Atlas Copco Stationary Air Compressors

GA315 VSD - GA315 W VSD

Instruction book

· Copyright 2002, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings.

· This instruction book meets the requirements for instructions specified by the machinery
directive 98/37/EC and is valid for CE as well as non-CE labelled machines.

No. 2920 1463 00

Registration code: APC G³180 VSD / 38 / 995

2002-06 www.atlascopco.com
 Instruction book

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

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

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

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

In all correspondence 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 3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.5 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.6 Taking out of operation . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Condensate drain system . . . . . . . . . . . . . . . . . . . . . . . . 5 3.7 Instructions for use of air receiver . . . . . . . . . . . . . . . . 30
1.4 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.6 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.1 Preventive maintenance schedule for the compressor . 32
1.7 Elektronikon® control system . . . . . . . . . . . . . . . . . . . . . 9 4.1.1 Regular service operations . . . . . . . . . . . . . . . . 32
1.7.1 Controlling the compressor speed . . . . . . . . . . . 9 4.1.2 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.7.2 Protecting the compressor . . . . . . . . . . . . . . . . . 9 4.1.3 Service agreements . . . . . . . . . . . . . . . . . . . . . . 32
1.7.3 Service warning . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1.4 Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.7.4 Automatic restart after voltage failure . . . . . . . 10 4.2 Motor greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.8 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.2.1 Fan motors on GA315 VSD . . . . . . . . . . . . . . . 32
1.8.1 LEDs/buttons/keys . . . . . . . . . . . . . . . . . . . . . . 10 4.2.2 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.8.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4.3 Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.8.3 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4.4 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.8.4 Emergency stop button . . . . . . . . . . . . . . . . . . . 11 4.5 Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9 Menu-driven control programs . . . . . . . . . . . . . . . . . . . 12 4.6 Storage after installation . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9.1 Function of control programs . . . . . . . . . . . . . 12 4.7 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9.2 Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9.3 Calling up other menus . . . . . . . . . . . . . . . . . . 14 5 Adjustments and servicing procedures . . . . . . . . . . . . . . . 34
1.9.4 External compressor status indication . . . . . . . 14 5.1 Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1 Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.4 Oil/water separators . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.2 Installation proposals . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.1 Dryer by-pass system for Full-Feature 6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 7.1 Readings on display . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5 Cooling water requirements . . . . . . . . . . . . . . . . . . . . . 23 7.2 Setting of safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5.1 Type of system . . . . . . . . . . . . . . . . . . . . . . . . . 23 7.3 Settings of circuit breakers - fuses . . . . . . . . . . . . . . . . 36
2.5.2 Cooling water parameters . . . . . . . . . . . . . . . . 23 7.4 Compressor specifications . . . . . . . . . . . . . . . . . . . . . . 36
7.4.1 Reference conditions . . . . . . . . . . . . . . . . . . . . 36
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 7.4.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 7.4.3 Specific data . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7.5 Conversion list of SI units into British/
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 American units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1 LEADING PARTICULARS The compressors include mainly:

- Air filters
- Compressor element
1.1 General description - Air receiver/oil separator
- Air cooler
GA VSD (Variable Speed Drive) are single-stage screw - Oil coolers
compressors directly driven by an electric motor. The - Drive motor
compressors deliver pulsation-free air. By continuously - Coupling housing
matching the speed of the drive motor to the air net pressure, - Elektronikon® control system
the compressors optimize energy consumption and reduce the - Variable speed drive units
operating pressure band. - Safety devices
- Additional air outlet and dryer shut-off valve to by-pass the
GA315 VSD are air-cooled, whereas GA315 W VSD are water- dryer
cooled.

S2 Emergency stop button 4 Air filters 8 Oil stop valve/check

1 Elektronikon regulator 5 Air cooler valve
2 Dryer 6 Oil coolers 9 Drive motor
3 Air receiver 7 Compressor element 10 Oil filters

Fig. 1.1 General view GA315 VSD

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S2 Emergency stop button 5 Fan motor, air cooler 10 Transport spacer

1 Electric cabinet 6 Condensate trap 11 Vibration damper
2 Elektronikon regulator 7 Air filters 12 Transport spacer
3 Fans, air dryer 8 Compressor element 13 Vibration damper
4 Flange (air outlet if by-passing 9 Oil stop valve/check valve 14 Drive motor
dryer)
Fig. 1.2 Front view GA315 VSD

1 Air cooler 6 Dryer shut-off valve 12 Transport spacer

2 Fans, compressor coolers 7 DD filter 13 Air receiver
3 Condensate trap 8 Compressed air outlet 14 Fan motor, oil coolers
4 Fan motor, air cooler 9 Fans, air dryer 15 Fan, oil coolers
5 Flange (air outlet if by-passing 10 Oil filler plug 16 Oil coolers
dryer) 11 Oil level sight-glass 17 Oil drain plugs
Fig. 1.3 Rear view GA315 VSD

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Full-Feature (FF) compressors are additionally provided with 1.4 Oil system (Fig. 1.4)
an air dryer integrated in the bodywork.
Air pressure forces the oil from receiver (17) through oil coolers
Oil/water separators - OSD (6), filters (7) and oil stop valve (15) to compressor element
Atlas Copco has oil/water separators (type OSD) which can be (14) and the lubrication points.
integrated in the bodywork. They separate oil from condensate
for the condensate to meet the requirements of the local Oil stop valve (15) prevents the compressor element from
environmental codes. flooding with oil when the compressor is stopped.

DD filter Valve (26) by-passes oil coolers (6) when starting the
Full-Feature compressors can be provided with an integrated compressor from cold condition, to ensure rapid warming of
filter of the DD type to limit carry-over of solid particles and the oil to normal working temperature. It also controls the oil
oil. temperature in cold ambient conditions to avoid condensation
in air receiver (17).

In air receiver (17) most of the oil is removed from the air
centrifugally. Almost all of the remaining oil is removed by
separator element (18).
1.2 Air flow (Fig. 1.4)
On water-cooled VSD, the system comprises a valve (1-Fig.
Air drawn through filters (1) is compressed in compressor 1.5) which regulates the oil flow over the oil cooler depending
element (14). Compressed air and oil are discharged through on the need for cooling capacity.
check valve (16) to air receiver/oil separator (17) in which oil
is separated from the compressed air. The air is blown through
minimum pressure valve (19) to air cooler (4). The cooled air
is discharged through condensate trap (28) and outlet valve
(27) towards the air net.

Full-Feature compressors have an integrated dryer which

removes moisture from compressed air. 1.5 Cooling system (Fig. 1.4)
Check valve (16) prevents blow-back of compressed air. On air-cooled VSD, the system includes air cooler (4) and oil
coolers (6), cooled by two fans. The speed of the fans is
Minimum pressure valve (19) prevents the receiver pressure controlled by frequency converter (A21-Fig. 1.6) depending
from dropping below a minimum pressure. The valve has a on the need for cooling capacity.
built-in check valve.
Water-cooled VSD are provided with a cooling water system,
including a combined oil cooler (2-Fig. 1.5) and air cooler (3-
Fig. 1.5), and a water flow regulating valve fitted in the water
piping next to the cooler block.

