Instruction book for compressors

GA5 - GA7 Pack and Full-feature

GA5 - GA7 - GA10 Standard Pack

Important
This book applies exclusively:
1. To GA5 - GA7 equipped with an electronic regulator as
shown on the left above. For these compressors, this
book must be used together with the "User manual for
electronic regulator for GA5 - GA7 - GA30 - GA37 -
GA45 compressors"
2. To GA5 - GA7 - GA10 with an electro-pneumatic
regulator as shown on the left below.

This instruction book meets the requirements for instructions specified by the machinery
directive 89/392/EEC and is valid for CE as well as non-CE labelled machines

Registration code
Collection: APC G5-10
Tab: 38
Sequence: 0988

Replaces
No. 2920 1206 00

Industrial Air Division No. 2920 1206 01

1995-02 B-2610 Wilrijk - Belgium
 Industrial Air Division

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

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

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

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

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

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

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

Contents

Page Page
1 Leading particulars .......................................................... 3 3.5 Manual control for GA Pack / Full-feature ................... 22
1.1 General description .................................................... 3 3.6 Stopping ................................................................. 22
1.1.1 Air flow .......................................................... 3 3.7 Taking out of operation at end of compressor
1.1.2 Oil system ...................................................... 3 service life .............................................................. 22
1.1.3 Cooling and condensate drain systems ............. 4
4 Maintenance .................................................................. 22
1.2 Unloading/loading system ........................................... 5
4.1 Compressor motor ................................................... 22
1.2.1 Unloading ...................................................... 5
4.2 Preventive maintenance schedule for the compressor . 23
1.2.2 Loading ......................................................... 5
4.3 Oil and oil filter change interval ................................. 24
1.3 Electrical system for GA Pack / Full-feature .................. 7
4.4 Oil specifications ..................................................... 24
1.4 Electronic control module for GA Pack / Full-feature ...... 7
4.4.1 Atlas Copco Roto-injectfluid ........................... 24
1.4.1 Electronic regulator ......................................... 7
4.4.2 Mineral oil .................................................... 24
1.4.2 Control panel ............................................... 10
4.5 Oil change .............................................................. 24
1.5 Electrical system for GA Standard Pack ...................... 11
4.6 Oil filter change ....................................................... 25
1.5.1 Regulator ...................................................... 11
4.7 Storage after installation ........................................... 25
1.5.2 Control panel ............................................... 13
4.8 Service kits ............................................................. 25
1.6 Air dryer on GA Full-feature ...................................... 13
1.6.1 Compressed air circuit .................................. 13 5 Adjustments and servicing procedures ......................... 25
1.6.2 Refrigerant circuit ......................................... 13 5.1 Air filter ................................................................... 25
5.2 Coolers ................................................................... 25
2 Installation ................................................................... 14 5.3 Safety valve ............................................................ 25
2.1 Dimension drawings ................................................. 14 5.4 Belt set exchange .................................................... 25
2.2 Electric cable size, settings of overload relay and 5.5 Fan control switch on GA Full-feature ........................ 26
main fuses .............................................................. 15 5.6 High pressure shut-down switch on GA Full-feature .... 26
2.3 Installation proposal ................................................. 16 5.7 Expansion valve on GA Full-feature ........................... 26
2.4 Electrical connections .............................................. 18 5.8 Load/unload pressure switch on GA Standard Pack .... 26
2.5 Pictographs ............................................................. 19 5.9 Temperature shut-down switch on GA Standard Pack . 27

6 Problem solving ............................................................ 28

3 Operating instructions ................................................... 20
3.1 Before initial start-up ................................................ 20
7 Principal data ................................................................ 29
3.1.1 Safety precautions ........................................ 20
7.1 Readings ................................................................ 29
3.1.2 User manual (GA Pack / Full-feature only) ...... 20
7.1.1 Readings on display on GA Pack / Full-feature 29
3.1.3 Outdoor/altitude operation ............................. 20
7.1.2 Readings on gauges on GA Standard Pack ..... 29
3.1.4 Handling ...................................................... 20
7.2 Setting of safety valve .............................................. 30
3.1.5 External compressor status indication
7.3 Dryer control switches and refrigerant specifications ... 30
(GA Pack / Full-feature only) .......................... 20
7.4 Compressor specifications ........................................ 30
3.1.6 Compressor control modes (GA Pack /
7.4.1 Reference conditions .................................... 30
Full-feature only) .......................................... 20
7.4.2 Limitations ................................................... 30
3.2 Initial start-up .......................................................... 20
7.4.3 Specifications of GA5 .................................... 31
3.3 Starting ................................................................... 21
7.4.4 Specifications of GA7 .................................... 31
3.4 During operation ...................................................... 21
7.4.5 Specifications of GA10 .................................. 32
3.4.1 Checking the display (GA Pack /
7.5 Conversion list of SI units into British units ................. 32
Full-feature only) .......................................... 21

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1 Leading particulars

1.1 General description GA Full-feature (Figs. 1, 2b and 6a)

GA Full-feature compressors are additionally provided with an air
GA are stationary, single-stage, oil-injected screw compressors dryer integrated in the bodywork. The dryer removes moisture
driven by an electric motor. GA5, GA7 and GA10 are air-cooled. from the compressed air by cooling the air to near freezing point
and automatically draining the condensate. See section 1.6.
GA Standard Pack (Figs. 2a and 9)
1.1.1 Air flow (Fig. 3)
The compressors are enclosed in a sound-insulated bodywork. A
control panel including the start/stop switch is provided. An electric Air drawn through filter (AF) and open inlet valve (IV) into
cabinet comprising the relay-controlled regulator and motor starter compressor element (E) is compressed. The compressed air flows
is located behind this panel. through oil separator (OS), minimum pressure valve (Vp) and air
cooler (Ca) to outlet valve (AV).
GA Pack (Figs. 1, 2b and 6a)
The compressors are enclosed in a sound-insulated bodywork. 1.1.2 Oil system (Fig. 3)
The front panel comprises an electronic control module including Air pressure forces the oil from oil tank (OT) through oil cooler (Co)
the start and stop buttons. An emergency stop button is also and filter (OF) to compressor element (E) and the lubrication
provided. An electric cabinet comprising the motor starter is points.
located behind this panel. An automatic condensate drain system
is provided.

AF. Air filter

Ca. Air cooler
Co. Oil cooler
FN. Fan
MT. Moisture trap
SV. Safety valve
1. Electric cabinet
2. Belts
3. Hose clip
4. Hose
5. Condenser (only Full-feature)

Fig. 1. Side view, GA Pack / Full-feature

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The system comprises a by-pass valve (BV). When the oil

temperature is below 75°C (167°F), there is no oil flow to the oil
cooler. At approx. 90°C (194°F), the valve is closed so that all the
oil passes through the cooler.

1.1.3 Cooling and condensate drain systems (Fig. 1)

The cooling system comprises air cooler (Ca) and oil cooler (Co).
The cooling air is generated by fan (FN).

A moisture trap (MT) is provided in the air outlet system of GA

Pack and Full-feature compressors. 1) The trap is equipped with a
valve for automatic condensate draining during operation (Da-Fig.
2b) and a manually operated valve for draining after stopping the
compressor (Dm1-Fig. 2b).

1) Available as option on GA Standard Pack.

