Atlas Copco GA 30+, GA 37, GA 45 Instruction Book
Atlas Copco
Oil-injected rotary screw compressors
GA 30+, GA 37, GA 45
Instruction book
Atlas Copco
Oil-injected rotary screw compressors
GA 30+, GA 37, GA 45
From following serial No. onwards: API 571 000
Instruction book
Original instructions
2016 - 04
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
No. 2920 7180 30
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................7
1.1 SAFETY ICONS................................................................................................................................... 7
1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................7
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................8
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 9
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR......................................................................... 10
2 General description......................................................................................................12
2.1 INTRODUCTION.................................................................................................................................12
2.2 AIR AND OIL CIRCUIT......................................................................................................................... 17
2.3 COOLING SYSTEM.............................................................................................................................20
2.4 CONDENSATE SYSTEM.......................................................................................................................20
2.5 REGULATING SYSTEM........................................................................................................................ 23
2.6 ELECTRICAL SYSTEM.........................................................................................................................24
2.7 AIR DRYER......................................................................................................................................25
3 Elektronikon® controller..............................................................................................27
3.1
3.2 CONTROL PANEL.............................................................................................................................. 28
3.3 ICONS USED ON THE DISPLAY..............................................................................................................29
3.4 MAIN SCREEN..................................................................................................................................31
3.5 SHUT-DOWN WARNING.......................................................................................................................32
ELEKTRONIKON® CONTROLLER............................................................................................................27
3.6 SHUT-DOWN....................................................................................................................................33
3.7 SERVICE WARNING............................................................................................................................35
3.8 SCROLLING THROUGH ALL SCREENS.....................................................................................................36
3.9 CALLING UP TEMPERATURES...............................................................................................................40
3.10 CALLING UP RUNNING HOURS..............................................................................................................41
3.11 CALLING UP MOTOR STARTS............................................................................................................... 42
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3.12 CALLING UP MODULE HOURS...............................................................................................................42
3.13 CALLING UP LOADING HOURS.............................................................................................................. 43
3.14 CALLING UP LOAD RELAY................................................................................................................... 43
3.15 CALLING UP/RESETTING THE SERVICE TIMER ......................................................................................... 44
3.16 SELECTION BETWEEN LOCAL, REMOTE OR LAN CONTROL........................................................................45
3.17 CALLING UP/MODIFYING CAN ADDRESS............................................................................................... 45
3.18 CALLING UP/MODIFYING IP, GATEWAY AND SUBNETMASK........................................................................47
3.19 CALLING UP/MODIFYING PRESSURE BAND SETTINGS.................................................................................48
3.20 MODIFYING THE PRESSURE BAND SELECTION......................................................................................... 50
3.21 CALLING UP/MODIFYING SERVICE TIMER SETTINGS...................................................................................50
3.22 CALLING UP/MODIFYING THE UNIT OF TEMPERATURE................................................................................51
3.23 CALLING UP/MODIFYING UNIT OF PRESSURE...........................................................................................51
3.24 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE...................................................................... 51
3.25 SELECTION BETWEEN Y-D OR DOL STARTING......................................................................................52
3.26 CALLING UP MODIFYING LOAD DELAY TIME............................................................................................. 52
3.27 CALLING UP MODIFYING MINIMUM STOP TIME..........................................................................................53
3.28 ACTIVATING PASSWORD PROTECTION................................................................................................... 53
3.29 ACTIVATE LOAD/UNLOAD REMOTE PRESSURE SENSING............................................................................. 54
3.30 CALLING UP/MODIFYING PROTECTION SETTINGS...................................................................................... 54
3.31 TEST SCREENS................................................................................................................................ 56
3.32 WEB SERVER.................................................................................................................................. 57
3.33 PROGRAMMABLE SETTINGS.................................................................................................................65
4 Elektronikon® Graphic controller............................................................................... 69
4.1 CONTROLLER...................................................................................................................................69
4.2 CONTROL PANEL.............................................................................................................................. 71
4.3 ICONS USED.................................................................................................................................... 72
4.4 MAIN SCREEN..................................................................................................................................75
4.5 CALLING UP MENUS.......................................................................................................................... 79
4.6 INPUTS MENU...................................................................................................................................80
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4.7 OUTPUTS MENU............................................................................................................................... 83
4.8 COUNTERS......................................................................................................................................84
4.9 CONTROL MODE SELECTION................................................................................................................85
4.10 SERVICE MENU................................................................................................................................ 87