1.3 Condensate drain system (Fig. 1.4)

A condensate trap (28) is installed downstream of the air cooler

to separate condensate from air. The trap is connected to a
water drain collector (type EWD) which has an electronically 1.6 Electrical system
controlled drain system. On compressors equipped with an
OSD system (see section 5.4), condensate trap (28) is provided The system mainly includes:
with a float valve for automatically draining condensate and
with a manual drain valve. - Elektronikon® regulator (2-Fig. 1.2)
- Emergency stop button (S2-Fig. 1.2)
Full-Feature compressors, which are provided with an air - Electric cabinet (1-Fig. 1.2) including the variable speed
dryer, have a second condensate trap (3) downstream of the drive unit for the compressor of the air dryer
dryer. The trap is connected to a water drain collector (type - Main VSD cabinet including the variable speed drive units
EWD) which has an electronically controlled drain system. On for the drive motor (A11-Fig. 1.6) and on air-cooled VSD
compressors equipped with an OSD system (see section 5.4), also for the fan motor of the air/oil cooler block (A21-Fig.
condensate trap (3) is provided with a float valve for 1.6)
automatically draining condensate and with a manual drain - Drive motor (14-Fig. 1.2)
valve. - Pressure and temperature sensors

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Y2 Blow-off valve 17 Air receiver 33 Solenoid valve

1 Air filters 18 Oil separator element 34 Drive motor
2 Heat exchanger 19 Minimum pressure valve 35 Shut-down switch, high condenser
3 Condensate trap 20 Check valve pressure
4 Air cooler 21 Oil scavenging line 36 Thermostatic expansion valve
5 Cooling fan 22 Safety valve 37 Refrigerant condenser
6 Oil coolers 23 Oil filler plug 38 Elektronikon regulator
7 Oil filters 24 Oil level indicator 39 Cooling fan
8 Refrigerant compressor 25 Oil drain plug 40 Dryer by-pass valve (customer’s
9 Liquid separator 26 Thermostatic valve installation)
10 Condenser 27 Air outlet valve (customer’s 41 By-pass pipe (customer’s
11 Cooling fan installation) installation)
12 Electronic water drain 28 Condensate trap 42 Dryer shut-off valve (customer’s
13 Flange 29 Dryer shut-off valve installation)
14 Compressor element 30 Flexible, receiver blow-off 43 Liquid refrigerant dryer/filter
15 Oil stop valve 31 Hot gas by-pass valve 44 Flange
16 Check valve 32 Heat exchanger 45 Check valve

Fig. 1.4 Air flow - regulating system, GA315 VSD Full-Feature

1 Oil flow regulating valve

2 Oil cooler
3 Air cooler

Fig. 1.5 Coolers on GA315 W VSD

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A11 Frequency converter, drive motor

A21 Frequency converter, fan motors
of air/oil cooler block (air-cooled
VSD only)
Q1 Circuit breaker, control circuit
Q2 Circuit breaker, circuit of fan
motors (air-cooled VSD Full-
Feature only) and compressor
motor of dryer
Q20 Circuit breaker, supply circuit of
cooler block fan motors (air-
cooled VSD only)
Q25 Circuit breaker, cooler fan motor
(air-cooled VSD only)
Q26 Circuit breaker, cooler fan motor
(air-cooled VSD only)

Fig. 1.6 VSD cabinet

A31 Frequency converter, compressor

motor of dryer
F3/5 Circuit breakers, control circuit
F17/47 Circuit breakers, condensate circuit
K13 Auxiliary relay, motor running
indication
K40 Contactor, compressor motor of air
dryer (Full-Feature only)
K41 Contactor, fan motor of air dryer
(air-cooled VSD Full-Feature only)
K42 Contactor, fan motor of air dryer
(air-cooled VSD Full-Feature only)
Q40 Circuit breaker, compressor motor
of air dryer (Full-Feature only)
Q41 Circuit breaker, fan motor of air
dryer (air-cooled VSD Full-Feature
only)
Q42 Circuit breaker, fan motor of air
dryer (air-cooled VSD Full-Feature
only)
T1/T2 Transformers
1X1 Terminal strip

Fig. 1.7 Electric cabinet

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1.7 Elektronikon control system

In general, the Elektronikon regulator has following functions:

- controlling the speed of the drive motor (Variable Speed
Drive), reducing the power consumption and pressure band
- on air-cooled compressors, controlling the speed of the fans
of the coolers, reducing the power consumption and noise
level
- on air-cooled Full-Feature compressors, controlling the
speed of the compressor motor of the air dryer, reducing
the power consumption and regulating the dryer
performance
- protecting the compressor
- service warning
- automatic restart after voltage failure
- feeding back the actual status of the compressor

Fig. 1.8 Example of a pressure/time diagram

1.7.1 Controlling the compressor speed

VSD compressors optimize the power consumption and reduce

the operating pressure band by matching the motor speed to
the air net pressure.

The regulator will continuously vary the motor speed

maintaining the net pressure as close as possible to the
programmed pressure setpoint. The pressure fluctuations will
be very low. The compressor will also be stopped in case of overload of the
drive motor or fan motors.
Indirect stopping (Fig. 1.8)
In case of overload of the dryer motor, the dryer will be stopped
If the motor is running at minimum speed and the net pressure and a message will appear on display (3-Fig. 1.9) to warn the
rises to a value equal to the sum of the programmed pressure operator.
setpoint and the programmed indirect stop offset, the
compressor will stop. Consult the safety precautions as mentioned in section 4 and
remedy the trouble. After remedying and when the shut-down
When the net pressure drops, the regulator will calculate the condition has disappeared, switch on the voltage and press the
optimum moment to restart the compressor to avoid that the key Reset.
net pressure decreases to below the pressure setpoint
(anticipated starting). Shut-down warning
Direct stopping If the element outlet temperature or compressor outlet
temperature exceeds a programmed value below the shut-down
In case the net pressure should rise to a value equal to the sum level, LED (7-Fig. 1.9) will be lit and a message will appear on
of the programmed pressure setpoint and the programmed direct display (3-Fig. 1.9) to warn the operator before the shut-down
stop offset, the compressor will be stopped immediately. level is reached.
The regulator will calculate the optimum moment to restart the Consult the safety precautions as mentioned in section 4, stop
compressor. the compressor and remedy the trouble. The message disappears
as soon as the warning condition disappears.
1.7.2 Protecting the compressor
1.7.3 Service warning
Shut-down and motor overload
A number of service operations are grouped (called Level A,
If the element outlet temperature or compressor outlet B, C, ...). Each level has a programmed time interval. If a time
temperature exceeds the programmed shut-down level, the interval is exceeded, a message will appear on display (3-Fig.
compressor will be stopped. LED (7-Fig. 1.9) will blink and a 1.9) to warn the operator to carry out the service actions
message will appear on display (3-Fig. 1.9). belonging to that level. See section 4.

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1.7.4 Automatic restart after voltage failure 1.8 Control panel

The regulator has a built-in function to automatically restart
the compressor if the voltage is restored after voltage failure. 1.8.1 LEDs/buttons/keys
For compressors leaving the factory, this function is made
inactive. If desired, the function can be activated. Consult
Atlas Copco. Ref. Designation Function

Warning If activated and provided the module was in the

1 Stop button Push button to stop the
automatic operation mode, the compressor will
compressor. LED (8) goes out.
automatically restart if the supply voltage to the
module is restored within a programmed time
2 Start button Push button to start the
period.
compressor. LED (8) lights up
indicating that the regulator is
The power recovery time (the period within which
operative (in automatic operation).
the voltage must be restored to have an automatic
restart) can be set between 1 and 255 seconds or
3 Display Indicates messages concerning the
to Infinite. If the power recovery time is set to
compressor operating condition, a
Infinite, the compressor will always restart after
service need or a fault.
a voltage failure, no matter how long it takes to
restore the voltage. A restart delay can also be
4 Scroll keys Keys to scroll through the display.
programmed, allowing e.g. two compressors to be
restarted one after the other.
5 Tabulator key Key to select the parameter
indicated by a horizontal arrow.
Only the parameters followed by
an arrow pointing to the right are
accessible for modifying.

Fig. 1.9 Control panel

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The functions of the keys vary depending on the displayed menu.

Ref. Designation Function
The actual function is indicated on the bottom line of the display
just above the relevant key. The most common functions are
6 Voltage on LED Indicates that the voltage is listed below.
switched on.
Designation Function
7 General alarm Is alight if a warning, service
LED warning or shut-down warning
condition exists or if a sensor is Add To add compressor start/stop commands (day/
out of order. hour)

7 General alarm Blinks in case of shut-down, if a Back To return to a previously shown option or
LED sensor with shut-down function is menu
out of order or after an emergency
stop. Cancel To cancel a programmed setting when
programming parameters
8 Automatic Indicates that the regulator is
operation LED automatically controlling the Delete To delete compressor start/stop commands
compressor.
Help To find the Atlas Copco internet address
9 Function keys Keys to control and program the
compressor. See below. Limits To show limits for a programmable setting

10 Pictograph Alarm Main To return from a menu to the main screen

11 Pictograph Automatic operation Menu Starting from the main screen: to have access
to submenus
12 Pictograph Voltage on
Menu Starting from a submenu, to return to the
S2 Emergency Push button to stop the compressor previous menu
stop button immediately in case of emergency.
After remedying the trouble, Modify To modify programmable settings
unlock the button by pulling it out.
Program To program modified settings

Reset To reset a timer or message

1.8.2 Display (3-Fig. 1.9)
Return To return to a previously shown menu
The following is a typical example of the main screen, showing
in short the status of the compressor: Extra To find information regarding the installed
modules

Compressor Outlet 6.6 bar

Compressor Speed 2100 rpm ¯

Menu
F1 F2 F3
1.8.4 Emergency stop button (S2-Fig. 1.9)
Fig. 1.10 Main screen
In case of emergency, press the button to stop the compressor
immediately.