Fig. 2a. Side view, GA Standard Pack

AV. Air outlet valve

Ca. Air cooler
Co. Oil cooler
Da. Automatic condensate drain outlet
Dm1. Manual condensate drain valve
Dm2. Oil drain valve
E. Compressor element
FC. Oil filler plug
M1. Motor
OF. Oil filter
OS. Oil separator
PSR19. Load/unload pressure switch
SG. Oil level sight-glass
Vp. Minimum pressure valve
1. Electric cabinet
2. Transport bolt
3. Transport spacer

Pictographs
4. Warning: voltage
5. Torques for bolts
6. Switch off voltage and depressurize compressor
before repairing

Figs. 2. Side views Fig. 2b. Side view, GA Pack / Full-feature

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1.2 Unloading/loading system (Fig. 3) 1.2.2 Loading

1.2.1 Unloading When the net pressure decreases to the loading pressure, solenoid
valve (Y1) is energized. The plunger of the valve moves against
If the air consumption is less than the air output of the compressor, spring force:
the net pressure increases. When the net pressure reaches the
unloading pressure, solenoid valve (Y1) is de-energized. The 1. Control pressure is fed from oil separator (OS) via solenoid
plunger of the valve returns by spring force: valve (Y1) to loading plunger (LP) and unloading valve (UV).
2. Unloading valve (UV) closes the air blow-off opening. Loading
1. The control pressure present in the chambers of loading plunger (LP) moves downwards and causes inlet valve (IV) to
plunger (LP) and unloading valve (UV) is vented to atmosphere open fully.
via solenoid valve (Y1).
2. Loading plunger (LP) moves upwards and causes inlet valve Air output is resumed (100 %), the compressor runs loaded.
(IV) to close the air inlet opening.
3. Unloading valve (UV) is opened by receiver pressure. The
pressure from oil separator (OS) is released towards unloader
(UA).

Air output is stopped (0 %), the compressor runs unloaded.

AF. Air filter OF. Oil filter 1. Oil scavenging line

AV. Air outlet valve OS. Oil separator element 2. Flexible, control air
BV. Oil cooler by-pass valve OT. Oil tank 3. Belts
Ca. Air cooler PS. Oil pre-separator
Co. Oil cooler PT20. Pressure sensor, air outlet On Full-feature also:
Da. Automatic condensate drain outlet SG. Oil level sight-glass FN1. Fan, dryer condenser
Dm1. Manual condensate drain valve SV. Safety valve M1. Refrigerant compressor
Dm2. Oil drain valve TT11. Temperature sensor, compressor M2. Motor, condenser fan
E. Compressor element element outlet 4. Expansion valve
E1. Control module TT90. Temperature sensor, dewpoint 5. Air/air heat exchanger
FC. Oil filler plug UA. Unloader 6. Air/refrigerant heat exchanger
FN. Fan UV. Unloading valve (evaporator)
IV. Inlet valve Vp. Minimum pressure valve 7. Liquid separator
LP. Loading plunger Vs. Oil stop valve 8. Condenser
M1. Compressor motor Y1. Loading solenoid valve 9. Liquid receiver
MT. Moisture trap
Fig. 3. GA5/7 Pack / Full-feature during loading (see next page)

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1.3 Electrical system for GA Pack / Full-feature

The system comprises:

1. Compressor motor (M1-Fig. 2b)

2. Electronic control module (Fig. 6a)
3. Compressor start button (I) and stop button (O) (Fig. 6a)
4. Emergency stop button (S3-Fig. 6a)
5. Electric cabinet (Fig. 4)
6. Sensors for the compressor element outlet temperature (TT11)
and for the air outlet pressure (PT20)
7. Dewpoint temperature sensor (TT90) for Full-feature
compressors

1.4 Electronic control module for GA Pack / Full-

feature

The control module consists of an electronic regulator and a control

panel.

See legend of Figs. 5 for denomination of components

Fig. 4. Electric cabinet of GA Pack / Full-feature (typical example)

1.4.1 Electronic regulator (E1-Fig. 4)

The regulator has following functions:

Controlling 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 Monitoring components subject to service
periods. The regulator continuously monitors the oil, oil filter, oil separator
and air filter. Each input is compared to programmed time
intervals. If these limits are exceeded, a message will appear on
Protecting the compressor the display (Fig. 6a) to warn the operator to replace the indicated
If the compressor element outlet temperature exceeds the component.
programmed shut-down level, the compressor will be stopped.
This will be indicated on the control panel (Fig. 6a). The Automatic restart after voltage failure
compressor will also be stopped in case of overload of compressor For compressors leaving the factory, this function is made inactive.
motor (M1). If desired, the function can be activated. Consult Atlas Copco.

If the compressor element outlet temperature exceeds a If activated and provided the module was in the automatic
programmed value below the shut-down level, this will also be operation mode, the compressor will automatically restart if the
indicated to warn the operator before the shut-down level is supply voltage to the module is restored within a programmed time
reached. period.

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Fig. 5a. Electrical diagram, GA Pack / Full-feature (50 Hz / star-delta)

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Fig. 5b. Electrical diagram, dryer on GA Full-feature

SENSORS/LOADING SOLENOID VALVE K21. Line contactor K10. Auxiliary relay, dryer
PT20. Pressure sensor, air outlet K22. Star contactor O. Stop button
TT11. Temperature sensor, compressor K23. Delta contactor S3. Emergency stop button
element outlet T1/T2. Transformers 2X1/6. Connectors
TT90. Temperature sensor, dewpoint 1) 1X1. Terminal strip
Y1. Loading solenoid valve 1X2. Terminal strip On GA Full-feature also:
1X4. Terminal strip C1. Capacitor
MOTORS M1. Refrigerant compressor/motor
M1. Compressor motor CONTROL MODULE (E1) M2. Motor, condenser cooling fan
M3. Fan motor 2) I. Start button S3. Control switch, condenser cooling
K01. Blocking relay fan
ELECTRIC CABINET K02. Auxiliary relay, star contactor S6. Thermal overload switch, motor of
F1/F6. Fuses K03. Auxiliary relay, delta contactor refrigerant compressor
F21. Overload relay, compressor motor K04. Auxiliary relay, loading/unloading S7. Shut-down switch, refrigerant high
K11. Auxiliary contactor for dryer 1) K05. Auxiliary relay, high/low air pressure pressure 3)

1) Only for Full-feature compressors.

2) Installed in electric cabinet of compressors designed for high-temperature conditions.
3) If provided.

Figs. 5. Electrical diagrams for GA Pack / Full-feature

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1.4.2 Control panel (Fig. 6a)

To control the compressor and to read and modify programmable

parameters, the regulator is provided with a panel including:

Ref. Designation Function

1 Automatic operation Indicates that the regulator is

LED automatically controlling the
compressor: the compressor is
loaded, unloaded, stopped and
restarted depending on the air
consumption and the limitations
programmed in the regulator.

2 Voltage on LED Indicates that the voltage is

switched on.

3 General alarm LED Is normally out. Is alight or blinks in

case of an abnormal condition. See
below.

4 Display Indicates:
- the name of the sensor of which
the actual reading is displayed
- the unit and actual reading
- messages regarding the S3. Emergency stop button 8. Start button
operating status, a sensor error, 1. LED, automatic operation 9. Stop button
a service need or a fault 2. LED, voltage on 10. Pictograph, emergency
3. LED, general alarm stop
5 Function keys Keys to control and program the 4. Display 11. Pictograph, automatic
compressor. The actual function of 5. Function keys operation
each key is abbreviated and 6. Scroll keys 12. Pictograph, voltage on
indicated on the bottom line. The 7. Tabulator key 13. Pictograph, alarm
most common ones are listed below.
Fig. 6a. Control panel of GA Pack / Full-feature
6 Scroll keys As long as an arrow is shown on the
right side of the display, the key with
the same symbol can be used to
scroll through the display.