4.11 SETPOINT MENU...............................................................................................................................91
4.12 EVENT HISTORY MENU.......................................................................................................................93
4.13 MODIFYING GENERAL SETTINGS...........................................................................................................94
4.14 INFO MENU......................................................................................................................................95
4.15 WEEK TIMER MENU...........................................................................................................................96
4.16 TEST MENU................................................................................................................................... 105
4.17 USER PASSWORD MENU...................................................................................................................106
4.18 WEB SERVER................................................................................................................................ 107
4.19 PROGRAMMABLE SETTINGS...............................................................................................................115
5 Energy recovery (optional)........................................................................................ 119
5.1 ENERGY RECOVERY UNIT................................................................................................................. 119
5.2 ENERGY RECOVERY SYSTEMS........................................................................................................... 120
5.3 OPERATION...................................................................................................................................121
5.4 MAINTENANCE............................................................................................................................... 123
5.5 ENERGY RECOVERY DATA................................................................................................................ 124
5.6 COOLING WATER REQUIREMENTS.......................................................................................................126
6 Installation...................................................................................................................131
6.1 DIMENSION DRAWINGS.....................................................................................................................131
6.2 INSTALLATION PROPOSAL................................................................................................................. 131
6.3 ELECTRICAL CONNECTIONS...............................................................................................................135
6.4 PICTOGRAPHS............................................................................................................................... 137
7 Operating instructions............................................................................................... 139
7.1 INITIAL START-UP............................................................................................................................139
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7.2 BEFORE STARTING..........................................................................................................................142
7.3 STARTING .................................................................................................................................... 144
7.4 DURING OPERATION........................................................................................................................145
7.5 CHECKING THE DISPLAY...................................................................................................................147
7.6 STOPPING ....................................................................................................................................148
7.7 TAKING OUT OF OPERATION..............................................................................................................149
8 Maintenance................................................................................................................151
8.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................151
8.2 OIL SPECIFICATIONS........................................................................................................................153
8.3 DRIVE MOTOR ...............................................................................................................................154
8.4 AIR FILTER....................................................................................................................................155
8.5 OIL AND OIL FILTER CHANGE.............................................................................................................156
8.6 COOLERS..................................................................................................................................... 157
8.7 SAFETY VALVES............................................................................................................................. 159
8.8 DRYER MAINTENANCE INSTRUCTIONS..................................................................................................159
8.9 SERVICE KITS................................................................................................................................ 160
8.10 STORAGE AFTER INSTALLATION......................................................................................................... 160
8.11 DISPOSAL OF USED MATERIAL........................................................................................................... 161
9 Problem solving..........................................................................................................162
10 Technical data.............................................................................................................166
10.1 READINGS ON DISPLAY.................................................................................................................... 166
10.2 ELECTRIC CABLE SIZE AND FUSES......................................................................................................167
10.3 PROTECTION SETTINGS....................................................................................................................173
10.4 DRYER SWITCHES...........................................................................................................................174
10.5 REFERENCE CONDITIONS AND LIMITATIONS.......................................................................................... 174
10.6 COMPRESSOR DATA........................................................................................................................175
10.7 TECHNICAL DATA CONTROLLER..........................................................................................................180
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11 Instructions for use.................................................................................................... 181
12 Guidelines for inspection...........................................................................................182
13 Pressure equipment directives................................................................................. 183
14 Declaration of conformity.......................................................................................... 184
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 General safety precautions
1. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel. The personnel should apply safe working practices by use of personal
protection equipment, appropriate tools and defined procedures.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing
quality, the compressed air must be adequately purified according to the applicable legislation and
standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.
Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with
extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
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9. If compressed air is used in the food industry and more specifically for direct food contact, it is
recommended, for optimal safety, to use certified Class 0 compressors in combination with
appropriate filtration depending on the application. Please contact your customer centre for advice on
specific filtration.
