GA 15, GA 18, GA 22

Instruction Book

1
OWNERSHIP DATA
Unit type : .....................................................................
Motor type : .................................................................
Delivery date : ..............................................................
Service Plan : ................................................................
Owner's machine No. : ................................................
Unit serial No. : ............................................................
Motor serial No. : .........................................................
First start-up date : ......................................................

Selected lubricants
Compressor : ................................................................ Capacity : ......................................................................
Bearing grease type, electric motor ............................

Printed Matter Nos.

Atlas Copco instruction book : .................................... Motor instruction book : ...............................................
Atlas Copco parts list : ................................................ Motor parts list : ..........................................................
Atlas Copco logbook : ..................................................

Local Atlas Copco Representative

Name : ............................................................................................................................................................................
Address : ..........................................................................................................................................................................
Telephone : .......................................... Contact persons : Service : ..................................................................
Telex : .................................................. Parts : ......................................................................

SAFETY PRECAUTIONS FOR STATIONARY COMPRESSORS AND EQUIPMENT

To be read attentively and acted accordingly before installing, operating or repairing the unit.
In addition to normal safety rules which should be observed with stationery air compressors
and equipment, the following safety directions and precautions are of special importance.
When operating this unit, the operator must employ safe working practices and observe all
related local work safely requirements and ordinances.
The owner is responsible for maintaining the unit in a safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
Installation, operation, maintenance and repair shall only be performed by authorized, trained,
competent personnel.
Normal ratings (pressures, temperatures, time settings etc.) shall be durably marked.
Any modifications on the compressor shall only be performed in agreement with Atlas Copco
and under supervision of authorized, competent personnel.
If any statement in this book, especially with regard to safety, does not comply with local
legislation, the stricter of the two shall apply.
These precautions are general and cover several machine types and equipment; hence some
statements may not apply to the unit(s) described in this book.
lnstallation
Apart from general engineering practice in conformity with the local safety regulations, the
following directives are specially stressed:
A compressor shall be lifted only with adequate equipment in conformity with local safety
rules.
Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden do
dwell or stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be
kept within safe limits.
Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting
up the pipes. Distribution pipes and connections shall be of correct size and suitable for the
working pressure.
 Atlas Copco Stationary Air Compressors

GA 15, GA 18, GA 22

Instruction Book

• Copyright Notice
Any unauthorised use or copying of the contents or any part thereof is
prohibited.

This applies in particular to trademarks, model denominations, part numbers

and drawings.

Use only authorised parts any damage or malfunction caused by the use of
unauthorised parts is not covered by warranty or product liability.

www.atlascopco.com

Marketing Handbook
No. 9095 0503 04
2013-05

Atlas Copco Compressor Sales

(A Division of Atlas copco (India) Ltd.)
Industrial Air Division
Pune - india
Instruction book

Table of Contents

1 Safety precautions........................................................................................................ 6

1.1 Precautions during installation................................................................................................................ 6

1.2 Safety precautions during operation ...................................................................................................... 8
1.3 Safety precautions during maintenance or repair ................................................................................. 9
1.4 Safety precautions during decommissioning ...................................................................................... 11

2 General description ....................................................................................................12

2.1 Introduction ............................................................................................................................................. 12

2.2 Air flow .................................................................................................................................................... 15
2.3 Oil system ............................................................................................................................................... 17
2.4 Cooling system ....................................................................................................................................... 18
2.5 Condensate system ................................................................................................................................ 19
2.6 Regulating system .................................................................................................................................. 20
2.7 Electrical system ..................................................................................................................................... 21
2.8 Electrical diagrams ................................................................................................................................. 22
2.9 Air dryer .................................................................................................................................................. 24

3 Controller ES99 ............................................................................................................25

3.1 General description ................................................................................................................................. 25

3.2 General features ..................................................................................................................................... 29
3.3 CONNECTIONS ..................................................................................................................................... 31

4 Installation ...................................................................................................................32

4.1 Dimension drawings ............................................................................................................................... 32

4.2 Installation proposal ................................................................................................................................ 36
4.3 Electrical connections ............................................................................................................................. 37
4.4 Pictographs ............................................................................................................................................. 38

5 Operating instructions ...............................................................................................39

5.1 Before initial start-up .............................................................................................................................. 39