Delivery air
7 Tabulator key Key to go to the next field of the
bar 7.0
display.
Auto loaded
Menu More Unld
8 Start button Push button to start the compressor.
LED (1) lights up indicating that the
regulator is operative (in automatic F1 F2 F3
operation). The LED goes out after
unloading the compressor manually. Fig. 6b. Example of the main display

9 Stop button Push button to stop the compressor.

LED (1) goes out. The compressor
Status data
will stop after running in unloaded
↓
condition for 30 seconds.
Main Slct

S3 Emergency stop button Push button to stop the compressor

immediately in case of emergency. F1 F2 F3
Must be unlocked before restarting.
Fig. 6c. Example of a main menu

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General alarm LED (3-Fig. 6a) 1) 1.5 Electrical system for GA Standard Pack
- The LED blinks in case of a shut-down (due to either too high a
compressor element outlet temperature or overload of the The system comprises:
compressor motor); at the same time the shut-down screen 1. Compressor motor (M1-Fig. 2a)
appears. See section 6. After eliminating the cause of the 2. Regulator enclosed in a cabinet (Fig. 7)
trouble and when the abnormal condition has disappeared, 3. Control panel with start/stop switch (S1-Fig. 9)
press key Rset (5). 4. Temperature shut-down switch (TSHH11-Fig. 9)
- The LED blinks and the compressor is shut down if the sensor 5. Load/unload pressure switch (PSR19-Fig. 2a)
of the compressor element (TT11-Fig. 15) is out of order; at the
same time the display will show a fault message. Switch off the 1.5.1 Regulator (Fig. 8)
voltage, depressurize and check the sensor and its wiring.
- The LED is alight in case of a shut-down warning; at the same
The regulator loads, unloads, stops and restarts the compressor
time a warning message appears. Remedy; see section 6.
according to the air consumption, and protects the compressor and
- The LED is alight if the dewpoint sensor (TT90) is out of order
motor from overloads. The unloading and loading pressures are
(on Full-feature compressors); at the same time a fault
the opening and closing pressures respectively of switch (PSR19).
message is shown. Stop the compressor, switch off the
See section 5.8.
voltage, depressurize and check the sensor and its wiring.

Selecting a menu
To facilitate controlling the compressor, menu-driven programs are
implemented in the electronic module. Use the function keys (5) to
select the menus in order to program and monitor the compressor.
The "User manual for electronic regulator for GA5-GA7-GA30-
GA37-GA45 compressors" deals elaborately with all regulator
functions.

Function keys

Abbre- Desig- Function

viation nation

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

hour)
Canc Cancel To cancel a programmed setting when
programming parameters
Del Delete To delete compressor start/stop commands
Lim Limits To show limits for a programmable setting
List List To list programmed start/stop commands (day/
hour)
Load Load To load the compressor manually
Main Main To return from a menu to the main display (Fig.
6b)
Menu Menu Starting from the main display (Fig. 6b), to
initiate the main menu (Fig. 6c) which gives
access to submenus
Starting from a submenu, to return to the main
menu (Fig. 6c)
Mod Modify To modify programmable settings
More More To have a quick look at the compressor status
Prog Program To program modified settings
Rset Reset To reset a timer or message
Rtrn Return To return to a previously shown option or menu
Slct Select To select a submenu or to read more details of
a selection shown on display
Unld Unload To unload the compressor manually

1) Consult the User manual for the electronic regulator, section See legend of Fig. 8 for denomination of components
"Status data submenu".
Fig. 7. Electric cabinet of GA Standard Pack (typical example)

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SWITCHES / LOADING SOLENOID VALVE ELECTRIC CABINET K26. Timer, delayed motor stopping (5
PSR19. Load/unload pressure switch F1/F3. Fuses minutes)
TSHH11. Temperature shut-down switch F21. Overload relay, compressor motor T1. Transformer (if provided)
Y1. Loading solenoid valve K21. Line contactor 1X1/3. Terminal strips
K22. Star contactor
MOTORS
K23. Delta contactor CONTROL PANEL
M1. Compressor motor
K24. Time relay, star-delta starter (10 P1. Hourmeter, motor running time
M2. Fan motor (provided on compres-
seconds) S1. Start/stop switch
sors designed for high-tempera-
ture conditions)
Fig. 8. Electrical diagram for GA Standard Pack with star-delta starter

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Delayed motor stopping

The time relay for delayed motor stopping (K26) limits the
frequency of automatic motor starts by stopping the motor only
after a set time of 5 minutes of uninterrupted unloaded operation.
If the net pressure drops to the loading pressure within the set
unloading time, the compressor will be loaded without stopping.

Compressor temperature shut-down switch (TSHH11)

The switch prevents damage resulting from too high a temperature
at the outlet of the compressor element.

Motor overload relay (F21)

The relay prevents damage resulting from too high a motor current.

1.5.2 Control panel (Fig. 9)

Gp. Gauge indicating the working pressure

P1. Hourmeter indicating the total motor running time
S1. Switch to start or stop the compressor
TSHH11. Gauge/switch, indicating the temperature at the outlet of
the compressor element as well as the shut-down
temperature; the regulator then stops the compressor
1. Pictograph, working pressure
2. Pictograph, outlet temperature of compressor element
3. Pictograph, running hours
4. Pictograph, compressor stop
Fig. 9. Control panel of GA Standard Pack
5. Pictograph, compressor start

1.6 Air dryer on GA Full-feature (Fig. 3)

GA Full-feature are provided with a dryer which removes moisture

from the compressed air. See Fig. 5b for the electrical diagram.

1.6.1 Compressed air circuit 1.6.2 Refrigerant circuit

Compressed air enters heat exchanger (5) and is cooled by the Compressor (M1) delivers high-pressure refrigerant gas which
outgoing, cold, dried air. Water in the incoming air starts to flows via liquid separator (7) through condenser (8) where most of
condense. The air then flows through heat exchanger (6) where the refrigerant condenses. The cooled refrigerant then collects in
the refrigerant evaporates and withdraws heat from the air. This receiver (9).
cools the air to close to the evaporating temperature of the
refrigerant. More water in the air condenses. The cold air then The liquid flows to expansion valve (4) where it expands to
flows through moisture trap (MT) where all the condensate is evaporating pressure. The refrigerant enters evaporator (6) where
separated from the air. The condensate is automatically drained it withdraws heat from the compressed air by further evaporation.
through outlet (Da). The cold dried air then flows through heat The vapour refrigerant leaving evaporator (6) flows into liquid
exchanger (5), where it is warmed up by the incoming air. separator (7) and is sucked in by compressor (M1).

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2 Installation

2.1 Dimension drawings (Figs. 10)

Fig. 10a. Dimension drawing for GA Pack and Full-feature

Fig. 10b. Dimension drawing for GA Standard Pack

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2.2 Electric cable size, settings of overload relay (F21) and main fuses
Attention those stated to comply with this requirement.
- Local regulations remain applicable if they are stricter than the - Max. cable length = 25 m, max. ambient temperature = 40°C,
values proposed below. cables in free air or in raceway, copper conductors.
- The voltage drop must not exceed 5 % of the nominal voltage. - On GA Full-feature, the current to the air dryer is 2.4 A.
It may be necessary to use cables with a larger section than

Compressor type Supply voltage Line current Cable section Overload relay Fuses
(V) (A) (mm²/AWG size) (A) (A)

50 Hz compressors with star-delta starter

GA5 230 22 4 13 35
GA5 400 13 2.5 7.5 20
GA5 500 10 2.5 6 20

GA7 230 29 6 17 35
GA7 400 17 4 10 25
GA7 500 14 2.5 8 20

GA10 230 38 10 22 50
GA10 400 22 6 13 35
GA10 500 18 4 10 25

60 Hz compressors with star-delta starter

GA5 220/230 23 4 13 35
GA5 380 13 2.5 8 25
GA5 440/460 12 2.5 7 20

GA7 220/230 31 6 18 35
GA7 380 18 4 10.5 25
GA7 440/460 16 2.5 9 20

GA10 220/230 38 10 22 50
GA10 380 23 6 14 35
GA10 440/460 19 4 11 25

60 Hz compressors with direct-on-line starter

CSA HRC UL Class K5

GA5 200 - AWG8 26 60 60

GA5 220/230 - AWG8 23 60 60
GA5 440/460 - AWG12 12 30 30
GA5 575 - AWG12 9 30 30

GA7 200 - AWG6 34 80 70

GA7 220/230 - AWG8 30 60 60
GA7 440/460 - AWG10 16 60 60
GA7 575 - AWG12 12 30 30

GA10 200 - AWG6 44 100 100

GA10 220/230 - AWG6 38 80 70
GA10 440/460 - AWG8 23 60 60
GA10 575 - AWG10 19 60 60

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2.3 Installation proposal (Fig. 11)