1.3 Safety precautions during installation
All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept
within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. In case the device is a compressor, place the machine where the ambient air is as cool and clean as
possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to
minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the
working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors and
particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people cannot
be drawn in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the electrical
isolating switch is open, locked and labelled with a temporary warning before any maintenance or
repair. As a further safeguard, persons switching on or off remotely controlled machines shall take
adequate precautions to ensure that there is no one checking or working on the machine. To this end,
a suitable notice shall be affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available
and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
12. The electrical connections must correspond to the applicable codes. The machines must be earthed
and protected against short circuits by fuses in all phases. A lockable power isolating switch must be
installed near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after voltage failure
is activated, a sign stating "This machine may start without warning" must be affixed near the
instrument panel.
Instruction book
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14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Nonreturn valves (check valves) must not be relied upon for isolating pressure systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure relieving device or devices as required.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high temperature
piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the dryer,
safety valves must be installed in the vessels of the dryer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation
All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during operation
1. Never touch any piping or components of the machine during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose
or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g.
to carry out routine checks. Wear ear protectors when opening a door.
On machines without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• No leaks occur
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• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to
avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.5 Safety precautions during maintenance or repair
All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during maintenance or repair
1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all damage or
injuries caused by the use of non-genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the
starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or
disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapors of cleaning liquids.
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10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly. If removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged,
replace it by genuine material from the manufacturer to prevent the sound pressure level from
increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. Only if applicable, the following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
2920 7180 30 11
2 General description
2.1 Introduction
GA 30+, GA 37 and GA 45 are single-stage, oil-injected screw compressors, driven by an electric motor.
The compressors are air cooled.
The compressors are controlled by an Elektronikon® controller. GA 30+ has an Elektronikon controller
with graphical display, while the basic version of the GA 37 and GA 45 have a basic version of the
Elektronikon controller. For the GA37 and the GA 45, the Elektronikon controller with graphical display is
available as standard option.
The controller is fitted to the right hand door panel on the front side. An electric cabinet comprising the
motor starter is located behind this panel.
The compressors are enclosed in a sound-insulated bodywork.
There are 2 versions of the compressor: Workplace Pack (without integrated dryer) and Workplace Full-
Feature (with integrated dryer).
Instruction book
The dryer removes water from the compressed air by cooling the air to near freezing point.
Front view, GA 30+ up to GA 45
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Motor side view, GA 30+ up to GA 45 Pack
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Instruction book
Service side view, GA 30+ up to GA 45 Pack
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Instruction book
Motor side view, GA 30+ up to GA 45 Full-Feature
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Instruction book
Service side view, GA 30+ up to GA 45 Full-Feature
References
1 Electric cabinet
AV Outlet valve
Ca Air cooler
Co Oil cooler
E Compressor element
ER
FN Cooling fan
M1 Motor of the compressor
S3 Emergency stop button
UA Unloader
Da (Dm) Condensate outlets
AF Air filter
AR Air receiver (oil separator tank)
OF Oil filter
DR Dryer (only on units with integrated dryer)
Elektronikon® controller
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Instruction book
2.2 Air and oil circuit
Air circuit
Flow diagram, air circuit (compressors without integrated dryer)
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Instruction book
Flow diagram, air circuit (compressors with integrated dryer)
Reference Description
1 Intake air
2 Air/oil mixture
3 Oil
4 Wet compressed air
5 Condensate
6 Dried compressed air
Description
Air drawn through inlet filter (AF) and open inlet valve (IV) of the unloader is compressed in compressor
element (E). A mixture of compressed air and oil flows into the air receiver/oil separator tank (AR). The air
is discharged through outlet valve (AV) via minimum pressure valve (Vp) and air cooler (Ca).
The air cooler is provided with a moisture trap (MT).
On compressors with integrated dryer, the air flows through air dryer (DR) before it is discharged through
outlet valve (AV). Also see section Air dryer.