5.2 Initial start-up .......................................................................................................................................... 39
5.3 Before starting......................................................................................................................................... 43
5.4 Starting .................................................................................................................................................... 43
5.5 During operation ..................................................................................................................................... 43
5.6 Stopping .................................................................................................................................................. 44

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6 Maintenance ................................................................................................................45

6.1 Preventive maintenance schedule ......................................................................................................... 45

6.2 Drive motor ............................................................................................................................................. 47
6.3 Oil specifications .................................................................................................................................... 47
6.4 Oil and oil filter change ........................................................................................................................... 48
6.5 Oil separator change .............................................................................................................................. 49
6.6 Storage after installation ........................................................................................................................ 50
6.7 Service kits.............................................................................................................................................. 51

7 Adjustments and servicing procedures ....................................................................52

7.1 Air filter ................................................................................................................................................... 52

7.2 Coolers ................................................................................................................................................... 53
7.3 Safety valves........................................................................................................................................... 53

8 Problem solving ..........................................................................................................55

8.1 Problem solving ...................................................................................................................................... 55

9 Technical data .............................................................................................................58

9.1 Electric cable size .................................................................................................................................. 58

9.2 Settings for overload relay and fuses ..................................................................................................... 58
9.3 Dryer switches (IFD) ............................................................................................................................... 58
9.4 Reference conditions and limitations ...................................................................................................... 59
9.5 Compressor data for GA 15 up to GA 22 ............................................................................................... 60

10 Instructions for use of air receiver .............................................................................61

10.1 Instructions for use .............................................................................................................................. 61

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1 Safety precautions

To be read attentively and acted accordingly before installing, operating, repairing or

decommissioning the unit.
These recommendations apply to machinery processing or consuming air or inert gas.

Processing of any other gas requires additional safety precautions typical to the application, which
are not included herein.

In addition to normal safety rules, which should be observed with stationary air compressors and
equipment, the following safety directions and precautions are of special importance.

When operating this unit, the operator must employ safe working practices and observe all related
local work safety requirements and ordinances.

The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.

Authorized, trained, competent personnel only shall perform installation, operation, maintenance or
repair.

Normal ratings (pressures, temperatures, time settings, etc.) shall be durably marked.

Any modification on the compressor shall only be performed in agreement with Atlas Copco and
under supervision of authorized, competent personnel.

If any statement in this book, especially with regard to safety, does not comply with local legislation,
the stricter of the two shall apply.

These precautions are general and cover several machine types and equipment; hence some
statements may not apply to the unit(s) described in this book.

1.1 Precautions during installation

Apart from general engineering practice in conformity with the local safety regulations, the following
directives are specially stressed:
1. A compressor shall be lifted only with adequate equipment in conformity with local safety rules.
Please consult Atlas Copco to check if a dedicated lifting device is designed for this purpose.
Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or
stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within
safe limits.
Wear a safety helmet when working in the area of overhead or lifting equipment.
2. Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the
pipes. Any device for protection during transport shall be removed. Distribution pipes and
connections shall be of correct size and suitable for the working pressure. Undersized pipe or
poor routing of pipe will degrade the performance of the compressor.