Fig. 11. Installation proposal, typical example for GA Standard Pack (installation of GA Pack / Full-feature is similar)

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Ref. Description/recommendation Ref. Description/recommendation

1 Install the compressor on a level floor suitable for taking the 4 Ventilation: the inlet grids and ventilation fan should be
weight of the compressor and with a minimum clearance of installed in such a way that any recirculation of cooling air
1.2 m above the unit (except for ventilation proposals 2 and to the compressor or dryer is avoided. The air velocity to
4). the grids must be limited to 5 m/s. The maximum allowable
pressure drop over the cooling air ducts is 30 Pa. If this
2 Position of compressed air outlet valve. pressure drop is exceeded, a fan is needed at the outlet of
the cooling air ducts. The maximum air temperature at the
3 The maximum total pipe length (including interconnecting compressor intake opening is 40°C (minimum 0°C).
piping between compressor and receiver) can be calculated
as follows: The required ventilation to limit the compressor room
temperature can be calculated as follows:
∆P x d 5 x P
L = ________________________
For alternatives 1 and 3: Qv = 0.92 N/ ∆T
450 x Qc 1.85
Qv = required ventilation capacity in m 3/s
L = pipe length in m N = shaft input of compressor in kW
∆P = maximum allowable pressure drop ∆T = temperature increase in compressor room
(recommended 0.1 bar)
d = inner diameter of pipe in mm For alternatives 2 and 4, the fan capacity should match the
P = compressor outlet pressure in bar absolute compressor fan capacity at a pressure head equal to the
Qc = free air delivery of compressor in l/s pressure drop caused by the cooling air outlet ducts.

Fig. 12. Transport fixations

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Ref. Description/recommendation

5 Position of condensate drain flexibles. The flexibles

towards the drain collector must not dip into the water of
the drain collector. Atlas Copco has oil separators to
separate the major part of oil from condensate to ensure
that the condensate meets the requirements of the
environmental codes. Fig. 13a. Supply from phase conductor/neutral conductor

6 Position of control panel.

7 Position of mains cables entry. See section 2.2 for the

recommended electric cables. See section 2.4 for
connecting the power supply.

8 A condensate trap is integrated in the bodywork of GA Pack

/ Full-feature. It is available as option for GA Standard Fig. 13b. Supply from two phase conductors
Pack. It is recommended to provide one.

9 Optional filters can be installed in the pressure line

downstream of the outlet valve:
- A DD filter for general-purpose filtration (filter traps
solid particles down to 1 micron with max. oil carry-
over of 0.5 mg/m³).
- A high-efficiency PD filter (traps solid particles down
to 0.01 micron with max. oil carry-over of 0.01 mg/m³).
A PD filter must be installed downstream of a DD
filter.
- If oil vapour and odours are undesirable, a filter of the Fig. 13c. Separate voltage supply
QD type should be installed downstream of the PD
filter.

- The air receiver (optional) should be installed in a frost-free

room and on a level concrete foundation.

For normal air consumption, the volume of the air net

(receiver and piping) can be calculated as follows:

7.5 x Q x P
______________________________
V =
∆P

V = volume of air net in l

Q = free air delivery of compressor in l/s Fig. 13d. Supply from optional voltage transformer
P = compressor air inlet pressure in bar absolute
∆P = Punload - Pload in bar
Figs. 13. Dryer connections on GA Full-feature

2.4 Electrical connections

General
- The installation must include an isolating switch near to and
visible from the compressor. Make sure that this switch is
open to isolate the compressor from the mains before
carrying out any connection . - The electrical connections must correspond to the local codes.
- See section 2.2 for the size of the electric cables. - The indications on the data plate of the drive motor must
- The installation must be earthed and protected against short correspond to the mains supply voltage and frequency.
circuits by fuses of the inert type in each phase. See section - Check the fuses and the setting of the overload relay. See
2.2. section 2.2.

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On GA Standard Pack 1. The dryer voltage supply is branched off from the
Connect the power supply to terminals (L1, L2 and L3) of terminal mains supply
strip (1X2-Fig. 8) and the earth conductor to terminal (PE). In case
of a 3 x 400 V plus neutral mains, connect the neutral conductor to - For a compressor supply voltage of 3 x 400 V plus
terminal (N). neutral conductor (Fig. 13a):
The dryer supply voltage is branched off between a phase
On GA Pack conductor and the neutral conductor.
Connect the power supply to terminals (L1, L2 and L3) of terminal - For a compressor supply voltage of 3 x 230 V (Fig. 13b):
strip (1X2-Fig. 4). Connect the earth conductor to terminal (PE) of The dryer supply voltage is branched off between two
terminal strip (1X2) and the neutral conductor to terminal (N). phase conductors.
Consult section 2.2. - For all other supply voltages (Fig. 13c):
A separate single-phase 230-V voltage supply must be
On GA Full-feature provided. Use wiring of minimum 1.5 mm². The dryer must
- Connect the power supply to terminals (L1, L2 and L3) of be protected by fuses. The current to the air dryer is 2.4 A.
terminal strip (1X2-Fig. 4). Connect the earth conductor to
terminal (PE) of terminal strip (1X2) and the neutral conductor 2. The dryer voltage is branched off from the optional
to terminal (N). Consult section 2.2. voltage transformer
- The electrical diagram of the dryer is stuck on the dryer The correct connections are shown on Fig. 13d.
module. The voltage to the dryer is supplied over the contacts
of relay (K11-Fig. 5a), which close when the compressor is
started. 2.5 Pictographs
- The voltage supply to the dryer must be single-phase
230 V. The voltage may be branched off directly from the Fig. 14 shows typical examples of pictographs used for GA
mains supply or via an optional voltage transformer. compressors. See also Fig. 9.

1. Water outlet
2. Water inlet
3. Manual condensate drain
4. Automatic condensate drain
5. Before connecting compressor electrically, consult instruction
book for motor rotation direction
6. Torques for steel (Fe) or brass (CuZn) bolts
7. Consult Instruction book before greasing
8. Switch off voltage before removing protecting cover inside
electric cubicle
9. Switch off voltage and depressurize compressor before
repairing

Fig. 14. Pictographs

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3 Operating instructions

3.1 Before initial start-up For remote starting and stopping: Connect a
remote start button (normally open contact)
3.1.1 Safety precautions between terminals 2 and 3 of connector (2X4)
1) and connect a remote stop button (normally
closed contact) between terminals 3 and 4 of
The operator must apply all relevant safety precautions, including
connector (2X4) 1).
those mentioned in this book.

Bridge terminal 28 of strip (1X1-Fig. 4) and

3.1.2 User manual (GA Pack / Full-feature only)
terminal 6 of connector (2X4) 1). In this mode,
the outlet pressure is still sensed by pressure
Read the "User manual for electronic regulator for GA5-GA7-GA30-
transducer (PT20), resulting in loading and
GA37-GA45 compressors" to familiarize yourself with all regulator
unloading of the compressor at the pressures
functions.
programmed in the electronic regulator. If
terminals 28 and 6 are not bridged, the
3.1.3 Outdoor/altitude operation compressor is switched out of automatic load/
unload operation and remains running
If the compressor is installed outdoors or if the air inlet temperature unloaded.
can be below 0°C (32°F), precautions must be taken. In this case,
and also if operating at high altitude, consult Atlas Copco. For remote loading/unloading (via external
pressure switch): Bridge terminal 28 of strip
3.1.4 Handling (1X1-Fig. 4) and terminal 7 of connector (2X4)
1) and connect a load/unload switch between
The bottom frame of the compressor is designed for easy handling terminal 28 of strip (1X1-Fig. 4) and terminal 6
with a pallet truck. of connector (2X4) 1). This results in loading
and unloading of the compressor at the closing
3.1.5 External compressor status indication (GA and opening pressures of the external pressure
Pack / Full-feature only) switch respectively.

Have the modifications checked by Atlas Copco.