Under all circumstances, the minimum pressure valve (Vp) keeps the pressure in the separator tank (AR)
above the minimum value that is required for lubrication of the compressor element. An integrated check
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valve prevents the compressed air downstream the minimum pressure valve from being vented to
atmosphere during unloaded operation. When the compressor is stopped, inlet valve (IV) closes, preventing
compressed air (and oil) to be vented into the air filter.
Oil circuit
Flow diagram, oil circuit
Reference Description
1 Intake air
2 Air/oil mixture
3 Oil
4 Wet compressed air
Description
Air pressure in the separator tank forces the oil via oil filter (OF) to compressor element (E), where it acts
as sealant, coolant, lubricant and corrosion inhibitive (during stand still periods).
In air receiver/oil separator tank (AR), most of the oil is separated from the air/oil mixture by gravity and
inertia. The remaining oil is separated by oil separator (OS). The oil collects in the lower part of air
receiver/oil separator (AR).
The oil circuit is provided with a thermostatic bypass valve (BV). When the oil temperature is below its
setpoint, the oil cooler is bypassed. Bypass valve (BV) starts opening the supply to cooler (Co) when the
oil temperature has increased to the setpoint temperature. At approx. 15 ˚C (27 ˚F) above the setpoint
temperature, all the oil flows through the oil cooler.
A tropical thermostatic valve (available as an option) offers a higher opening temperature, it helps avoiding
condensate accumulation in the oil. This option is advised when the compressor operates in high humidity
conditions.
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2.3 Cooling system
Diagram
Instruction book
Reference Description
1 Intake air
2 Air/oil mixture
3 Oil
4 Wet compressed air
5 Condensate
Description
The cooling system on air-cooled compressors comprises air cooler (Ca) and oil cooler (Co).
The cooling air flow is generated by fan (FN).
2.4 Condensate system
The condensate, collected in the moisture trap of the air cooler, is evacuated via an automatic drain. A
compressor with integrated dryer has an additional drain on the moisture trap of the dryer. Each drain is
connected to its outlet connection (Da) and a manual drain valve (Dm).
Mechanical drains
GA 37 and GA 45 have a mechanical condensate drain (MWD).
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Mechanical condensate drain
A float opens or closes the outlet dependant on the level of the condensate in the bowl.
Electronic drains
The GA 30+ Pack has an electronic water drain (EWD). On Full-Feature GA 30+ compressors, an
additional electronic water drain is provided.
The condensate accumulates in the collector of the drain. When the condensate reaches a certain level, it is
discharged through the automatic drain outlet (Da).
Testing the electronic water drain can be done by briefly pressing the test button (1) on top of the drain.
Electronic condensate drains
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Drain connections
Instruction book
Condensate drain connections
Reference Designation
Da Automatic drain connection
Dm Manual drain valve
Da1 Automatic drain connection of the dryer (only on units with integrated dryer)
Dm1 Manual drain valve of the dryer (only on units with integrated dryer)
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2.5 Regulating system
Load/unload regulating system
Loading
When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results:
Air delivery is 100%, the compressor runs loaded.
Unloading
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-energised. Results:
Regulating system (loaded condition)
• The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank
pressure (1) via the solenoid valve.
• Unloading valve/blow-off valve (UV) moves downwards, closing off the connection to channels (2)
and (3).
• Underpressure from the compressor element causes loading plunger (LP) to move downwards and
inlet valve (IV) to open fully.
• The pressure above unloading valve/blow-off valve (UV) is released to atmosphere and the space
above valve (UV) is no longer in connection with the oil separator tank pressure (1).
• Unloading valve/blow-off valve (UV) moves upwards, connecting the oil separator tank pressure (1)
with channels (2) and (3).
• The pressure in channel (2) causes the loading plunger (LP) to move upwards, causing inlet valve
(IV) to close, while the pressure is gradually released to atmosphere.
• The pressure in the separator tank stabilises at low value. A small amount of air is kept drawn in to
guarantee a minimal pressure, required for lubrication during unloaded operation.
Air output is stopped, the compressor runs unloaded.