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3. Place the unit where the air is as cool and clean as possible. If necessary, install a suction duct.
Never obstruct the air inlet. Care shall be taken to minimize the entry of moisture with the inlet
air. Stationary compressors are not designed for outdoor operation.
4. The aspired air shall be free from corrosive chemicals (e.g. sulfur) and flammable fumes or
vapors (e.g. paint solvents that can lead to internal fire or explosion).
5. Air-cooled units shall 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 inlet.
6. Arrange the air intake so that loose clothing of people cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the after-cooler or air net is free to expand
under heat and that it is not in contact with or close to flammable material.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of
strain.
9. If remote control is installed, the unit shall bear an obvious sign reading: “DANGER: This
machine is remotely controlled and may start without warning.”
As a further safeguard, persons switching on remotely controlled units shall take adequate
precautions to ensure that there is no one checking on or working on the machine. To this end, a
suitable notice shall be affixed to the start equipment.
10. On units with automatic start-stop system, a sign stating “This machine may start without
warning.” Shall be attached near the instrument panel.
11. Manual valves shall be installed to isolate each compressor from other compressors or from the
system air pressure. Non-return valves (check valves) shall not be relied upon for safely isolating
pressure systems A check valve in the air piping from the compressor can interfere with the
proper operation of the compressor controls.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the unit. Every
pressure vessel or auxiliary installed outside the unit to contain air above atmospheric pressure
shall be protected by a pressure-relieving device or devices as required.
13. Pipework or other parts with a temperature in excess of 70°C and which personnel in normal
operation may accidentally touch, shall be guarded or insulated. Other high-temperature
pipework shall be clearly marked.
14. If the ground is not level or can be subject to variable inclination, consult Atlas Copco.
15. Never drill holes in an electrical cabinet. Small metallic burrs can cause short-circuits in electrical
components.
16. Make sure to avoid condensation on electrical components (e.g. cubicle, Elektronikon and
frequency converter).
17. To preserve the protection of the electric cabinet and to protect its components from dust from
the environment and the entry of moisture in the electrical cabinet, it is absolutely necessary to
use a proper cable gland when connecting the power supply cable to the compressor.
Use of an improper cable gland can result in damage to or failure of the equipment. This
could also result in fire and fatalities.
18. For shipboard applications where variable inclination is expected, consult Atlas Copco’s line of
dedicated Marine equipment.
19. Avoid contact with sharp edges or hot surfaces to prevent damage to cable insulation.
20. The unit shall be protected against short circuits by fuses or adequate circuit breakers.
21. The customer shall provide a main disconnecting device in the compressor room.

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22. Before initial start-up and after service interventions, make sure the following final inspection
checks are made:
a. Inspect all electrical connections to verify there are no loose connections and all are tightened
correctly.
b. Check for strain relief on the (main) power cables.
c. Verify that the power requirement for the unit has been provided for by referencing to the unit
power label on the inside of the electrical cabinet door of the unit.
d. The branch circuit protection and supply cable size for the compressor must be sized to meet
the power requirement per local electrical codes.
e. Verify that the unit is correctly grounded using the proper size of wire connected to a tested
earth ground.
An improper electrical installation can result in damage to or failure of the equipment. This
could also result in fire and fatalities.
23. Before initial start-up and after service interventions, make sure the following final mechanical
inspection checks are made:
a. Inspect all connections to make sure they are tight, sealed and secured.
b. Visually inspect metal or nylon tubing located in the compressor. Tubes can come loose or
get damaged in shipping. Verify the flexibility of the nylon tubes while inspecting for damage.
Verify that all tubes are secure in their fittings to insure that none might leak or come loose
when the compressor is in operation.
Damaged or loose tubes can result in lubricant being sprayed on hot surfaces when the
compressor is in operation and result in damage to the compressor or fire.

After inspection, the power can be put to the installed compressor. With the proper power applied, the
rotation of the compressor and the cooling fan can be verified.

1.2 Safety precautions during operation

1. Air hoses shall be of correct size and suitable for the working pressure. Never use frayed,
damaged or deteriorated hoses. Use only the correct type and size of hose end fittings and
connections. When blowing through a hose or airline, 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.
2. Never play with compressed air. Do not apply it to your skin or direct an air stream at people.
Never use it to clean dirt from clothes. When using it to clean equipment, do so with extreme
caution and use eye protection.
3. The compressor is not considered as capable of producing air for breathing quality. For breathing
air quality, the compressed air must be adequately purified according to local legislation and
standards.
4. Never operate the unit when there is a possibility of taking in flammable or toxic fumes.
5. Never operate the unit at pressures below or in excess of its limit ratings as indicated on the
Principal Data sheet.
6. Keep all bodywork doors shut during operation. The door may be opened for short periods only,
e.g. to carry out checks. Wear ear protection when opening a door.

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7. People staying in environments or rooms where sound pressure level reaches or exceeds 90dB
(A) shall wear ear protection.
8. Periodically check that:
a. All guards are in place and securely fastened.
b. All hoses, tubes and / or pipes inside the unit are in good condition, secure and not rubbing.
c. There are no leaks.
d. All fasteners are tight.
e. All electrical cables are secure and in good order.
f. Safety valves and other pressure-relief devices are not obstructed by dirt or paint.
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse.
h. There is no excess of dust in the electrical cabinet.
9. If warm cooling air from compressors is used in heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of or tamper with the sound-damping material.