A relay box for external compressor status indication (E2-Fig. 5a) is
Stop the compressor and switch off the voltage
available as option. It can be connected to the electronic control
before connecting external equipment. Only
module (E1). The relay box has relays for indication of:
voltage-free contacts are allowed.
- manual load/unload or automatic operation (K06)
- warning condition (K07) 3.2 Initial start-up
- shut-down condition (K08)
1. Remove the transport bolts and spacers (two underneath the
Maximum load for these contacts: 1 A / 250 V AC. Stop the compressor element bottom plate, one underneath the oil
compressor and switch off the voltage before connecting external separator). See Fig. 12.
equipment. 2. Check that the electrical connections correspond to the local
codes and that all wires are clamped tight to their terminals.
3.1.6 Compressor control modes (GA Pack / Full- See section 2.4.
3. Check the voltage selecting wires at the primary side of
feature only)
transformer (T1-Fig. 4) 3), the setting of compressor motor
overload relay (F21), and that overload relay (F21) is set for
The electronic regulator has two switches (CMS1/2) at the
automatic resetting.
extremity of strip (1X1-Fig. 4) to select following compressor
4. Fit air outlet valve (AV-Figs. 2). Close the valve. Connect the
control modes (0 = open / 1 = closed):
air net to the valve.
5. Fit valve (Dm1-Fig. 2b). Close the valve. Connect the valve to
CMS1 CMS2 Compressor mode
a drain collector. 2)
0 0 Compressor off 6. Connect the automatic drain outlet (Da-Fig. 2b) to a drain
collector. 2)
1 0 Compressor in local control mode (remote
control is made inactive). 1) At the back of the electronic module.
2) An automatic drain system for GA Standard Pack is available
0 1 Compressor in remote control mode (local as option.
control is made inactive). 3) For GA Standard Pack: if a transformer is provided.

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7. The drain pipes to the drain collector must not dip into the 3.4 During operation
water. For draining of pure condensate water, install an oil/
water separator which is available from Atlas Copco as option. 1. Check the oil level during loaded operation : the sight-glass
If the pipes have been led down outside the room where (SG-Fig. 15) must be between 1/4 and 3/4 full.
freezing is possible, they must be insulated.
8. Check the oil level. The level in sight-glass (SG-Fig. 15) should For GA Pack / Full-feature (Fig. 6a)
be clearly visible. 2. If automatic operation LED (1) is alight, the regulator is
9. A sticker dealing in short with the operating instructions and automatically controlling the compressor, i.e. loading,
explaining the pictographs is delivered with the literature set. unloading, stopping of the motors and restarting.
Affix the sticker next to the control panel. Make yourself
familiar with the instructions and pictographs explained, as well
as with those mentioned in section 2.5. 3.4.1 Checking the display (GA Pack / Full-feature
10. Check the motor (M1-Figs. 2) for correct direction of rotation.
only) 1)
An arrow is provided on the motor cooling air duct.
To facilitate this check, follow the instructions on the sheet
1. Regularly check the display for readings and messages.
attached to the ventilation outlet grating on the roof of the
Normally the main display (Fig. 6b) is shown, indicating the
compressor: Switch on the voltage. With the doors of the
compressor outlet pressure, the status of the compressor and
bodywork closed, look at the sheet after pressing button (8-Fig.
the abbreviations of the functions of the keys below the display.
6a) or moving switch (S1-Fig. 9) to "I": if the sheet is not
See section 1.4.
blown away, stop the compressor immediately by pressing
2. Always check the display (4) and remedy the trouble if alarm
button (9-Fig. 6a) or moving switch (S1-Fig. 9) to "O", switch off
LED (3) is alight or blinks. See section 1.4.
the voltage and reverse two of the voltage supply lines. Repeat
3. The display (4) will show a service message if one of the
the procedure: if the sheet is blown away, the direction of
monitored components is to be serviced; replace the
rotation is correct. Remove the sheet.
component and reset the relevant timer.
11. On GA Pack / Full-feature, check the programmed settings. 1)
Notes:
12. Start and run the compressor for a few minutes. Check that
- Whenever a shut-down, shut-down warning, service
the compressor operates normally.
request, sensor error or motor overload message is
displayed, the free spaces on the display between the
3.3 Starting
function keys (5) are filled with blinking indicators (**).
- When more than one message needs to be displayed (e.g.
For GA Pack / Full-feature (Fig. 6a)
both warning and service), the messages will be displayed
1. Check the oil level: the level should be clearly visible in sight-
one after the other for 3 seconds.
glass (SG-Fig. 15).
2. Switch on the voltage. Check that voltage on LED (2) lights up.
4. Regularly press the key More (5) 2) to call up information about
The message compressor off appears.
the actual compressor condition:
3. Close condensate drain valve (Dm1-Fig. 2b).
- the status of controlling the compressor (automatic or
4. Open air outlet valve (AV-Fig. 2b).
manual, local or remote)
5. Press start button I (8). The compressor starts running and
- the status of the compressor start/stop timer (on or off) 3)
automatic operation LED (1) lights up. Ten seconds 2) after
- the maximum allowable unloading pressure
starting, the compressor motor switches over from star to delta.
- the outlet pressure
At the same time 2) the compressor starts running loaded. The
- the compressor element outlet temperature
message on display (4) changes from Auto unloaded to Auto
- the dewpoint temperature (on Full-feature compressors)
loaded.
- the status of the motor overload protection (normal or not)
- the total running and loading hours
For GA Standard Pack
1. Check the oil level: the level should be clearly visible in sight-
glass (SG-Fig. 15).
2. Switch on the voltage.
3. If installed, close the condensate drain valve. 3)
4. Open air outlet valve (AV-Fig. 2a).
5. Move switch (S1-Fig. 9) to "I".

1) Consult the User manual for the electronic regulator, sections

"Status data submenu" and "Service submenu".
2) If the More function is not indicated on the bottom line of
1) Consult the User manual for the electronic regulator, sections display (4-Fig. 6a), press key Menu (5) until function Main
regarding the submenus "Measured data", "Service", "Modify appears above key (F1), then press the key Main.
settings", "Timer" and "Programmable settings". 3) The compressor is automatically started and stopped if these
2) Programmable. See the User manual for the electronic start/stop commands are programmed and activated; consult
regulator, section "Programmable settings". the User manual for the electronic regulator, section "Timer
3) An automatic condensate drain system is available as option. submenu".

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3.5 Manual control for GA Pack / Full-feature (Fig. Programmed stop appears. The compressor runs unloaded
6a) 1) for 30 seconds and then stops.
2. To stop the compressor in case of emergency, press button
(S3). Alarm LED (3) blinks. After remedying the fault, unlock
Normally, the compressor runs in automatic operation, i.e. the
the button by turning it anticlockwise and press key Rset (5)
electronic regulator loads, unloads, stops and restarts the
before restarting. The message All conditions are OK
compressor automatically. LED (1) is then alight.
appears. Press keys Menu and Main.
3. Close air outlet valve (AV-Fig. 2b) and switch off the voltage.
If required, the compressor can be unloaded manually. In this
4. Open condensate drain valve (Dm1-Fig. 2b).
case, the compressor is switched out of automatic operation, i.e.
the compressor remains running unloaded unless it is loaded again
For GA Standard Pack
manually.
1. Move switch (S1-Fig. 9) to position "O".
2. Close air outlet valve (AV-Fig. 2a) and switch off the voltage.
Manually unloading
3. If installed, open the condensate drain valve. 2)
Press the key Unld (unload) (5). LED (1) goes out. The message
Manual Unloaded appears on the display.
3.7 Taking out of operation at end of compressor
Manually loading service life
Press the key Load (5). LED (1) lights up. The command Load
does not force the compressor in loaded condition, but it will switch 1. Stop the compressor and close the air outlet valve.
the compressor to automatic operation again, i.e. the compressor 2. Switch off the voltage and disconnect the compressor from the
will be loaded if required by the air net pressure. mains.
3. Depressurize the compressor by opening plug (FC-Fig. 15) one
Manually starting/number of motor starts turn and opening valve (Dm1-Fig. 2b). 2)
In automatic operation, the regulator limits the number of motor 4. Shut off and depressurize the part of the air net which is
starts. If the compressor is stopped manually, it must not be connected to the outlet valve. Disconnect the compressor air
restarted within 6 minutes after the last stop. outlet pipe from the air net.
5. Drain the oil (Dm2-Figs. 2) and condensate circuits (Dm1-Fig.
3.6 Stopping 2b). 2)
6. Disconnect the compressor condensate piping (Da/Dm1-Fig.
For GA Pack / Full-feature (Fig. 6a) 2b) from the local condensate drain system. 2)
1. Press stop button O (9). LED (1) goes out. The message

1) If the Load or Unld (unload) function is not indicated on the bottom line of display (4), press key Menu (5) until the function Main
appears above key (F1), then press the key Main.
2) A condensate drain system is available as option for GA Standard Pack.