1.8.3 Function keys Pushing the button breaks the circuit to:
- the variable speed drive unit for the drive motor (A11)
The keys are used: - the variable speed drive unit for the fan motors of the coolers
- To call up or to program settings (A21) (air-cooled only)
- To reset a motor overload, shut-down or service message, - the variable speed drive unit for compressor motor of dryer
or an emergency stop (A31) (Full-Feature only)
- To have access to all data collected by the regulator - the fan motors of the dryer (air-cooled Full-Feature only)

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The circuit to the control circuit and other electrical

Program/ Description
components is not broken.
Function
By pushing the button, valve (Y2-Fig. 3.2) will open the blow-
off port, resulting in depressurizing of the air receiver. - fan motor: minimum speed, maximum
RPM reduction
Warning Before any maintenance or repair, consult the - dryer motor: proportional band,
Warning in section 4. integration time, minimum speed,
maximum RPM reduction, dryer
operation mode
1.9 Menu-driven control programs - parameters: minimum stop time,
communication time-out
To facilitate programming and controlling the compressor, - protections: compressor outlet pressure,
menu-driven programs are implemented in the electronic oil separator pressure drop, air filter
module. pressure drop, .... (see Fig. 1.11)
- service plans: timers for service plans
A simplified menu flow is shown in Fig. 1.11. - clock functions: automatic compressor
start/stop/pressure band commands
- configuration: time, date, display
1.9.1 Function of control programs language, …

Program/ Description Service Calling up service plans and resetting the

Function timers after carrying out the service actions
belonging to a plan. See section 4.

Main screen Shows in short the operation status of the Saved data Calling up the saved data: last shut-down,
compressor. It is the gateway to all last emergency stop data
functions. See Fig. 1.10.

Status data Calling up the status of the compressor

protection functions:
- shut-down
- shut-down warning
- service warning
- warning 1.9.2 Main screen
Resetting of a shut-down, motor overload
and service condition. When the voltage is switched on, the Main screen is shown
automatically, showing in short the operation status of the
Measured data Calling up: compressor.
- actually measured data
- the status of a number of inputs such as
the fan motor overload protection Compressor Outlet 6.6 bar

Counters Calling up the: Compressor Speed 2100 rpm ¯

- running hours Menu
- number of motor starts
- regulator (module) hours F1 F2 F3
- accumulated volume
Fig. 1.10 Main screen, typical example
Test Allows a display test.

Modify Modifying the settings for:

parameters - compressor and motor: setpoints,
indirect and direct stop levels, If the function keys or arrow keys are not used for some minutes,
proportional band, integration time, the display will automatically return to the Main screen.
minimum speed, maximum RPM
reduction Whenever displayed on a submenu screen, press the key Main
to return to the Main screen.

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Fig. 1.11 Menu flow

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1.9.3 Calling up other menus 2 INSTALLATION

Starting from the Main screen: Important - Working with machinery controlled by a
frequency converter requires special safety
- Use the ¯ key for a quick look at the actual compressor precautions which depend on the type of
status network (TN, TT or IT). Consult Atlas Copco.
- Press the key Menu (F1), the option Status data will be - The unit complies with class A limits for
followed by a horizontal arrow: radiated emission according to EN 55011
- either press the tabulator key (5-Fig. 1.9) to select this (1998). Beware of possible electro-magnetic
menu interferences in case stricter limitations are
- or use the ¯ key to scroll until the desired submenu is valid.
followed by a horizontal arrow and then press tabulator - The unit complies with limits according to
key (5-Fig. 1.9) to select this menu standards EN61000-4-2:1995, EN61000-4-
3:1996, EN61000-4-4:1995, EN61000-4-
6:1996 for immunity of the equipment
1.9.4 External compressor status indication

Terminal strip (1X1-Fig. 1.7) is provided with auxiliary contacts

for external indication of:
2.1 Dimension drawing
Indication Relay Terminals Max. load
on strip 1X1 See pages 15 and 16.

Warning K08 13-14 10 A / 230 V AC

Shut-down K09 15-16 10 A / 230 V AC
Compressor running K13 19-20 10 A / 230 V AC 2.2 Installation proposals (Figs. 2.3 and 2.4)

Warning Have the external equipment checked by Atlas See pages 17 and 18.
Copco. Before connecting the equipment, stop
the compressor and apply the safety precautions
as mentioned in section 4. Ref.

See ref. 1
Install the compressor on a level floor suitable for taking the
weight of the compressor. For ventilation proposal 1, the
minimum distance between the top of the bodywork and the
ceiling is 1200 mm.

See ref. 2
Remove the plastic plug (if provided) from the compressor air
outlet pipe (8-Fig. 1.3) and fit the air outlet valve (to be provided
by the customer) to the pipe. Close the valve and connect it to
the net.

See ref. 3
The pressure drop over the air outlet pipe can be calculated as
follows:

dp = (L x 450 x Qc1.85) / (d5 x p)

dp = pressure drop (recommended maximum = 0.1

bar)
L = length of outlet pipe in m
d = inner diameter of the outlet pipe in mm
p = absolute pressure at the compressor outlet in
bar(a)
Qc = free air delivery of the compressor in l/s

14 2920 1463 00
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Fig. 2.1 Dimension drawing GA315 VSD

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 Instruction book

Fig. 2.2 Dimension drawing GA315 W VSD

16 2920 1463 00
Instruction book

E Cooling air inlet,

integrated dryer
F Cooling air outlet,
air cooler and oil
A Cooling air inlet, coolers
air cooler and oil
coolers Important: Ducting or forced
B Cooling air outlet, ventilation is not allowed for
converters B, C, C', C'', D, E
C Cooling air outlet,
motor and dryer Fig. 2.3 Installation
C' - C'' Additional cooling proposal GA315
air outlet for VSD
tropical version
dryer
D Cooling air inlet,
motor and
converters

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 Instruction book

A Compressor air inlet

B Cooling air outlet,
converters
C Cooling air outlet,
motor
D Cooling air inlet,
motor and converters

Fig. 2.4 Installation

proposal
GA315 W
VSD

18 2920 1463 00
Instruction book

It is strongly recommended that the connection of the See ref. 8

compressor air outlet pipe is made on top of the main air net Connections for water supply for optional energy recovery
pipe to minimize carry-over of possible remainder of system.
condensate.
For GA315 W VSD
See ref. 4 Fit a water shut-off valve and a water drain valve in the
The inlet grids and ventilation fan should be installed in such a compressor water inlet pipe and outlet pipe. Remove the plastic
way that any recirculation of cooling air to the compressor is plugs (if provided) from the compressor water pipes and connect
avoided. The maximum air velocity through the grids is 5 m/s. the pipes to the cooling water circuit.