1.3 Safety precautions during maintenance or repair

Maintenance and repair work shall only be carried out under supervision of someone qualified for
the job.
To maintain warranty and to insure the compressor operates correctly and safely, genuine parts
must be used. Use of non-genuine parts, failure to correctly install equipment or perform
recommended scheduled maintenance will void warranty and result in damage to or failure of the
equipment. This could also result in fire and fatalities.
Before performing any maintenance, stop the compressor, close the shut-off valve at the unit
discharge, remove all electrical power from the equipment, verify the receiver tank on the unit is at
zero pressure and let the machine cool down. Take positive precautions to ensure that the unit
cannot be started inadvertently by following a lock-out tag-out procedure. In addition, a warning sign
bearing a legend such as “work in progress; do not start” shall be attached to the starting
equipment.

1. Before removing any pressurized component, effectively isolate the unit from all sources of
pressure and relieve the entire system of pressure and electrical power. Take positive
precautions to ensure that the unit cannot be started inadvertently. In addition, a warning sign
bearing a legend such as “work in progress; do not start” shall be attached to the starting
equipment.
2. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
3. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapors of cleaning liquids.
Never use caustic solvents, which can damage materials of the air net, e.g. polycarbonate bowls.
4. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with clean cloth, paper or tape. Make sure that no tools, loose parts
or rags are left in or on the unit.

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5. 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.
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.
Never use a light source with open flame for inspecting the interior of a machine,
pressure vessel, etc.
6. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam-cleaning or due to condensation of humid ambient air.
7. If the branch circuit is provided using a fused disconnect to supply power to the compressor, then
verify that all the fuses are of the same type and properly sized. If a circuit breaker is used to
supply power, verify that it is properly sized.
8. Visually inspect and verify that the connections at the branch circuit protection device are tight
and the wire insulation is not degraded.
9. Visually inspect the wire from the branch circuit protection device to the compressor starter to
verify that it is sized correctly and in good order.
10. Verify that the power wire and ground connections at the compressor starter are tight and in good
order.
11. Verify that the wire connections from the compressor starter to the compressor motor are tight
and in good order.
12. Replace filters in the electrical cabinet when they are saturated with dust.
13. Check if the sealing of the electrical cabinet is in perfect condition. If not, replace it.
14. Inspect all tubing in the compressor for possible leaks or normal aging and replace with genuine
parts if needed.
15. Verify if all tube fittings are tight and tubes are securely held in the fittings.
16. Also check all nylon tubes for chaffing, cracks and flexibility and replace with genuine parts to
insure safe operation.
17. Drain any condensate that may have collected in the receiver tank.
18. Take oil samples for evaluation and be sure to mark with customer name, compressor model,
compressor serial number and running hours of the compressor. Respect oil service intervals.
Oxidized oil will result in higher compressor temperatures that could result in fire.
19. Replace oil with genuine compressor oil of the same type when needed.
Low oil will result in oil foaming, oil carry over and higher compressor temperatures that
could result in fire.
20. Replace all consumables at recommended service intervals or sooner if operating conditions
warrant or replace every 12 months.
21. Make sure that all sound-damping material, e.g. 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 to
prevent the sound pressure level from increasing.
22. 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.

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23. Before clearing the unit for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct and that the control and shutdown devices function
correctly. If removed, check that the coupling guard of the compressor drive shaft has been
reinstalled.
24. The following safety precautions are stressed when handling refrigerant:
a. Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
b. 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 of or remove the
latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away;
then seek medical first aid.
c. Always wear safety glasses.
Poor maintenance or use of non-genuine parts will cause equipment failure and possibly result in
fire.

1.4 Safety precautions during decommissioning

Before decommissioning, stop the compressor, close the shut-off valve at the unit discharge,
remove all electrical power from the equipment, verify the receiver tank on the unit is at zero
pressure and let the machine cool down. Take positive precautions to ensure that the unit cannot be
started inadvertently. In addition, a warning sign bearing a legend such as “work in progress; do
not start” shall be attached to the starting equipment.

1. Before performing other work on the compressor, remove the power cable from the power
supply.
2. Before removing any pressurized component, effectively isolate the unit from all sources of
pressure and relieve the entire system of pressure.
3. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
4. Drain any condensate that may have collected in the receiver tank.
5. The following safety precautions are stressed when handling refrigerant:
a. Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
b. 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 of or remove the
latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away;
then seek medical first aid.
c. Always wear safety glasses.
6. Dispose of the compressor according to local waste handling regulations.