4 Maintenance

Attention The air outlet valve can be locked during maintenance or repair as
Before starting any maintenance: follows:
- Close the valve.
1. Stop the compressor: - Remove the bolt fixing the handle.
- On GA Standard Pack, move switch (S1-Fig. 9) to "O" - Lift the handle and turn it until the slot of the handle fits over
- On GA Pack / Full-feature, press button O (9-Fig. 6a), wait the blocking edge on the valve body.
until the compressor has stopped (approx. 30 seconds) and - Lock the handle using the special bolt and wrench delivered
press button (S3-Fig. 6a). loose with the compressor.
2. Switch off the voltage. If a separate voltage supply is provided
for the dryer of GA Full-feature (see section 2.4), make sure 4.1 Compressor motor (M1-Figs. 2)
that the voltage to the dryer is also switched off.
3. Close air outlet valve (AV-Figs. 2) and depressurize the air The motor bearings are greased for life.
system.
4. Apply all relevant safety precautions, including those
mentioned in this book.

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4.2 Preventive maintenance schedule for the compressor

Attention
For overhauling or carrying out preventive maintenance, service The schedule comprises a summary of the maintenance
kits are available. See section 4.8. Atlas Copco offers several instructions. Read the respective section before taking
types of Service contracts, relieving you of all preventive maintenance measures. The "longer interval" checks must
maintenance work. For more details, consult your nearest Atlas also include the "shorter interval" checks. When servicing,
Copco representative. replace all disengaged packings, e.g. gaskets, O-rings, washers.

Period 1) Running See See Operation

hours 1) section note

Daily Before starting

" -- 3.3 -- Check oil level

During operation
" 8 3.4/7.1 -- Check readings on display or gauges
" 8 -- 11/13 Check that condensate is discharged during loading (Da)
" 8 3.4 -- Check oil level (SG)

After stopping
" -- 3.6 13 Drain condensate (Dm1)

Monthly -- -- -- Check condition of belts

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

" -- -- 9 Carry out a LED/display test (not on GA Standard Pack)
" -- -- 8 Check for possible leaks
" 500 5.2 1/8 Inspect coolers (Ca/Co); clean if necessary
" 500 -- 1/7 Remove air filter element (AF), inspect
" -- -- 1 Clean compressor

6-monthly -- -- 1 On GA Full-feature, brush or blow off the finned surface of condenser

Yearly -- 5.3 -- Have safety valve tested

" -- -- -- Have operation of electrical components tested
" -- -- 10 Test temperature shut-down protection
" 2000 4.4/4.6 2/3/6 If Roto-injectfluid is used, replace oil filter (OF)
" 4000 -- 13 Remove, dismantle and clean float valve of moisture trap (MT)
" 4000 4.4/4.5 3/5/6 If Roto-injectfluid is used, change oil
-- 4000 -- 6/12 Have oil separator (OS) replaced
" 4000 5.1 6 Replace air filter element (AF)
" 6000 -- -- Replace belts

For 13 bar and 175 psi compressors

" 500 4.4/4.5/4.6 2/6 If oil as specified in section 4.4.2 is used, change oil and oil filter (OF)

For 7 bar, 10 bar, 100 psi, 125 psi and 150 psi compressors
" 1000 4.4/4.5/4.6 2/6 If oil as specified in section 4.4.2 is used, change oil and oil filter (OF)
" -- -- 4 Have all flexibles inspected
" -- 2.5 -- Switch off voltage. Check terminals in electric cabinet for tightness

1) Whichever interval comes first. The local Sales Company may overrule the maintenance schedule, especially the service intervals,
depending on the environmental and working conditions of the compressor.

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Notes 4.4.2 Mineral oil

1. More frequently when operating in a dusty atmosphere.
2. Use an oil filter as specified in the Parts list. The part number Although Roto-injectfluid is recommended, a high-quality mineral oil
is marked on the filter. with oxidation inhibitors and anti-foam and anti-wear properties can
3. Special Atlas Copco oil for screw compressors keeping the also be used after taking some precautions. The previously used
compressor in excellent condition. oil should first be drained and the system flushed. The oil filter
4. Damaged flexibles must be replaced immediately. should be replaced. The viscosity grade must correspond to the
5. It is strongly recommended to use Atlas Copco Roto-injectfluid. ambient temperature and ISO 3448, as follows:
6. Consult the User manual for the electronic regulator for
resetting the service timer (not for GA Standard Pack). Ambient temperature Viscosity Viscosity
7. Replace the filter if damaged. grade index
8. Any leak should be attended to immediately. Consistently above 25°C (77°F) ........... ISO VG 68 Minimum 95
9. Consult the User Manual for the electronic regulator, section Between 25°C (77°F) and 0°C (32°F) ... ISO VG 46 Minimum 95
"Display test" (not for GA Standard Pack).
10. For GA Pack / Full-feature: Consult the User Manual for the If using this oil, consult the User Manual for the electronic regulator
electronic regulator, section "Modify settings submenu", before to decrease the oil service setting to the value specified in section
modifying the temperature protection settings. 4.2.
Decrease the shut-down warning level and shut-down level for
the compressor element outlet temperature to the minimum 4.5 Oil change (Fig. 15)
settings. Run the compressor: when reaching the setting, the
unit must shut down. Afterwards, reset the warning and shut- 1. Run the compressor until warm. Stop it and close valve (AV-
down levels to their original values. Figs. 2). Wait a few minutes. Depressurize the oil system by
For GA Standard Pack, consult Atlas Copco for testing. opening oil filler plug (FC) one turn to permit any pressure to
11. Atlas Copco has oil separators to separate the major part of oil escape.
from condensate to ensure that the condensate meets the
requirements of the environmental codes.
12. Install the new separator element with the mark TOP upwards.
13. An automatic condensate drain system is available as option
on GA Standard Pack.

4.3 Oil and oil filter change interval

Consult section 4.2 for the change intervals and section 4.4 for the
oil specifications.

4.4 Oil specifications

Never mix oils of different brands or types. Consult Atlas Copco for
the recommended oils. Use only non-toxic oils where there is a
risk of inhaling delivered air.

4.4.1 Atlas Copco Roto-injectfluid

It is strongly recommended to use Atlas Copco Roto-injectfluid.

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

Dm2. Oil drain valve TT11. Temperature sensor,

E. Compressor element compressor element outlet
Atlas Copco Roto-injectfluid can be ordered in following quantities: FC. Oil filler plug Vp. Minimum pressure valve
OF. Oil filter 1. Plug
Quantity Ordering number OS. Oil separator 2. Bush
15-litre can 2901 0086 01 SG. Oil level sight-glass 3. Nut
25-litre can 2901 0001 01
Fig. 15. Oil system components

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2. Remove plug (1). Drain the oil by opening valve (Dm2). Close 4.7 Storage after installation
the valve and reinstall the plug. Collect the oil in a collector
and deliver it to the local oil collection service. Run the compressor twice a week until warm. Load and unload the
3. Remove filler plug (FC) and fill with oil until the level reaches compressor a few times.
the plug. Reinstall and tighten plug (FC). Open valve (AV-Figs.
2). If the compressor is stored without running from time to time,
4. Run the compressor for a few minutes. Stop it and close valve protective measures must be taken. Consult Atlas Copco.
(AV-Figs. 2). Wait a few minutes. Depressurize the oil system
and fill with oil until the level is in the middle of sight-glass 4.8 Service kits
(SG). Tighten plug (FC). Open valve (AV-Figs. 2).
5. Reset the oil service warning. 1)
Service kits are available offering the benefits of genuine Atlas
Copco parts while keeping the maintenance budget low. The kits
4.6 Oil filter change (Fig. 15) comprise all parts needed for servicing.