The required ventilation to limit the compressor room

temperature can be calculated as follows:
2.2.1 Dryer by-pass system for Full-Feature
compressors
For GA315 VSD: Qv = 0.9 N/dT
It is strongly recommended to provide a by-pass pipe system
Qv = required ventilation capacity in m3/s to by-pass the dryer in case of servicing the dryer (Fig. 2.5).
N = N1+N2
N1 = power input of compressor including cooling Important
fans (consult Atlas Copco) in kW (for - The pressure sensor must be repositioned from location (P)
ventilation alternative 1 or 3) to location (P'), downstream of valve (2) and upstream of
N1 = 10% of power input of compressor in kW (for valve (4). Fit the sensor upright.
ventilation alternative 2 or 4) - The temperature sensor must be repositioned from location
N2 = heat dissipated by cooling air flow of the dryer (T) to location (T'), downstream of valve (2) and upstream
in kW (only Full-Feature) of valve (4).
dT = temperature increase in compressor room (°C)
Dryer in operation:
For GA315 W VSD: Qv = 0.9 N/dT (with a minimum Open valve (1)
of 2.5 m³/s) Open valve (2)
Close valve (3)
Qv = required ventilation capacity in m3/s
N = 10% of power input of compressor in kW Dryer by-passed:
(consult Atlas Copco) Open valve (3)
dT = temperature increase in compressor room Close valve (1)
Close valve (2)
If cooling air ducts are installed, the maximum allowable
pressure drop over the ducts is 30 Pa. The maximum Remark: closing valves (2) and (3) will cause the safety valve
pressure drop depends on the ambient temperature. The to open.
fan capacity should match the compressor fan capacity
at a pressure head equal to the pressure drop caused by
the cooling air outlet ducts. Consult Atlas Copco.
2.3 Electric cable size
See ref. 5 For the main power supply cable use heat-resistant cables, 70
Remove the plastic plugs (if provided) from the condensate °C or higher (XLPE). The Cu-cables are dimensioned for fixed
outlets (see remarks-Fig. 3.3). Lay out the drain piping towards installation. Shielded cable is strongly recommended.
the condensate collector. The drain pipes must not dip into the
water of the drain collector. It is recommended to provide a
funnel to allow visual inspection of the condensate flow. For IEC

See ref. 6 Supply cable 1

Location of the Elektronikon regulator.
Cable: 3x185 + 95 SV mm²
See ref. 7 Number:3
Location of mains cable entry box. See section 2.3 for the
recommended size of the supply cables. Check that the Maximum cable length at 800 A (allowable short-circuit time 5
electrical connections correspond to the local codes. The seconds): 81 m
installation must be earthed and protected against short circuits Maximum cable length at 800 A (allowable short-circuit time
by fuses in all phases. An isolating switch must be installed 0.4 seconds): 44 m
near the compressor.

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 Instruction book

1 Dryer shut-off valve 6 Dryer by-pass pipe T Temperature sensor

2 Dryer shut-off valve 7 Adapter
3 Dryer by-pass valve E Electric wiring Note: Items 2, 3, 4, 6 and 7 to be
4 Compressor shut-off valve P Pressure sensor provided by customer
5 Adapter (DIN/ANSI)
Fig. 2.5 dryer by-pass system

Supply cable 2 Maximum cable length at 800 A (allowable short-circuit time 5

seconds): 81 m
Cable: 3x120 + 70 SV mm² Maximum cable length at 800 A (allowable short-circuit time
Number:4 0.4 seconds): 44 m

Maximum cable length at 800 A (allowable short-circuit time 5 Supply cable 2

seconds): 56 m
Maximum cable length at 800 A (allowable short-circuit time Cable: 3xAWG0000 (125 °C) + 70 SV mm²
0.4 seconds): 33 m Number:4

For CSA/UL Maximum cable length at 800 A (allowable short-circuit time 5

seconds): 56 m
Supply cable 1 Maximum cable length at 800 A (allowable short-circuit time
0.4 seconds): 33 m
Cable: 3xMCC350 (125 °C) + 95 SV mm²
Number:3

20 2920 1463 00
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A1 RFI filter K42 Contactor, fan motor of air dryer Q20 Circuit breaker, supply circuit of
A11 Frequency converter, drive (air-cooled VSD Full-Feature only) cooler block fan motors (air-
motor M Drive motor cooled VSD only)
A21 Frequency converter, fan M25 Cooler fan motor (air-cooled VSD Q25 Circuit breaker, cooler fan motor
motors of air cooler (air-cooled only) (air-cooled VSD only)
VSD only) M26 Cooler fan motor (air-cooled VSD Q26 Circuit breaker, cooler fan motor
A31 Frequency converter, only) (air-cooled VSD only)
compressor motor of dryer M40 Compressor motor of air dryer (Full- Q40 Circuit breaker, compressor
K13 Auxiliary relay, motor running Feature only) motor of air dryer (Full-Feature
indication M41 Fan motor of air dryer (air-cooled only)
K21 Contactor, emergency stop VSD Full-Feature only) Q41 Circuit breaker, fan motor of air
K40 Contactor, compressor motor of M42 Fan motor of air dryer (air-cooled dryer (air-cooled VSD Full-
air dryer (Full-Feature only) VSD Full-Feature only) Feature only)
K41 Contactor, fan motor of air Q1 Circuit breaker, control circuit Q42 Circuit breaker, fan motor of air
dryer (air-cooled VSD Full- Q2 Circuit breaker, circuit of fan motors dryer (air-cooled VSD Full-
Feature only) (air-cooled VSD Full-Feature only) Feature only)
and compressor motor of dryer
Fig. 2.6 Electrical connections (typical example)

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 Instruction book

2.4 Pictographs

Fig. 2.7 Pictographs, control panel

Fig. 2.8 Pictographs, other locations (typical examples)

1 Emergency stop 19 Switch off the voltage and depressurize the compressor
2 Stop before maintenance or repair
3 Start 20 Before connecting the compressor electrically, consult
4 Scroll key, upwards the Instruction book for the motor rotation direction
5 Tabulator key 21 Torques for steel (Fe) or brass (CuZn) bolts
6 Scroll key, downwards 22 Consult the Instruction book before greasing
7 Voltage on 23 Switch off the voltage before removing the protecting
8 Alarm cover inside the electric cabinet
9 Automatic operation 24 Oil the gaskets, screw on the filters and tighten by hand
13 Automatic condensate drain (approx. one half turn)
14 Automatic condensate drain for optional oil/water 25 Consult the Instruction book before maintenance or
separator (type OSD) repair
15 Manual condensate drain 26 Cooling water inlet
16 Stop the compressor before maintenance or repair 27 Cooling water outlet
17 Warning: under tension 28 Oil outlet
18 Read Instruction book before starting the compressor 29 Switch off main isolating switch and wait 6 minutes
before removing screen

Figs. 2.7 and 2.8 Pictographs

22 2920 1463 00
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2.5 Cooling water requirements 2.5.2 Cooling water parameters

The cooling water quality must meet certain minimum The Rysnar stability index (RSI)
requirements.
The Rysnar Index (RSI) is a parameter for predicting whether
No general recommendation can encompass the effects of all water will tend to dissolve or precipitate calcium carbonate.
combinations of the various compounds, solids and gases The adhesion of scaling depositions and their effect are different
typically found in cooling water in interaction with different on different materials, but the equilibrium of the water (scaling
materials. or corrosive) is only determined by its actual pH value and by
the saturation pH value (pH ).
s
This recommendation is a general guide line for acceptable The saturation pH value is determined by the relationship
coolant quality. between the calcium hardness, the total alkalinity, the total solids
concentration and the temperature.

2.5.1 Type of system The Rysnar Index is calculated as follows :

Closed system RSI = 2*pH - pH

s
In a closed system, the same cooling water is circulating through
a system without contact with air. where pH = measured pH (at room temperature) of
water sample
Open system pH = pH at saturation
s
An open system is a pass-through system, or a circulating system
with a cooling tower. In the latter case, the composition of the The pH is calculated by using :
s
water that enters the cooler must be considered, and not the
composition of the make-up water. Due to the evaporative effect pH = (9.3 + A + B) - (C + D)
s
in the cooling tower, much higher concentrations of ions can
be obtained in the circulating water than in the make-up water. A: depends on the total solids
concentration (mg/l).

B: depends on the highest cooling

water temperature (°C),
For GA units take T = 75°C

C: depends on the calcium hardness

(ppm CaCO ).
3
D: depends on the HCO - concentration
3
or M-alkalinity (mval/l).

The values from A, B, C and D are found in the

table on the next page.