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2 General description
2.1 Introduction
lntroduction
GA 15 up to GA 22 are single-stage, oil-injected screw compressors driven by an electric motor.
The compressors are air-cooled.

GA Pack
GA Pack are enclosed in sound-insulated bodywork. The compressors are controlled by the
Atlas Copco ES99 I regulator. The electronic control module is fitted to the door on the front side.
An electric cabinet comprising the motor starter is located behind this panel.

Front view, GA 15 up to GA 22 Floor-mounted Pack

Floor-mounted compressors are directly installed on the floor.

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Front 1iew, GA 15 up to GA 22 Tank-mounted Pack

GA 15 up to GA 22 Tank-mounted are mounted on a large air receiver (AR) of 500 l (125 gal, 4.5
cu.ft)

Reference Name
AF Air filter
AR Air receiver
AV Air outlet valve
Ca Air cooler
Co Oil cooler
Dm1 Manual drain, air receiver
E1 Control panel
M1 Drive motor
MT Condensate trap
OF Oil filter
OS Oil separator
OT Oil tank
S3 Emergency stop button

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GA Full-Feature
GA Full-Feature (FF) are controlled by the Atlas Copco ES99. They are provided with an air dryer
integrated in the sound-insulated bodywork. The dryer removes condensate from the compressed
air by cooling the air to near freezing point and automatically draining the condensate

Front view, GA 15 up to GA 22 Floor-mounted Full-Feature

Floor-mounted compressors are directly installed on the floor.

Front 1iew, GA 15 up to GA 22 Tank-mounted Full-Feature

GA 15 up to GA 22 Tank-mounted are mounted on a large air receiver (AR) of 500 l (125 gal, 4.5
cu.ft)

9095 0503 04 14
 Instruction book

Reference Name
AF Air filter
AR Air receiver
AV Air outlet valve
Ca Air cooler
Co Oil cooler

Reference Name
Dm1 Manual drain, air receiver
DR Dryer
ER1 Elektronikon I regulator
M1 Drive motor
OF Oil filter
OS Oil separator
OT Oil tank
S3 Emergency stop button

2.2 Air flow

Flow diagram, GA Pack

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Flow diagram, GA Full-Feature

Reference Description
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
F Condensate
G Dry compressed air

Description
Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed.
Compressed air and oil flow into the oil tank (OT). The air is discharged through outlet valve (AV) via
minimum pressure valve (Vp) and air cooler (Ca).
Pack units are provided with a condensate trap (MT).

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On Full-Feature compressors, the air flows through air dryer (DR) before it is discharged through
outlet valve (AV). Also see section Air dryer IFD.

2.3 Oil system

Flow diagram

Oil system

References Description
1 For Pack units, compressed air flow to the condensate trap
For Full-Feature units, compressed air flow to the air dryer
A Air intake
B Air/oil mixture
C Oil
D Wet compressed air
F Condensate

Description
In oil tank (OT) most of the oil is removed from the air/oil mixture centrifugally. The rest is removed by
oil separator (OS). The oil collects in the lower part of oil tank (OT).
Air pressure forces the oil from oil tank (OT) through oil cooler (Co) and filter (OF) to compressor
element
(E) and the lubrication points.
Thermostatic by-pass valve (BV) starts opening the supply from cooler (Co) when the oil temperature
has increased to the set point. At approx. 15 ·C (27 ·F) above the set point, all the oil flows through the
oil cooler.

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2.4 Cooling system

Flow diagram

Cooling system

References Description
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate

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

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2.5 Condensate system

Condensate drains

Condensate drains pack units

Condensate drain Full-Feature units

Pack units have a condensate trap (MT). The condensate trap is provided with a manual drain (Dm)
and an automatic drain (Da).
Full-Feature units have an electronic drain (1). The electronic drain is provided with an automatic
drain (Da). Tank-mounted units are provided with an additional manual drain on the air receiver.

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2.6 Regulating system

Flow diagram

Regulating system of GA 15 up to GA 22

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. The
plunger of the valve returns:
• Solenoid valve (Y1) de-activates unloading valve/blow-off valve (UV).
• Unloading valve/blow-off valve (UV) connects the air receiver pressure (1) with chamber (2)
and to the blow-off opening (3).
• The pressure in chamber (2) causes the loading plunger (LP) to move upwards.
• The pressure is stabilised at low value. A small amount of air is kept drawn in and is
blown to the unloader.