1. Stop the compressor and close valve (AV-Figs. 2). Service kit for oil filter, oil separator Ordering number
Depressurize by unscrewing oil filler plug (FC) one turn to and air filter
permit any pressure in the system to escape.
2. Remove oil filter (OF). GA5-GA7-GA10 2901 0099 02
3. Clean the filter seat on the manifold. Oil the gasket of the new
element. Screw the element into place and tighten firmly by
hand.
4. Check that the oil level is clearly visible.
5. Tighten plug (FC) and open valve (AV-Figs. 2).
6. Reset the oil filter service warning. 1)

5 Adjustments and servicing procedures

5.1 Air filter (AF-Fig. 1) 5.3 Safety valve (SV-Fig. 1)

1. Stop the compressor. Remove the air filter element. Discard Operate the safety valve by unscrewing the cap one or two turns
damaged elements. and retightening it or by pulling the valve lifting lever.
2. Fit the new element.
3. Reset the air filter service warning. 1) Testing
The valve can be tested on a separate compressed air line. If the
5.2 Coolers (Co/Ca-Fig. 1) valve does not open at the pressure marked on the valve, consult
Atlas Copco. No adjustments are allowed. Never run the
Keep the coolers clean to maintain the cooling efficiency. compressor without safety valve.

Remove any dirt from the coolers with a fibre brush. Never use a 5.4 Belt set exchange
wire brush or metal objects. Then clean by air jet in reverse
direction of normal flow. If it should be necessary to wash the The belts must be replaced as a set, even if only one of them
coolers with a cleansing agent, consult Atlas Copco. seems worn. Use Atlas Copco belts only.

1. Loosen clip (3-Fig. 1) and retract hose (4-Fig. 1) from the fan
housing.
2. Unscrew nut (3-Figs. 15/16) to fully loosen the spring force on
1) Consult the User manual for the electronic regulator, section
the belts.
"Service submenu" (not for GA Standard Pack).

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5.7 Expansion valve on GA Full-feature

The valve is a regulator which keeps the evaporator pressure, and

consequently also the temperature, stable. The valve is controlled
by its own outlet pressure. The valve is factory-set to keep the
effective evaporator pressure at no-load at a minimum of 4.1 bar
(59 psi), which corresponds to 1°C (34°F). If necessary, have the
valve adjusted.

5.8 Load/unload pressure switch on GA Standard

Pack

The switch allows the operator to select the unloading pressure

and the pressure difference between the unloading and loading
pressures. The unloading and loading pressures are the opening
and closing pressures of the air pressure switch.

Adjustment can only be carried out when the air pressure

switch is pressurized. Remove blocking device (1-Fig. 17) before
adjusting knob (2).

1. Nut The unloading pressure is controlled by adjusting knob (2). Turn

2. Bush the knob clockwise to raise the unloading pressure, anti-clockwise
3. Nut to lower it.
4. Motor plate
5. Spacer The pressure difference between unloading and loading is
adjusted by means of the same knob. The adjustment range is
Fig. 16. Belt tensioning equipment given in Figs. 18. Push down the knob and turn it clockwise to
reduce the pressure difference, anti-clockwise to increase it.

3. Take the belts out of the pulley grooves. The belts can be
pulled over the fan housing without disconnecting the latter.
4. Install new belts.
5. Screw on nut (3-Figs. 15/16) until the spacer (5-Fig. 16) above
the nut touches bush (2-Figs. 15/16). Make sure that the
threaded rod remains perpendicular to the motor bottom plate.
The belt tension is now correct.
6. Tighten nut (1-Fig. 16) to block the motor bottom plate (4-Fig.
16).
7. Refit hose (4-Fig. 1).

5.5 Fan control switch on GA Full-feature

The switch is factory-adjusted and must be replaced if the switch-

on or cut-out pressure deviates from the values given in section
7.3.
1. Blocking device (to be removed before turning
knob 2)
5.6 High pressure shut-down switch on GA Full-
2. Adjusting knob
feature (TÜV-approved units only) 3. Switch
4. Spring housing
The switch is factory-adjusted and must be replaced if the shut-
down value deviates from the value given in section 7.3. Fig. 17. Air pressure switch (PSR19)

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Fig. 18a. Switch MDR 53/11 Fig. 18b. Switch MDR 53/16

Example (see Fig. 18a):

- unloading pressure(e): 8 bar

- loading pressure(e): adjustable between 5 bar and 7.6 bar

Figs. 18. Pressure difference adjustment ranges

5.9 Temperature shut-down switch on GA Standard

Pack

Switch (TSHH11-Fig. 9) has an adjusting screw in the centre at the

back of the housing of the switch.

The reset screw is located in the centre of the indicator scale and is
protected by a cap. To reset the switch after tripping, unscrew the
cap and turn the reset screw with a screw driver anti-clockwise.

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6 Problem solving

Attention b. Consult Atlas Copco

c. Leak in control air flexibles
- Before starting any maintenance: c. Have leak repaired
- Stop the compressor: d. Minimum pressure valve (Vp) leaking (when net is
On GA Standard Pack, move switch (S1-Fig. 9) to "O". depressurized)
On GA Pack / Full-feature, press button O (9-Fig. 6a), wait d. Consult Atlas Copco
until the compressor has stopped (approx. 30 seconds) and
press button (S3-Fig. 6a). 2. Compressor does not unload, safety valve blows
- Switch off the voltage. If a separate voltage supply is a. Solenoid valve (Y1) out of order
provided for the dryer of GA Full-feature (see section 2.4), a. See 1a
make sure that the voltage to the dryer is also switched off. b. Inlet valve (IV) does not close
- Close the air outlet valve and depressurize the air system. b. See 1b
The outlet valve can be locked in closed position. See
section 4. 3. Condensate is not discharged from moisture trap 1) during
- Apply all relevant safety precautions, including those loading
mentioned in this book. a. Discharge flexible clogged
a. Check and correct as necessary
- The chart helps to solve mechanical problems. An electrical b. Float valve malfunctioning
fault must be traced by an electrician. Check that the wires are b. Consult Atlas Copco
not damaged and that they are clamped tight to their terminals.
4. Compressor air output or pressure below normal
For GA Pack / Full-feature also: a. Air consumption exceeds air output of compressor
- To facilitate solving some problems, a number of messages a. Check equipment connected
may appear on the control panel. Examples: b. Choked air inlet filter element (AF)
b. Replace filter element
Message Action c. Solenoid valve (Y1) malfunctioning
System failure 10 or 106 Switch off the voltage. Check the c. See 1a
terminals on connector (2X1) and d. Leak in control air flexibles
emergency stop button (S3) for d. See 1c
correct connection. e. Inlet valve (IV) does not fully open
e. See 1b
System failure 11 Switch off the voltage. Check for f. Oil separator element (OS) clogged
possible connection with the ground f. Have element replaced. Consult Atlas Copco
of one of the digital inputs at g. Air leakage
connector (2X4). g. Check and correct as necessary
h. Safety valve (SV) leaking
System failure 104 Switch off the voltage. Check that h. Have valve replaced. Consult Atlas Copco
the contacts to the digital inputs at i. Compressor element (E) out of order
the connectors of the module are i. Consult Atlas Copco
voltage-free.
5. Excessive oil consumption; oil carry-over through
Connector (2X5) must only be used for connecting the Atlas discharge line
Copco Relay expansion box (optional) which allows indication a. Oil level (SG) too high
of manual/automatic operation, warning condition or shut-down a. Check for overfilling. Release pressure and drain oil to correct
condition. level
b. Incorrect oil causing foam
- Consult the User manual for the electronic regulator if a service
b. Change to correct oil
message or fault message appears on the display (4-Fig. 6a) or
c. Oil separator element (OS) defective
when alarm LED (3-Fig. 6a) is alight or blinks.
c. Have element checked. Replace, if necessary. Install the
element with the mark TOP at the top and the seam at the
Mechanical faults and suggested remedies (Fig. 3)
bottom