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2.6 Electrical system
Electrical components
The electrical system comprises following components:
Instruction book
Typical example of electric cubicle
Reference Designation
F1 Fuse
F2 Fuse
F3 Fuse
F7/8/9 Fuses (only on units with integrated dryer)
F21 Overload relay, compressor motor
Q15 Circuit breaker, fan motor (on air-cooled compressors)
K5 Auxiliary relay
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Reference Designation
K11 Auxiliary contactor (only on units with integrated dryer)
K12 Auxiliary contactor (only on units with integrated dryer)
K25 Phase sequence relay
E10 Smartbox
K21 Line contactor
K22 Star contactor
K23 Delta contactor
T1 Transformer
PE Earth terminal
Electrical diagram
9828 5102 00 Service diagram
The complete electrical diagram can be found in the electric cubicle and on the CD-ROM, supplied with
the machine.
2.7 Air dryer
(On compressors with integrated dryer only)
Flow diagram
Air dryer
Reference Name
AI Air inlet
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Reference Name
AO Air outlet
1 Air/air heat exchanger
2 Air/refrigerant heat exchanger/evaporator
3 Condensate separator
4 Automatic drain / condensate outlet
5 Refrigerant compressor
6 Refrigerant condenser
7 Liquid refrigerant dryer/filter
8 Capillary
9 Bypass valve
10 Condenser cooling fan
11 Pressure switch, fan control
12 Liquid separator
Instruction book
Compressed air circuit
Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the
incoming air starts to condense. The air then flows through heat exchanger/evaporator (2), where the
refrigerant evaporates, causing the air to be cooled further to close to the evaporating temperature of the
refrigerant. More water in the air condenses. The cold air then flows through separator (3) where all the
condensate is separated from the air. The condensate is automatically drained through condensate drain (4).
The cold, dried air flows through heat exchanger (1) where it is warmed up by the incoming air.
Refrigerant circuit
Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most
of the refrigerant condenses.
The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to capillary tube (8). The refrigerant
leaves the capillary tube at about evaporating pressure.
The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further
evaporation at about constant pressure. The heated refrigerant leaves the evaporator and is sucked in by the
compressor (5) through a liquid separator (12).
Bypass valve (9) regulates the refrigerant flow. Fan (10) is switched on or off by switch (11) depending on
the pressure degree of the condensate.
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Instruction book
3 Elektronikon® controller
3.1
Control panel
Introduction
Elektronikon® controller
The Elektronikon® controller has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (made inactive)
Automatic control of the compressor
The controller 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 within a given period of time are taken
into account.
The controller stops the compressor whenever possible to reduce the power consumption and restarts it
automatically when the net pressure decreases. If the expected unloading period is to short, the compressor
is kept running to prevent too short stand-still periods.
Protecting the compressor
Several sensors are provided on the compressor. If one of the measured signals exceeds the programmed
shutdown level, the compressor will be stopped or a warning is given.
Shutdown
Example: If the compressor element outlet temperature exceeds the programmed shutdown level, the
compressor will be stopped. This will be indicated on the display of the controller. The compressor will
also be stopped in case of overload of the drive motor or overload of the fan motor.
Before remedying, consult the Safety precautions.
Shutdown warning
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A shutdown warning level is a programmable level below the shutdown level.
If one of the measurements exceeds the programmed shutdown warning level, this will also be indicated to
warn the operator before the shutdown level is reached.
Service warning
If the service timer exceeds a programmed value, this will be indicated on the display to warn the operator
to carry out some service actions.
Other warnings
On compressors equipped with an integrated dryer, a warning message will appear if the dew point is too
high or too low for the given ambient temperature.
Automatic restart after voltage failure
The controller has a built-in function to automatically restart the compressor when the voltage is restored
after voltage failure. For compressors leaving the factory, this function is made inactive. If desired, the
function can be activated. The ARAVF label 1079 9932 74 (see section Pictographs) shall be glued near to
the controller. Consult your local supplier.
Instruction book
If activated, and if the controller was in the automatic operation mode, the compressor
will automatically restart when the supply voltage to the module is restored!
3.2 Control panel
Detailed description
Control panel of the Elektronikon controller
Reference Designation Function
1 Display Shows icons and operating conditions.
2 Automatic operation symbol
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