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 Instruction book

Total Dissolved   Temperature   Ca-hardness   M-Alkalinity  

solids (mg/l) A (°C) B (ppm CaCO ) C (mval/l) D
3

50 - 300 0.1 0-1 2.6 10 - 11 0.6 0.20 - 0.22 1.0

400 - 1000 0.2 2-6 2.5 12 - 13 0.7 0.24 - 0.26 1.1
    7-9 2.4 14 - 17 0.8 0.28 - 0.34 1.2
    10 - 13 2.3 18 - 22 0.9 0.36 - 0.44 1.3
    14 - 17 2.2 23 - 27 1.0 0.46 - 0.54 1.4
    18 - 21 2.1 28 - 34 1.1 0.56 - 0.70 1.5
    22 - 27 2.0 35 - 43 1.2 0.72 - 0.88 1.6
    28 - 31 1.9 44 - 55 1.3 0.90 - 1.10 1.7
    32 - 37 1.8 56 - 69 1.4 1.12 - 1.38 1.8
    38 - 44 1.7 70 - 87 1.5 1.40 - 1.76 1.9
    45 - 50 1.6 88 - 110 1.6 1.78 - 2.20 2.0
    51 - 56 1.5 111 - 138 1.7 2.22 - 2.78 2.1
    57 - 63 1.4 138 - 174 1.8 2.80 - 3.54 2.2
    64 - 71 1.3 175 - 220 1.9 3.54 - 4.40 2.3
    72 - 80 1.2 230 - 270 2.0 4.6 - 5.4 2.4
        280 - 340 2.1 5.6 - 7.0 2.5
        350 - 430 2.2 7.2 - 8.8 2.6
        440 - 550 2.3 9.0 - 11.0 2.7
        560 - 690 2.4 11.2 - 13.8 2.8
        700 - 870 2.5 14.0 - 17.6 2.9
        880 - 1000 2.6 17.8 - 20.0 3.0

The interpretation of the values obtained is :

RSI < 6 boiler scale formation

RSI 6 - 7 neutral water
RSI > 7 corrosive water

A more detailed interpretation follows below :

RSI Tendency of the water Action

RSI < 3.9 Very high scale formation Water cannot be used

4.0 < RSI < 5.5 High boiler scale formation Regular control and descaling operation necessary

5.6 < RSI < 6.2 Slight boiler scale formation Water treatment not necessary
Occasional inspection recommended

6.3 < RSI < 6.8 Neutral water Water treatment not necessary
Occasional inspection recommended

6.9 < RSI < 7.5 Slight corrosion at higher temperature Water treatment not necessary
Occasional inspection recommended

7.6 < RSI < 9.0 Strong corrosion Regular control necessary, use of corrosion inhibitor
recommended

9.1 < RSI < 11 Very strong corrosion Regular control necessary, use of corrosion inhibitor required

RSI > 11 Very strong corrosion in complete

water system Water should not be used

24 2920 1463 00
Instruction book

This table indicates that distilled or demineralised water should Ammonia

never be used, as their RSI is >11.
< 0.5 ppm
The RSI is only indicating the equilibrium of scaling – descaling.
A cooling water showing good RSI conditions can still be Copper
unsuitable due to other factors.
< 1 ppm
From the table above, the RSI index should be between 5.6
and 7.5, otherwise contact a specialist. Iron and Manganese

pH < 1 ppm

The effect of pH is already calculated in the Rysnar index, but Organics

the pH itself has some additional limitations :
No algae.
For GA units 6.8 < pH No oil.

Total Dissolved solids (TDS) Suspended solids

This is the sum of all ions in the water. It can be derived from Non-soluble particles, size < 1 mm.
the dry residue after evaporation (but not including suspended < 10 ppm
solids), or it can be estimated from the electrical conductivity.

In a closed system, the following limits apply :

All units TDS < 3000 mg/l (<3800 µS/cm)

For an open system, the following limits apply :

For GA units TDS < 450 mg/l ( < 580 µS/cm)

Chlorides (Cl-)

Chloride ions will create pitting corrosion on stainless steel.

Their concentration should be limited :

Closed cooling system : Chlorides < 500 ppm

Open cooling system : Chlorides < 150 ppm

However, if the water is scaling, lower limits should be used.

(See The Rysnar stability index (RSI)).

Free chlorine (Cl )

2

Continuously, a level of 0.5 ppm should not be exceeded.

For shock treatments, a maximum limit of 2 ppm for maximum
30 minutes/day applies.

Sulphates (SO --)

4

Closed cooling system : Sulphates < 400 ppm

Open cooling system : Sulphates < 150 ppm

Carbonate hardness

Closed cooling system : 50-1000 ppm CaCO

3
Open cooling system : 50-500 ppm CaCO
3

HCO / SO - 2-
should be > 1
3 4

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 Instruction book

3 OPERATING INSTRUCTIONS
Safety precautions
The operator must apply all related safety precautions including
those mentioned in this book.

Ambient conditions
Consult section 7 for the limitations with regard to the ambient
conditions and altitude operation.

Moving/lifting
The compressor can be moved by a lift truck using the slots in
the frame. Make sure to place the forks at the motor side and
to put them as far as possible (more than half of the frame).
The compressor can also be lifted after inserting beams in the
slots. Make sure that the beams cannot slide and that they
protrude from the frame equally. The chains must be held
parallel to the bodywork by chain spreaders in order not to
damage the compressor. The lifting equipment must be placed
in such a way that the compressor will be lifted perpendicularly.
Lift smoothly and avoid twisting.

1 Plug
3.1 Initial start-up Y2 Blow-off valve

1. Consult section 2 for the electric cable size, installation Fig. 3.2 Blow-off valve
proposals and dimension drawings.
2. A sticker dealing in short with the operation instructions is
delivered with the literature set. Affix the sticker next to
the control panel.

3. The coupling housing supports, motor support and air

receiver supports are secured to the frame, immobilizing
the vibration dampers during transport:
Remove bushes from the coupling housing supports (4-Fig.
3.1), from the motor support (2-Fig. 3.1) and from air
receiver supports (5-Fig. 3.6). If provided, also remove
the red bracket underneath the DD filter (7-Fig. 1.3).
4. Remove plug (1-Fig. 3.2) from the air inlet flange and pour
approx. 5 l of oil into the compressor element. Reinstall
the plug.
5. If provided, close the condensate drain valve(s) (Fig. 3.3).
6. For water-cooled VSD, check that the cooling water drain
valves (customer's installation) in the inlet and outlet lines
are closed and that the water shut-off valves (customer's
installation) are open. Open the water regulating valve
(located inside the compressor next to the oil/water coolers)
and check for water flow.
7. Check that the compressor is filled with oil: the pointer of
oil level indicator (4-Fig. 3.6) should be in the green range.
1 Vibration damper 8. For Full-Feature compressors: it is strongly recommended
2 Bush (to be removed) to provide a by-pass system for the air dryer; make sure
3 Vibration damper that the dryer shut-off valves are open and that the dryer
4 Bush (to be removed) by-pass valve is closed (see section 2.2).
5 Oil stop valve/check valve 9. For compressors provided with an OSD oil/water separation
system (see section 5.4): fill the vessels with water to the
Fig. 3.1 Transport fixations, coupling housing level of the water outlet and re-install the cover.

26 2920 1463 00
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10. Check that the electrical connections correspond to the local

codes. The installation must be earthed and protected by
fuses in all phases. An isolating switch must be provided.
11. Check the connections at the primary sides of transformers
(T1 and T2-Fig. 1.7). Check the setting of the circuit
breakers. See Fig. 2.6 and section 7.3.
12. Switch on the voltage. Start the compressor and stop it
immediately. Check for correct direction of rotation
while the motor is coasting to a stop. The correct rotation
direction is indicated by an arrow on the drive motor
coupling housing. Consult Atlas Copco if the rotation
direction is wrong.