1. Compressor starts running, but does not load after a delay

time
a. Solenoid valve (Y1) out of order
a. Have valve inspected
1) Available as an option on GA Standard Pack.
b. Inlet valve (IV) stuck in closed position

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6. Safety valve (SV) blows after loading a. Check for cooling air restriction or improve ventilation of
a. Inlet valve (IV) malfunctioning compressor room. Avoid recirculation of cooling air. If
a. See 1b installed, check capacity of compressor room fan
b. Minimum pressure valve (Vp) malfunctioning b. Oil level too low (SG)
b. See 1d b. Check and correct as necessary
c. Oil separator element (OS) clogged c. Oil cooler (Co) clogged
c. See 4f c. Clean cooler
d. Safety valve (SV) out of order d. By-pass valve (BV) malfunctioning
d. See 4h d. Have valve replaced
e. For Full-feature: dryer pipes clogged by formation of ice e. Air cooler (Ca) clogged
e. Have refrigerant system checked. Consult Atlas Copco e. Clean cooler
f. Compressor element (E) out of order
7. Element outlet 1) or air outlet temperature above normal f. See 4i
a. Insufficient cooling air or cooling air temperature too high

1) A warning message will appear on display (4-Fig. 6a) (not for

GA Standard Pack).

7 Principal data

7.1 Readings On Full-feature also:

7.1.1 Readings on display on GA Pack / Full-feature Ref.: Dewpoint temperature

Reading: Approx. 3°C
(4-Fig. 6a) 1)
Shown: When using the key More (5-Fig. 6a) on the main
display (Fig. 6b)
Ref.: Air outlet pressure
Sensor: TT90
Reading: Modulates between programmed unloading and loading
pressures.
7.1.2 Readings on gauges on GA Standard Pack
Shown: On main display (Fig. 6b), when:
- switching on voltage (Fig. 9)
- selecting main display with keys Menu and Main
(5-Fig. 6a) Ref.: Air outlet pressure (Gp)
- keys of module are not used for four minutes Reading: Modulates between preset unloading and loading
Sensor: PT20 pressures

Ref.: Compressor element outlet temperature Ref.: Compressor element outlet temperature (TSHH11)
Reading: Approx. 60°C above cooling air temperature Reading: For GA5/7 approx. 60°C above cooling air temperature
Shown: When using the key More (5-Fig. 6a) on the main For GA10 approx. 65°C above cooling air temperature
display (Fig. 6b) Setting: 110°C
Sensor: TT11

1) See User manual for electronic regulator, sections "Modify

settings submenu" and "More function".

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7.2 Setting of safety valve

The part number and set pressure are stamped on the valve. Also
consult the Parts list. If the valve is malfunctioning, replace it by
one with the same number. No adjustments are allowed.

7.3 Dryer control switches and refrigerant

specifications (on GA Full-feature)

Fan control switch Cut-out Switch-on Unit

pressure pressure

Fan control switch ...................... 13 16 bar(e)

Dryer shut-down switch (only on Breaks at Unit

TÜV-approved GA Full-feature)

Dryer shut-down switch ............................... 25 bar(e)

Refrigerant

Difluormonochlormethane CHF2CI ............... R134a

Total charge, approx. ................................... kg 0.9

7.4 Compressor specifications

7.4.1 Reference conditions

Normal working pressure as stated below

Air inlet pressure (absolute) ......................... bar 1
Air inlet temperature .................................... °C 20
Relative humidity ........................................ % 0

7.4.2 Limitations

Maximum inlet temperature .......................... °C 40

Minimum inlet temperature ........................... °C 0
Minimum working pressure .......................... bar(e) 4

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7.4.3 Specifications of GA5 1)

Compressor type GA5-7.5 GA5-10 GA5-13 GA5-100 GA5-125 GA5-150 GA5-175

Frequency .................................................. Hz 50 50 50 60 60 60 60
Oil capacity ................................................ l 5 5 5 5 5 5 5

GA Pack and GA Standard Pack

Maximum (unloading) pressure .................... bar(e) 7.5 10 13 7.4 9.1 10.8 12.5
Normal working pressure ............................. bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving air outlet valve at
normal working pressure ............................. °C 32 32 32 33 33 33 33
Shaft input power ........................................ kW 6.2 6.2 6.2 6.1 6.2 6.2 6.2

GA Full-feature
Maximum (unloading) pressure .................... bar(e) 7.25 9.75 12.75 7.15 8.85 10.55 12.25
Normal working pressure ............................. bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving air outlet valve at
normal working pressure ............................. °C 25 25 25 28 28 28 28
Pressure dewpoint ...................................... °C 3 3 3 3 3 3 3
Shaft input power ........................................ kW 6.3 6.3 6.3 6.2 6.3 6.3 6.3

GA Pack and GA Full-feature

Sound pressure level 2) ............................... dB(A) 68 68 68 69 69 69 69

GA Standard Pack
Sound pressure level 2) ............................... dB(A) 70 70 70 71 71 71 71

7.4.4 Specifications of GA7 1)

Compressor type GA7-7.5 GA7-10 GA7-13 GA7-100 GA7-125 GA7-150 GA7-175

Frequency .................................................. Hz 50 50 50 60 60 60 60
Oil capacity ................................................ l 5.5 5.5 5.5 5.5 5.5 5.5 5.5

GA Pack and GA Standard Pack

Maximum (unloading) pressure .................... bar(e) 7.5 10 13 7.4 9.1 10.8 12.5
Normal working pressure ............................. bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving air outlet valve at
normal working pressure ............................. °C 32 32 32 35 35 35 35
Shaft input power ........................................ kW 8.6 8.6 8.6 8.5 8.6 8.6 8.6

GA Full-feature
Maximum (unloading) pressure .................... bar(e) 7.25 9.75 12.75 7.15 8.85 10.55 12.25
Normal working pressure ............................. bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving air outlet valve at
normal working pressure ............................. °C 25 25 25 28 28 28 28
Pressure dewpoint ...................................... °C 3 3 3 3 3 3 3
Shaft input power ........................................ kW 8.7 8.7 8.7 8.6 8.7 8.7 8.7

GA Pack and GA Full-feature

Sound pressure level 2) ............................... dB(A) 70 70 70 71 71 71 71

GA Standard Pack
Sound pressure level 2) ............................... dB(A) 71 71 71 72 72 72 72

1) At reference conditions.
2) According to CAGI PNEUROP PN8NTC2.2.

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7.4.5 Specifications of GA10 1)

Compressor type GA10-7.5 GA10-10 GA10-13 GA10-100 GA10-125 GA10-150 GA10-175

Frequency .................................................. Hz 50 50 50 60 60 60 60
Oil capacity ................................................ l 5.5 5.5 5.5 5.5 5.5 5.5 5.5

GA Standard Pack
Maximum (unloading) pressure .................... bar(e) 7.5 10 13 7.4 9.1 10.8 12.5
Normal working pressure ............................. bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Temperature of air leaving air outlet valve at
normal working pressure .............................. °C 32 32 32 35 35 35 35
Shaft input power ........................................ kW 11.5 10.8 10.6 11.3 11.6 11.4 11.7
Sound pressure level 2) ............................... dB(A) 72 72 72 73 73 73 73

7.5 Conversion list of SI units into British units

1 bar = 14.504 psi

1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
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 m = 3.281 ft
1 mm = 0.039 in
1 m3/min = 35.315 cfm
1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x°C = (32 + 1.8x) °F
∆t 1°C = ∆t 1.8 °F

1) At reference conditions.
2) According to CAGI PNEUROP PN8NTC2.2.

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