Loading
When the net pressure decreases to the loading pressure, solenoid valve (Y1) is energised. The
plunger of solenoid (Y1) moves upwards:
• Solenoid valve (Y1) controls the unloading valve/blow-off valve (UV).
• Unloading valve/blow-off valve (UV) closes the air blow-off opening (3) and shuts off the
supply to chamber (2).
This causes loading plunger (LP) to move downwards and inlet valve (IV) to open fully. Air delivery is
resumed (100%), the compressor runs loaded.

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2.7 Electrical system

General
Also consult sections Electrical diagrams and Electrical connections.

Electrical components
The electrical system comprises following components:

Electric cubicle on GA 15 up to GA 22, typical example

Reference Designation
F1/2/3 Fuses
F4/5/6 Fuses
F7/8 Fuses for dryer (only on Full-Feature compressors)
F21 Overload relay, compressor motor
K11 Auxiliary contactor for dryer (only on Full-Feature compressors)
K21 Line contactor
K22 Star contactor
K23 Delta contactor
Reference Designation
T1/T3 Transformers
1X0 Terminal strip (voltage supply)
1X1 Terminal strip (motor)
X103/X108 Connectors
PE Earth terminal

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2.8 Electrical diagrams

Service diagram

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Diagram for Control Panel

Reference Compressor
T1 Transformer
K25 Phase sequence relay
K22 Start contactor
K23 Start contactor
K21 Line contactor
F1 Fuse
F2 Fuse
F3 Fuse
F21 Overload relay, compressor motor

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2.9 Air dryer

Description

Air dryer

Compressed air enters heat exchanger (10) 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 (4)
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 (5) where all the condensate is separated from the air. The condensate is automatically
drained. The cold, dried air flows through heat exchanger (10) where it is warmed up by the
incoming air.

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3 Controller ES99
3.1 General description
ES99 is a control box for small and medium capacity compressors.
The board enables to manage all the operations concerning starting and stopping of the compressor. The same
board checks the status of the machine and informs about defaults.

3.1.1 Input devices

The board has 7 digital inputs optoinsulated and equipotential.
The chart below shows the use of the inputs and how the contacts should be in normal conditions.

Description Contact

1 Overload el. motor Normally closed

2 Wrong rotation Normally closed

3 Oil over temperature Normally closed

4 Emergency push button Normally closed

Open : P>Pmax
5 Pressure switch
Closed : P<Pmin
6 Remote control Normally closed
Open : t1_vuoto
7 Unload settings
Closed : t2_vuoto

3.1.2 Output devices

The board controls 4 output signals described as follows:

Description Contact

1 Power relay Normally open

2 Star power relay Normally open

3 Delta power relay Normally open

4 Solenoid valve Normally open

3.1.3 Dip –Switch

Two dip-switches are located aside of the control box and enable to select the running option in presence of
tension when the ‘Remote control’ is activated.

Dip Switch Position Action

ON Remote control activated

1
OFF Remote control not activated

ON Automatic re-starting when power energy had been interrupted

2
OFF Waiting for re-set when power energy had been interrupted

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3.1.4 Serial port

A telephone socket is located aside the control box and it allows a serial connection with a Personal Computer
or screen display. This is to modify the settings of the control box and to control the compressor from a remote
source, replicating the starting and stopping signals as well alarms warnings and machine status.

3.1.5 Timing and running setting

In order to make the use of the control box easier, it has been decided to store the setting values into the static
memory type Eeprom. The following cross reference chart shows the default parameters set from the
compressor manufacturer:
Values and mes. Minimum and
Parameter Description
units maximum values

t_waiton Wait for starting following a stop 10 sec. 10÷60 sec.

Length of time to control the wrong rotation

t_rotaz 20 sec. 10÷ 60 sec
signal
Length of time during start of closing the
t_stella 4 sec. 3÷ 15sec.
star power relay
Delay to open the solenoid valve when
t_ritev 2 sec. 1 ÷10 sec.
compressor switch to load
Length of time of no-load running before to
t_spegn 30 sec. 10 ÷60 sec.
stop the compressor
Length of time in no-load running before
TX_1 6 min. 2÷ 12 min.
switching in Wait status. Bridge open
Length of time in no-load running before
TX_2 4 min. 1 ÷8 min.
switching in Wait status. Bridge closed

TY_1 Length of time in stand by Open bridge 6 min. 2÷12 min.