1 Water outlet (GA315 W VSD)

2 Water inlet (GA315 W VSD)
3 Connection for optional energy recovery system
4 Connection for optional energy recovery system

Fig. 3.4 Side view

13. Run the compressor for a few minutes and check that it
operates normally. On air-cooled Full-Feature compressors:
1 Connection for air outlet valve when the dryer starts running, check the rotation direction
2 Voltage supply inlet of the fan motors (3-Fig. 1.2): cooling air must be drawn in
3 Automatic condensate drain for optional oil/water through grating (9-Fig. 3.3).
separator (type OSD)
4 Automatic oil drain for optional DD filter Remarks
5 Possible location for manual condensate valve (in case
of Full-Feature with OSD, see remarks) - Compressors without dryer have one condensate trap with
6 Automatic condensate drain (Full-Feature) an automatic drain outlet.
7 Possible location for manual condensate valve (in case - Full-Feature compressors have two condensate traps each
of OSD, see remarks) with an automatic drain outlet.
8 Automatic condensate drain - On compressors with an oil/water separation system (type
9 Cooling air inlet, integrated dryer (air-cooled Full- OSD, see also section 5.4), the condensate trap has an
Feature) automatic outlet and a manual valve underneath the trap
(on later production compressors, the valve may be fitted
Fig. 3.3 Connections outside the bodywork).

2920 1463 00 27
 Instruction book

- Full-Feature compressors with an oil/water separation 6. On water-cooled VSD, open the water shut-off valves
system (type OSD, see also section 5.4) have two condensate (customer's installation) and regulating valve (located inside
traps each with an automatic drain outlet and a manual valve the compressor next to the oil/water coolers) and check for
underneath the trap (or fitted outside the bodywork). water flow.

Lay out the drain piping towards the local condensate collector.
The drain pipes must not dip into the water of the drain collector.
It is recommended to provide a funnel to allow visual inspection
of the condensate flow. 3.3 Starting

1. Press start button (2-Fig. 3.5). The compressor starts

3.2 Before starting running and automatic operation LED (8) lights up.
2. On water-cooled VSD, adjust the water flow with the
Attention compressor running loaded, using the regulating valve
- The operator must apply all relevant safety precautions, located inside the compressor next to the oil/water
including those mentioned in this instruction book. coolers, to obtain the most suitable air temperature at the
- In case the water system was drained (see section 3.5), close outlet of the compressor element, i.e. between 2 and
the drain valves. approx. 7 degrees Celsius above the relevant temperature
- Switch off your cell phone in the neighbourhood of a GA in Fig. 3.7. Consult section 7.4 for the cooling water
VSD compressor which is under tension. consumption. If needed, consult Atlas Copco for correct
adjustment.
1. Switch on the voltage. Voltage on LED (6-Fig. 3.5) lights
up. Warning - When the compressor is stopped and automatic
2. If provided, close the condensate drain valve(s) (Fig. 3.3). operation LED (8) is alight, the compressor
3. Open air outlet valve (1-Fig. 3.3). may start automatically.
4. Check oil level indicator (4-Fig. 3.6): the pointer should be - If the start/stop timer is active, the compressor
in the green range or orange range. may start automatically, even if it was stopped
5. For GA Full-Feature, make sure that the dryer shut-off manually.
valves are open and that the dryer by-pass valve is closed
(consult section 2.2).

See section 1.8.1.

Fig. 3.5 Control panel

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3.4 During operation 3.5 Stopping

When automatic operation LED (8) is alight, the Elektronikon 1. Press stop button (1-Fig. 3.5). The compressor will stop
regulator is automatically controlling the compressor: the speed and LED (8) will go out.
will continuously vary to match the air delivery to the air 2. To stop the compressor in case of emergency, press
consumption, the compressor will start and stop whenever emergency stop button (S2-Fig. 3.5).
necessary. 3. Close air outlet valve (1-Fig. 3.3).
4. Open the condensate drain valve(s) (Fig. 3.3).
Keep all doors closed during operation.
On GA315 W VSD
5. Close the water shut-off valves.
6. If the compressor is installed in a room where freezing
temperatures are expected, drain the cooling system by
Checking the display (3-Fig. 3.5) opening the drain valves in the water inlet and outlet pipes
(customer's installation).
1. Daily check the display for readings and messages. 7. Switch off the voltage.
Normally, the main display (Fig. 1.10) is shown, indicating
the compressor outlet pressure, the motor speed and the
functions of the keys below the display. 3.6 Taking out of operation
2. Always check the display and remedy the trouble if alarm
LED (7) is alight or blinks. Consult section 1.7. At the end of the service life of the compressor, proceed as
3. The display (3) will show a service message if a service follows:
plan interval has been exceeded or if a service level for a
monitored component has been exceeded. Carry out the 1. Stop the compressor and close the air outlet valve.
service actions of the indicated plans or replace the 2. Depressurize the compressor (see the Warning above).
component and reset the relevant timer. Consult your Atlas Loosen plug (3-Fig. 3.6) one turn to permit any pressure to
Copco Customer Centre. See also section 4.1. escape.
4. For a quick look at the compressor status, consult section 3. Switch off the voltage and disconnect the compressor from
1.9.3. the mains.

Warning Before starting any maintenance or repairs:

- Stop the compressor. Close the air outlet valve.
- Press the test button on top of the electronic
water drain (Fig. 3.8) until the air system
between the air receiver and outlet valve is fully
depressurized. On units with an OSD system
(see section 5.4), open the manual drain valve
underneath condensate trap (6-Fig. 1.2) until
the air system between the air receiver and
outlet valve is fully depressurized (see also Fig.
3.3); close the valve after maintenance or
repair.
- Press the emergency button (S2-Fig. 3.5) to
cause the blow-off port of valve (Y2-Fig. 3.2)
to open, resulting in depressurizing of the air
receiver.
- Open the isolating switch (customer's
installation) to switch off the voltage to the
compressor.
- Repairs on VSD units (A11 and A21-Fig. 1.6)
and on VSD unit (A31-Fig. 1.7) may only be
carried out by Atlas Copco.
- Wait at least 6 minutes before starting any 1 Air receiver 5 Transport spacer
electrical repairs as hazardous high voltage 2 Oil drain plug 6 Oil drain plugs
remains on the condensers of the start and 3 Oil filler plug 7 Safety valve
speed regulation units for 6 minutes after 4 Oil level sight-glass
switching off the voltage.
Fig. 3.6 Air receiver

2920 1463 00 29
 Instruction book

Example: ambient temperature 20 degrees Celsius, relative humidity 100 % and working pressure 10 bar(e). The minimum
allowable temperature at the outlet of the compressor element is 68 degrees Celsius. Regulate the cooling water flow to obtain
a temperature between 70 and approx. 75 degrees Celsius at the outlet of the compressor element.

Fig. 3.7 Minimum allowable air temperature at outlet of compressor element (for water-cooled compressors)

4. Shut off and depressurize the part of the air net which is
connected to the outlet valve. Disconnect the compressor
air outlet pipe from the air net.
5. Drain the water, oil and condensate circuits.
6. Disconnect the compressor condensate piping from the
condensate drain net.
7. Disconnect the cooling water pipes from the compressor.

3.7 Instructions for use of air receiver

1. This equipment can contain pressurized air and oil; be aware

of its potential danger in case of misuse.
2. This equipment shall only be used as compressed air/oil
separator and shall be operated within the specified limits.
3. No alterations shall be made to this equipment by welding,
drilling, grinding or other methods of mechanical working
without written permission of the manufacturer. In case of 1 Condensate collector
damage to a part under pressure from any cause, the
complete part shall be replaced. Fig. 3.8 Electronic condensate drain (EWD)

30 2920 1463 00
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4. For the oil separator vessel: original bolts have to be used 4 MAINTENANCE
after opening for inside inspection. The bolts shall be
removed and fitted with the correct tool. The bolts shall be Warning Before starting any maintenance or repairs:
tightened with a torque of 355 Nm (+/- 85 Nm). Damaged - Stop the compressor. Close the air outlet valve.
bolts shall not be re-used. O-rings shall be replaced. - Press the test button on top of the electronic
5. The safety valve is designed in such a way that the pressure water drain (Fig. 3.8) until the air system
will not permanently exceed the maximum allowable between the air receiver and outlet valve is fully
operating pressure of the vessel, except for short pressure depressurized. On units with an OSD system
surges up to 1.1 times the design pressure. (see section 5.4), open the manual drain valve
6. Use only oil as specified by the manufacturer. underneath condensate trap (6-Fig. 1.2) until
7. Make sure to fully depressurize the vessel before opening the air system between the air receiver and
the drain plug or fill plug. outlet valve is fully depressurized (see also Fig.
8. This vessel and other parts under pressure have been 3.3); close the valve after maintenance or
designed and built to guarantee an operational lifetime in repair.
excess of 20 years and an infinite number of pressure load - Press the emergency button (S2-Fig. 3.5) to
cycles. A visual inspection (for damages, non-authorized cause the blow-off port of valve (Y2-Fig. 3.2)
alterations,...) of the vessel (at the outside and inside) is to open, resulting in depressurizing of the air
recommended every 5 years. Make sure to fully receiver.
depressurize and isolate the vessel before an inside - Open the isolating switch (customer's
inspection. installation) to switch off the voltage to the
9. At every inspection, also check the oil drain flexible. compressor.
Replace it in case of any wear or damage. - Repairs on VSD units (A11 and A21-Fig. 1.6)
and on VSD unit (A31-Fig. 1.7) may only be
carried out by Atlas Copco.
- Wait at least 6 minutes before starting any
electrical repairs as hazardous high voltage
remains on the condensers of the start and
speed regulation units for 6 minutes after
switching off the voltage.

