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Atlas Copco GA200 User Manual

Atlas Copco GA200
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Atlas Copco Stationary Air Compressors
Important
1. This book applies to the compressors from serial number
AIF-024 378 onwards.
2. This book must be used together with the "User manual for Elektronikon
®
regulator", printed matter no.
2920 1291 0x.
*2920125102*
No. 2920 1251 02
Registration code: APC G 90/'99 / 38 / 995
Replaces 2920 1251 01
2000-01
GA90 - GA110 - GA132 - GA160 - GA200 - GA250 - GA315
GA90 W - GA110 W - GA132 W - GA160 W - GA200 W -
GA250 W - GA315 W
Instruction Book
Copyright 2000, 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
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Atlas Copco GA200 Specifications

General IconGeneral
ModelGA 200
TypeRotary Screw Compressor
Power200 kW
Drive TypeDirect Drive
Cooling MethodAir Cooled
CategoryIndustrial Air Compressor

Summary

1 Leading Particulars

1.1 General description

Overview of GA and GA W compressors, their types, and applications.

1.2 Elektronikon control system

Details about the electronic control system for compressor operation and protection.

1.2.1 Automatic control of compressor operation

How the regulator maintains pressure by loading/unloading.

1.2.1.2 Protecting the compressor

Information on shut-down and warning conditions for compressor protection.

1.2.1.3 Monitoring components subject to service

How the regulator monitors components for maintenance needs.

1.2.1.4 Automatic restart after voltage failure

Functionality for automatic compressor restart after power interruptions.

1.2.1.5 Permissive start

Explanation of the permissive start function for compressor element safety.

1.2.2 Control panel

Details on indicators, keys, and buttons of the compressor control panel.

Indicators, keys and buttons

Description of control panel indicators, keys, and buttons.

Selecting a menu

Guide on navigating menus for compressor control and monitoring.

1.2.3 Compressor control modes

Explanation of the four selectable control modes for the compressor.

1.2.4 External compressor status indication

How to get external indication of compressor status via terminal strip.

1.2.5 External communication

Information on connecting the compressor to external systems like ES100.

1.3 Regulating system

Overview of the compressor's regulating system.

1.3.1 Air flow

Description of the air flow path through the compressor.

1.3.2 Condensate drain system

Details on the condensate drain system, including moisture traps.

1.3.3 Oil system

Explanation of the oil system for lubrication and cooling.

1.3.4 Cooling system

Description of the air and oil cooling systems.

1.3.5 Regulating system

How the Elektronikon regulator controls pressure via loading/unloading.

1.3.5.1 Unloading

Step-by-step explanation of the compressor unloading process.

1.3.5.2 Loading

Step-by-step explanation of the compressor loading process.

2 Installation

2.1 Dimension drawings

Detailed dimension drawings for GA90 and -110 models.

Dimension drawing GA W 90 and -110

Dimension drawings for GA W 90 and -110 models.

Dimension drawing GA132 and -160

Dimension drawings for GA132 and -160 models.

Dimension drawing GA W 132 and -160

Dimension drawings for GA W 132 and -160 models.

Dimension drawing GA200 up to -315

Dimension drawings for GA200 up to -315 models.

2.2 Installation proposal

Guidelines for proposing and preparing the compressor installation.

Fig. 7. Installation proposal

Visual representation of installation proposals and ventilation options.

2.3 Electric cables

Details on selecting and sizing electric cables for compressor connections.

2.3.1 GA - 50 Hz

Electric cable specifications for GA compressors at 50 Hz.

2.3.2 GA W - 50 Hz

Electric cable specifications for GA W compressors at 50 Hz.

2.3.3 GA/GA W - 60 Hz (except for Canada/USA)

Electric cable specifications for GA/GA W at 60 Hz (excluding Canada/USA).

2.3.4 GA/GA W - 60 Hz compressors for Canada/USA

Electric cable specifications for GA/GA W at 60 Hz (Canada/USA).

2.4 Pictographs

Explanation of pictographs used on the control panel and bodywork.

Fig. 10b. Pictographs on/inside bodywork

Pictographs indicating maintenance and safety instructions on the bodywork.

2.5 Cooling water requirements

General requirements for cooling water to prevent problems.

3 Operating Instructions

Safety precautions

General safety precautions to be followed by the operator.

Outdoor/altitude operation

Precautions for operating the compressor outdoors or at high altitudes.

Moving/lifting

Instructions and precautions for moving or lifting the compressor.

3.1 Preparation for initial start-up

Steps to prepare the compressor for its first operation.

3.2 Before starting

Actions to take before starting the compressor.

3.3 Routine starting

Procedure for starting the compressor during normal operation.

3.4 Starting after emergency stop or shut-down

Steps to restart the compressor after an emergency stop or shutdown.

3.5 During operation

Instructions for operating the compressor during normal running.

3.5.1 Checking the display

How to check the display for readings, messages, and service needs.

3.6 Manual unloading/loading

How to manually control the compressor's loading and unloading states.