TY_2 Length of time in stand by Closed bridge 4 min. 1÷ 8 min.

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3.1.6 Keyboard
This is the layout of the keyboard

with three bush buttons.

Button Symbol Description

By pushing the button, the board is cleared by alarms. Keeping the

1 button pushed for more of 3 seconds, a test is carry out to check that all
L.E.D. run.

By pushing the button, the compressor starts. This feature is valid if the
2
remote control is not activated.

3 By pushing the button, the stopping procedure starts

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And ten lights to shows the following status:

Light Colour Symbol Light on Light blinking

An overload problem has

An overload problem on the electric
1 Red been noticed on the electric
motor is occurring
motor

A wrong rotation problem has

2 Red A wrong rotation problem is occurring
been noticed

A oil over temperature has A oil over temperature problem is

3 Red
been noticed occurring
Compressor starting: when the star
4 Yellow
power relay is activated

5 Green Compressor works in full load

The emergency button has

6 Red When any alarm is occurring
been pushed

When the unit has been

7 Green
switched off by remote control

When the unit is running in no load

8 Green EEPROM alarm
before to stop
When the compressor is When the compressor is wait for
9 Green
running starting

10 Green Unit plugged on

3.1.7 Technical features

Measurement unit
Power supply 12 Vac
Absorption 6 VA
Min. and max. temperature for stocking -20..+70 C°
Min. and max. working temperature 0.. + 50 C°
IEC801-4 3 Class
Output contact to replay 5 A
Output current triacs EV (NOT AVAILABLE) 5 A
Input current 8 mA

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3.2 General features

3.2.1 Starting
When the start button is pushed, the control box begins the starting sequence carrying out the following steps:
1. Waiting for a time set into the parameter “t_wait” in the case when the power relay has just been
released. This is showed by the control box by the blinking of light n.9
2. The starting mode is showed by light n.4 blinking for the length of time set into “t_stella” and it means
that the power and star relays are activated. From when the power relay is activated and for the length
of time set into “t_rotaz”, it controlled the input signal called “ Wrong rotation”, stopping immediately
the unit if the contact is open
3. When the length of time “t_stella” is expired, the star relay is deactivated and only the power relay
remains activated for a fixed time of 50 msec.
4. When the length of time “t_stella” is expired, the star power relay is activated and the light 9 is on. The
solenoid valve is energised after the time set in “t_ritev” if the pressure switch gives permission.
N.B.: Starting procedure is not available if the “remote control” feature is activated and the contact is
open.

3.2.2 Stopping
By pushing the button during the first two positions of starting, it makes the sudden stop of the compressor. If
the button is pushed when the star power relay is activated , the stopping procedure starts by counting the
length of time set in “t_spegn” on which the compressor runs in no-load mode with the solenoid valve not
energised. During all stopping procedure, the light 8 blinks. If the electronic control box is in “Stand-by” status,
pushing the stopping button makes the cancellation of all running procedures.

3.2.3 Stand By
In absence of air compressed needs from the user and with the pressure value over Pmax (signal from
pressure switch open), the compressor run in no load.
In order to reduce the energy costs, the compressor stops (stand-by) as soon as the following criteria are
matched:
1. Number of starting per hour .
2. When the compressor is still, starting must be immediate in order to supply satisfy the needs of the
user.
3. The time of no load before to stop the compressor in the case of no demand of air from the user,
must be the shortest as possible, compatible with the point 1).

The following is the criteria followed by the electronic board to define the time of no load before to stop
the compressor:
• When the compressor reached the maximum pressure for the first time, the no load time is set up to
30 seconds. This parameter is not changeable.
• When the compressor reaches the maximum pressure after the first cycle, the electronic card starts
to count the time of no load. If this time is lower than TX_1 (or TX_2 depending if the bridge is open
or closed) the next cycle the compressor will run in no load for all TY_1 (or TY_2 depending from the
• bridge 3 and 7)
• On the other hand, if the time of no load is bigger than TX_1 (or TX_2 depending if the bridge is
open or closed) the next cycle the compressor will run only for 30 seconds in no load.