Warranty-Product Liability

Use only Atlas Copco authorized genuine parts. Any damage

or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability.

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 Instruction book

4.1 Preventive maintenance schedule for the compressor

4.1.1 Regular service operations

To ensure safe operation and long service life carry out following operations at the interval (period or running hours) which
comes first. The "longer interval" checks must also include the "shorter interval" checks.
The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the environmental and working
conditions of the compressor.

Period Running hours Operation

Daily 8 Check readings on display.

Daily 8 Check that condensate is discharged during loading.

Daily -- Check oil level. Before starting, the level should be in the green or orange range.

Monthly 200 If an OSD system is provided: check the oil level in the oil collectors. If necessary, empty the
collectors and deliver the oil to the local collection service. Keep the covers of the vessels
installed to prevent possible evaporation. See section 5.4.

3-monthly -- If an OSD system is provided: remove, dismantle and clean float valve of condensate traps.

3-monthly -- Clean compressor.

3-monthly -- Check for possible leaks.

3-monthly 500 Check coolers, clean if necessary.

3-monthly 500 Remove air filters and inspect. Replace if dirty or damaged.

4.1.2 Service kits 4.1.4 Service plan

Atlas Copco Customer Centres will be glad to provide you with A number of service operations are grouped (called Level A,
a wide range of service kits. Service kits comprise all parts Level B, Level C, ...). Each level stands for a number of service
needed for servicing components and offer the benefits of actions to be carried out at the time intervals programmed in
genuine Atlas Copco parts while keeping the maintenance the Elektronikon regulator.
budget low. See also section 4.7.
When reaching a level, a message will appear on the screen.
After carrying out all service actions, the interval timers are to
be reset using the key "Reset" in menu "Service". Consult your
Atlas Copco Customer Centre.
4.1.3 Service agreements

Atlas Copco Customer Centres have a range of service

agreements to suit your needs:
4.2 Motor greasing
- An Inspection plan
- A Preventive maintenance plan 4.2.1 Fan motors on GA315 VSD
- A Total responsibility plan
The bearings are greased for life. Contact your Customer Centre
Contact your Customer Centre to agree on a tailor-made service for the replacement interval of the motor bearings. See also
agreement. It will ensure optimum operational efficiency, section 4.1.
minimise downtime and reduce the total life cycle costs.

32 2920 1463 00
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4.2.2 Drive motor (9-Fig. 1.1) 4.5 Oil filter change

Contact your Customer Centre for the greasing quantity and 1. Stop the compressor and close the outlet valve.
interval for the motor bearings. Recommended grease: Atlas Depressurize by pressing the test button of the drain
Copco Roto-Glide. See also section 4.1. collector (or by opening the valve underneath the
condensate trap) and by pressing the emergency stop
button. Consult the warning section at the beginning of
chapter 4. Unscrew plug (3-Fig. 3.6) only one turn to permit
any pressure in the system to escape.
4.3 Oil specifications 2. Provide an oil pan to avoid possible oil spilling. Remove
oil filters (10-Fig. 1.1).
Use following Atlas Copco oils: 3. Clean the filter seats on the manifold. Oil the gaskets of the
new filters and screw them into place until the gaskets
Roto-Inject Fluid is a high-quality lubricant for single-stage, contact their seats, then tighten by hand.
oil-injected screw compressors. 4. Tighten filler plug (3-Fig. 3.6).
5. After carrying out the maintenance operations of the related
HD Roto-FluidPlus ensures optimum lubrication for an service plan, the service warning must be reset. See also
extended service life for single-stage and two-stage oil-injected section 4.1.
screw compressors.

Contact your Customer Centre for the changing interval. See 4.6 Storage after installation
also section 4.1.
Run the compressor, e.g. twice a week, until warm.
Important
Never mix oils of different brands or types. If the compressor is going to be stored without running from
time to time, protective measures must be taken. Consult your
Atlas Copco Customer Centre.

4.4 Oil change 4.7 Service kits

1. Run the compressor until warm. The service kits are mentioned in the relevant Parts List.
2. Stop the compressor and close the outlet valve.
Depressurize by pressing the test button of the drain Atlas Copco Roto-injectfluid
collector (Fig. 3.8) (or by opening the valve underneath Atlas Copco Roto-injectfluid (see section 4.3) can be ordered
the condensate trap) and by pressing the emergency stop in following quantities:
button. Consult the warning section at the beginning of
chapter 4. Unscrew plug (3-Fig. 3.6) only one turn to permit Quantity Ordering number
any pressure in the system to escape. 20-litre can 2901 0522 00
3. Loosen the vent plug on top of the flexible between the oil 209-litre drum 2901 0045 01
coolers and oil filter housing.
4. Drain the oil by removing the drain plugs. A plug is provided Atlas Copco HD Roto-FluidPlus
on the air receiver (2-Fig. 3.6) and two plugs underneath Atlas Copco HD Roto-FluidPlus (see section 4.3) can be
oil stop valve/check valve (5-Fig. 3.1). In addition, GA315 ordered in following quantities:
VSD have drain plugs (6-Fig. 3.6) in the flexibles connected
to the coolers. Tighten the plugs after draining. Quantity Ordering number
5. Remove filler plug (3-Fig. 3.6). Fill the air receiver with 20-litre can 2901 0769 00
oil until the level reaches the filler opening. Reinstall and 209-litre drum 2901 0770 00
tighten plug (3-Fig. 3.6). Tighten the vent plug.
6. Run the compressor loaded for a few minutes to allow the
oil cooler by-pass valve to open. Stop the compressor and
wait a few minutes.
7. Depressurize the system (see step 2). Remove plug (3-Fig.
3.6). Fill the air receiver with oil until the level reaches the
filler opening. Tighten plug (3-Fig. 3.6).
8. After carrying out the maintenance operations of the related
service plan, the service warning must be reset. See also
section 4.1.

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5 ADJUSTMENTS AND SERVICING 5.4 Oil/water separators (Fig. 5.1)

PROCEDURES As an option, an oil/water separation system can be integrated
inside the bodywork to separate the major part of the oil from
5.1 Air filters (4-Fig. 1.1) the condensate. The condensate meets the requirements of the
environmental codes.
1. Stop the compressor and switch off the voltage to the
compressor. Remove the filters. The system includes an OSD315 oil/water separator (shown at
2. Fit the new filters. the left) connected to the condensate trap downstream of the
3. After carrying out the service actions of the related service air cooler. The condensate is led from the condensate trap
plan, the service warning must be reset. See also section through inlet (8) and filter (6) towards water vessel (3) where
4.1. the oil rises due to the difference in specific mass. The water
flows through condensate outlet (1) to the outside of the
bodywork. The oil flows into collector (7) which must be
5.2 Coolers emptied regularly.

Keep the coolers clean to maintain the cooling efficiency. For Full-Feature compressors, the system also includes an
OSD90 (shown at the right) connected to the dryer condensate
On air-cooled VSD trap. OSD90 are additionally provided with a pre-filter (4)
Stop the compressor and switch off the voltage to the and a pressure gauge (5).
compressor. Rotate the fans away from the cooler block. Blow
air from the compressor element compartment through the
coolers. Remove any dirt. Reposition and fix the fans. Make
sure that the fans rotate freely.