3.7 Stopping

Procedures for stopping the compressor normally or in an emergency.

3.8 Taking out of operation

Steps for decommissioning and removing the compressor from service.

4 Maintenance

4.1 Preventive maintenance schedule for the compressor

Schedule of maintenance tasks based on operating hours or time intervals.

4.2 Motors

Maintenance procedures for fan and drive motors.

4.2.1 Fan motors (GA only)

Specific maintenance for fan motors on GA models.

4.2.2 Drive motor

Maintenance for the main drive motor, including greasing.

4.3 Oil specifications

Recommended oil type and properties for compressor lubrication.

4.4 Oil change

Step-by-step guide for changing the compressor oil.

4.5 Oil filter change

Procedure for replacing the oil filters.

4.6 Storage after installation

Procedures for storing the compressor when not in use.

4.7 Service kits

Information on available service kits for maintenance parts.

5 Adjustments and Servicing Procedures

5.1 Air filters

Steps for inspecting and replacing air filters.

5.2 Coolers

Instructions for cleaning and maintaining air and oil coolers.

5.3 Safety valve

Operating and testing procedures for the safety valve.

6 Problem Solving

Faults and suggested remedies

Specific problems and their recommended solutions.

7 Principal Data

7.1 Readings on display

Explanation of readings shown on the compressor display.

7.2 Programmable settings

Overview of adjustable settings for compressor operation and protection.

7.3 Settings of safety valves

Specifications for setting safety valves based on pressure versions.

7.4 Settings of overload relay, circuit breakers and fuses

Recommended settings for motor overload relays and circuit breakers.

7.4.1 Motor overload relay and fuses for GA/GA W - 50 Hz with ABB motors

Fuse and overload relay settings for 50 Hz ABB motor compressors.

7.4.2 Motor overload relay and fuses for GA/GA W - 60 Hz with ABB motors

Fuse and overload relay settings for 60 Hz ABB motor compressors.

7.4.3 Motor overload relay and fuses for GA/GA W - 60 Hz with Siemens motors (USA/Canada only)

Fuse and overload relay settings for 60 Hz Siemens motor compressors.

7.4.4 Fan motor circuit breakers for GA - 50 Hz

Circuit breaker settings for fan motors on GA 50 Hz models.

7.4.5 Fan motor circuit breakers for GA - 60 Hz

Circuit breaker settings for fan motors on GA 60 Hz models.

7.5 Compressor specifications

General specifications for compressor performance under reference conditions.

7.5.1 Reference conditions

Standard conditions for compressor performance data.

7.5.2 Limitations

Operating limitations for inlet air, water, and pressure.

7.5.3 Specific data of GA/GA W 90 up to -160 7.5 bar - 50 Hz

Detailed performance data for GA/GA W 90-160 at 7.5 bar, 50 Hz.

7.5.4 Specific data of GA/GA W 90 up to -160 10 bar - 50 Hz

Detailed performance data for GA/GA W 90-160 at 10 bar, 50 Hz.

7.5.5 Specific data of GA/GA W 90 up to -160 13 bar - 50 Hz

Detailed performance data for GA/GA W 90-160 at 13 bar, 50 Hz.

7.5.6 Specific data of GA/GA W 90 up to -160 100 psi - 60 Hz

Detailed performance data for GA/GA W 90-160 at 100 psi, 60 Hz.

7.5.7 Specific data of GA/GA W 90 up to -160 125 psi - 60 Hz

Detailed performance data for GA/GA W 90-160 at 125 psi, 60 Hz.

7.5.8 Specific data of GA/GA W 90 up to -160 150 psi - 60 Hz

Detailed performance data for GA/GA W 90-160 at 150 psi, 60 Hz.

7.5.9 Specific data of GA/GA W 90 up to -160 200 psi - 60 Hz

Detailed performance data for GA/GA W 90-160 at 200 psi, 60 Hz.

7.5.10 Specific data of GA/GA W 200 and -250 7.5 bar - 50 Hz

Detailed performance data for GA/GA W 200-250 at 7.5 bar, 50 Hz.

7.5.11 Specific data of GA/GA W 200 and -250 10/13 bar - 50 Hz

Detailed performance data for GA/GA W 200-250 at 10/13 bar, 50 Hz.

7.5.12 Specific data of GA/GA W 200 up to -315 100 psi - 60 Hz

Detailed performance data for GA/GA W 200-315 at 100 psi, 60 Hz.

7.5.13 Specific data of GA/GA W 200 up to -315 125 psi - 60 Hz

Detailed performance data for GA/GA W 200-315 at 125 psi, 60 Hz.

7.5.14 Specific data of GA/GA W 200 up to -315 150 psi - 60 Hz

Detailed performance data for GA/GA W 200-315 at 150 psi, 60 Hz.

7.5.15 Specific data of GA/GA W 250 and -315 200 psi - 60 Hz

Detailed performance data for GA/GA W 250-315 at 200 psi, 60 Hz.

7.6 Conversion list of SI units into British/US units

Table for converting SI units to British/US units.

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