handling
valves, hoses, etc. are in good repair, free of wear or abuse refrigerant:
8. If warm cooling air from compressors is used in air heating systems, a. Never inhale refrigerant vapours. Check that the working area
e.g. to warm up a workroom, take precautions against air pollution is adequately ventilated; if required, use breathing protection.
and possible contamination of the breathing air.
b. Always wear special gloves. In case of refrigerant contact with
9. Do not remove any of, or tamper with, the sound-damping material. 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
Maintenance refrigerant is flushed away; then seek medical first aid.
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job. c. Always wear safety glasses.
1. Use only the correct tools for maintenance and repair work. 15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be Note: W ith stationary machine units driven by an internal combustion
undertaken when the unit is stopped, the main power supply is engine, allowance has to be made for extra safety precautions, e.g. spark
switched off and the machine has cooled down. Take positive arrestors, fuelling care, etc. Consult Atlas Copco.
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in All responsibility for any damage or injuryresulting from neglecting
progress; do not start" shall be attached to the starting equipment. these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
4. Before removing any pressurized component, effectively isolate the not expressly mentioned in this book, will be disclaimed by Atlas
unit from all sources of pressure and relieve the entire system of Copco.
pressure.
2920 1377 03 2/2

Ga30 55c Instruc Eii

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Instruction book

Atlas Copco Stationary Air Compressors

GA30 - GA37 - GA45 - GA55C

With Elektronikon I and Elektronikon II regulator

Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium.

No. 2920 1460 03

(Replaces 2920 1460 02)

Registration code: APC G30-55C / 38 / 978

2920 1460 03 -1-

2920 1460 03 -2-

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3.7.3 Checking the display ................................................................................................................... 50

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1.1.1 Compressor variants

Fig. 1.1 Elektronikon I regulator Fig. 1.2 Elektronikon II regulator

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Fig. 1.3 Front view of GA37 Workplace Full-Feature with IFD

Fig. 1.4 Front view of GA37 Workplace Full-Feature with ICD

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Fig. 1.5 Rear view of GA37 Workplace Full-Feature with IFD

AF Air filter ER II Elektronikon II regulator

Figs. 1.3 up to 1.5 GA37 Workplace Full-Feature

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1.1.2 Air flow (Figs. 1.6 up to 1.8)

1.1.3 Oil system (Figs. 1.6 up to 1.8)

1.1.4 Cooling system (Figs. 1.6 up to 1.8)

1.1.5 Condensate drain system (Fig. 1.9)

1.2 Unloading/loading system

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Fig. 1.6 GA Workplace Full-Feature with IFD during unloading

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Fig. 1.7 GA Workplace Full-Feature with ICD during loading

(2) AIR INLET

WATER-COOLED PACK (1)

COMPRESSED AIR OUT (2) OIL (5)

AIR INLET (3) WATER (6)

COMPRESSED AIR (4) CONTROL AIR (7)

Fig. 1.8 GA Pack during loading

(1) WATER-COOLED PACK

AF Air filter LP Loading plunger

On GA Pack FF and GA Workplace FF with IFD also

On GA Workplace FF with ICD also

Figs. 1. 6 up to 1.8 Air-oil and unloading-loading systems

Da Automatic condensate drain

Fig. 1.9 Condensate outlets

1.2.2 Loading (Figs. 1.7 and 1.8)

Air output is resumed (100 %), the compressor runs loaded.

AF Air filter ER II Elektronikon II regulator

Fig. 1.10 Water-cooled GA30C Workplace FF

1.3 Elektronikon II regulator

1 Stop button 8 Automatic operation LED

Fig. 1.11 Control panel, Elektronikon II

1.3.1 Main functions

1.3.1.2 Protecting the compressor

1.3.1.3 Automatic restart after voltage failure

1.3.2 Control panel (Fig. 1.11)

Fig. 1.11 Control panel, GA Workplace / GA Workplace FF

Ref. Designation Function

Fig. 1.12 Example of the main display

1.3.4 Calling up other menus