Note
If it should be necessary to wash the coolers with a cleansing
agent, consult your Atlas Copco Customer Centre.

On water-cooled VSD
Consult your Atlas Copco Customer Centre for cleaning.

5.3 Safety valve (7-Fig. 3.6)

3 2 2 3
The valve can only be tested on a separate compressed air line.

Warning Never run the compressor without safety valves. 1 1

No adjustments are allowed. 4
8
8
6 5

7 6 50891F

1 Water outlet
2 Oil outlet
3 Water vessel
4 Pre-filter
5 Pressure gauge
6 Filter
7 Oil collector
8 Condensate inlet

Fig. 5.1 OSD90/315 oil separators (option)

34 2920 1463 00
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6 PROBLEM SOLVING 5 Compressor air delivery or pressure below normal

a Air consumption exceeds air delivery of compressor
Warning Before starting any maintenance or repairs: a Check equipment connected
- Stop the compressor. Close the air outlet valve. b Choked air filters
- Press the test button on top of the electronic b Replace filters
water drain (Fig. 3.8) until the air system c Air leakages
between the air receiver and outlet valve is fully c Check and correct
depressurized. On units with an OSD system
(see section 5.4), open the manual drain valve 6 Compressor element outlet temperature or compressor
underneath condensate trap (6-Fig. 1.2) until outlet temperature above normal
the air system between the air receiver and a Insufficient cooling air
outlet valve is fully depressurized (see also Fig. a Check for cooling air restriction. Improve ventilation of
3.3); close the valve after maintenance or compressor room. Avoid recirculation of cooling air
repair. b On GA315 W VSD, cooling water temperature too high or
- Press the emergency button (S2-Fig. 3.5) to flow too low
cause the blow-off port of valve (Y2-Fig. 3.2) b Increase water flow. See also section 7
to open, resulting in depressurizing of the air c Oil level too low
receiver. c Check and correct as necessary
- Open the isolating switch (customer's d Oil cooler(s) clogged
installation) to switch off the voltage to the d Consult Atlas Copco
compressor. e Air cooler clogged
- Repairs on VSD units (A11 and A21-Fig. 1.6) e Consult Atlas Copco
and on VSD unit (A31-Fig. 1.7) may only be f On GA315 W VSD, restriction in cooling water system due
carried out by Atlas Copco. to dirt or formation of scale
- Wait at least 6 minutes before starting any f Consult Atlas Copco
electrical repairs as hazardous high voltage
remains on the condensers of the start and 7 If an oil/water separation system (OSD) is provided:
speed regulation units for 6 minutes after turbulences in separator vessel(s)
switching off the voltage. a Air leakage through condensate flexibles towards vessels
a Consult Atlas Copco
Faults and suggested remedies
8 If an oil/water separation system (OSD) is provided:
1 A service message appears on the display condensate is not discharged through OSD outlets
Replace the indicated component, change the oil or grease a Strainer/restrictors at the inlets of the separator vessels or
the drive motor as the case may be. Remedy the trouble flexibles clogged
and reset the message (menus Status data menu and Service). a Consult Atlas Copco
Consult your Atlas Copco Customer Centre. b Float valves of condensate traps malfunctioning
b Consult Atlas Copco
2 A shut-down warning message appears on the display
LED (7-Fig. 1.9) will light up indicating that the temperature
at the outlet of the compressor element or the compressor
outlet temperature is too high. See below. The message
disappears as soon as the cause of the trouble is remedied.
Consult your Atlas Copco Customer Centre.

3 Unit is shut-down
LED (7-Fig. 1.9) will blink indicating that the outlet
temperature is too high (see below) or in case of motor
overload. Remedy the trouble and reset the message (menu
Status data). Consult your Atlas Copco Customer Centre.

4 Condensate is not discharged from condensate trap(s)

during loading
a EWD (electronically controlled water drain system)
malfunctioning
a Consult Atlas Copco
b Float valve of condensate trap(s) malfunctioning (on units
with OSD system)
b Consult Atlas Copco

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7 PRINCIPAL DATA
7.1 Readings on display (Fig. 1.9)

Outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) Depends on pressure setpoint

Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm Varies (controlled by regulator)
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) See section 7.4

7.2 Setting of safety valve

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 12

7.3 Settings of circuit breakers - fuses

Voltage Network Frequency Approval Main Q1 Q2 Q2 Q2 Q20 Q25 Q26 Q40 Q41 Q42
supply system (Hz) fuses (A) (A) (A) (A) (A) (A) (A) (A) (A)
(V) (A) GA GA GA W
FF

400 TT/TN 50 IEC 800 3.4 46 46 27 16 8 8 27 2.1 2.1

500 TT/TN 50 IEC 800 2.8 37 37 22 13 7 7 22 1.8 1.8
380 TT/TN 60 IEC 800 4.0 50 50 32 19 10 10 32 2.5 2.5
440/460 TT/TN 60 CSA/UL 800 3.5 43 43 29 18 8.6 8.6 29 2.3 2.3

Notes
- For location of the circuit breakers, see Figs. 1.6 and 1.7.
- For the electrical connections, see Fig. 2.6.

7.4 Compressor specifications

7.4.1 Reference conditions

Absolute inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(a) 1

Relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . % 0
Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 20
Cooling water inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . °C 20
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 1800

7.4.2 Limitations

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

Minimum ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . °C 0
Maximum altitude operation . . . . . . . . . . . . . . . . . . . . . . . . . . m 1000
Maximum cooling water temperature at inlet, open circuit . . . °C 40
Maximum cooling water temperature at outlet, open circuit . . °C 50
Maximum cooling water temperature at inlet, closed circuit . . °C 40
Maximum cooling water temperature at outlet, closed circuit °C 60
Maximum cooling water inlet pressure . . . . . . . . . . . . . . . . . . bar(e) 10

36 2920 1463 00
Instruction book

7.4.3 Specific data

At pressure setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 4 7 9.5

Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7.5 7.5 10.5
Maximum working pressure, Full-Feature . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7.25 7.25 10.25
Maximum working pressure, Full-Feature and DD filter . . . . . . . . . . . . . bar(e) 6.9 6.9 9.9
Minimum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 4 4 4
Maximum motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 2250 2250 1900
Minimum motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 600 600 600
Power input at maximum speed, GA315 VSD . . . . . . . . . . . . . . . . . . . . . kW 272 316 299
Power input at maximum speed, GA315 VSD Full-Feature . . . . . . . . . . . kW 283 327 311
Power input at maximum speed, GA315 W VSD . . . . . . . . . . . . . . . . . . . kW 265 309 293
Power input at maximum speed, GA315 W VSD Full-Feature . . . . . . . . . kW 275 320 303
Oil capacity, GA315 VSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 145 145 145
Oil capacity, GA315 VSD with energy recovery . . . . . . . . . . . . . . . . . . . . l 160 160 160
Oil capacity, GA315 W VSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 118 118 118
Oil capacity, GA315 W VSD with energy recovery . . . . . . . . . . . . . . . . . l 133 133 133
Sound pressure level at minimum speed, GA315 VSD 1) . . . . . . . . . . . . . dB(A) 64 64 64
Sound pressure level at maximum speed, GA315 VSD 1) . . . . . . . . . . . . dB(A) 75 76 75
Sound pressure level at minimum speed, GA315 W VSD 1) . . . . . . . . . . dB(A) 64 64 64
Sound pressure level at maximum speed, GA315 W VSD 1) . . . . . . . . . . dB(A) 75 76 75
For GA315 W VSD, cooling water flow at maximum power at
temperature rise of 13 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 5.9 5.9 5.9
For GA315 W VSD, cooling water flow at maximum power at
temperature rise of 35 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 2.3 2.3 2.3
For GA315 W VSD, extra water cooling flow through dryer, approx. . . . l/s 0.6 0.6 0.6

7.5 Conversion list of SI units into British/American 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 degrees Celsius = (32 + 1.8 x) degrees Fahrenheit 2)

Footnotes chapter 7

1) According to PNEUROP PN8NTC2.2 under free field conditions at 1 m distance.

2) A temperature difference of 1 degree Celsius = a temperature difference of 1.8 degrees Fahrenheit.

2920 1463 00 37