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3.2.4 Controllo remoto

The remote control allows stopping the compressor from a remote source by opening the contract
between 11 and 3 in the control box. It necessary that the compressor has been started by pushing the
start button otherwise the remote control does not have any effect. By opening the contact, the stopping
procedure starts and light 7 turns on. By closing the contact, the compressor starts following the
starting procedure.
N.B.: The remote control function is managed by the dip switch n.1 located aside the electronic
box. If the position is OFF, the function is not operating and by opening the switch does not
have any effect.

3.2.5 Test
By pushing the button for a time less than 3 seconds, you clear all the alarms recorded by the
electronic control box; if you keep pushing for more than 3 seconds an automatic procedure is starting
to verify the good operational of the control box.

3.2.6 Alarms
The alarms controlled by the electronic control box are:
Overload electric motor
Wrong rotation
Over temperature
Emergency

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In case of one of the above alarms, the compressor is immediately stopped and the related light shows
the reason. Flashing of the light shows that the alarm is still on, while fixed light turned on means
waiting for reset.

3.3 CONNECTIONS
3.3.1 Terminal board
1 12 Vac energy supply
2 12 Vac energy supply
3 Signal input ground
4 Overload thermal motor input
5 Wrong rotation input
6 Oil over temperature input
7 Time mode selection input
8 Connection to the ground
9 NC
10 Pressure switch input
11 Remote control input
12 Emergency push button input
13 NC
14 Signal input ground
15 NC
16 Star relay output connection
17 Power relay output connection
18 Delta relay output connection
19 Signal output ground
20 Solenoid valves output
ti
3.3.2 Circuit diagram

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4 Installation
4.1 Dimension drawings
Dimension drawings, GA 15 up to GA 22

GA 15 up to GA 22 Floor-mounted Pack - 9096998631-01

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GA 15 up to GA 22 Floor-mounted Full-Feature - 9096998633-01

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GA 15 up to GA 22 Tank-mounted Pack - 9096998632-01

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GA 15 up to GA 22 Tank-mounted Full-Feature - 9096998634-01

Type GA 15 GA 18 GA 22 GA 15 GA 18 Full- GA 22 Full-

Pack Pack Pack Full- Feature Feature
Weight of Floor- 375 395 410 440 470 485
mounted version
(kg)
Weight of Tank- 500 520 535 565 595 610
mounted version
(kg)

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Ref. Name
1 Compressor air inlet
2 Motor and cooling air inlet
3 Compressed air outlet
4 Motor and compressor cooling air outlet
5 Electrical cable entry
6 Dryer cooling air inlet
7 Dryer cooling air outlet
8 Automatic drain
9 Manual drain

4.2 Installation proposal

Compressor room example

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Description

1 Install the compressor unit on a solid, level floor suitable for taking the weight.
Recommended minimum distance between top of the unit and ceiling is 900 mm (35
in). Distance between unit and walls stated are minimum.
* Recommed distance is 500 mm for easy access.
Air receiver may not be bolted to the ground.
2 Position of the compressed air outlet valve (can be located on both sides of the air
receiver).
3 The maximum total pipe length (including interconnecting piping between compressor
and receiver) can be calculated as follows:
dp = (L x 450 x Qc1.85) / (d5 x p)
d = Inner diameter of the outlet pipe in mm
dp = Pressure drop (recommended maximum = 0.1 bar/1.5 psi)
L = Length of outlet pipe in m
p = Absolute pressure at the compressor outlet in bar(a)
Qc = Free air delivery of the compressor in l/s
4 Ventilation: the inlet grids and ventilation fan should be installed in such a way that any
recirculation of cooling air to the compressor is avoided. The maximum air velocity
through the grids is 5 m/s (16.5 ft/s).
Cooling air ducts are not allowed.
The maximum air temperature at the compressor intake is 46 ·C (115 ·F) (minimum 0
·C / 32 ·F).
Qv = Required ventilation capacity in m 3/s
N = Shaft input of compressor in kW
dT = Temperature increase in compressor room
5 Mains cable entry.

4.3 Electrical connections

Description

Also see section Electrical diagrams.

1. Provide an isolating switch.
2. Check that the motor cables and wires inside the electric cabinet are clamped tight to their
terminals.
3. Check the fuses and the setting of the overload relay. See section Settings of overload relay and
fuses.
4. Connect the power supply cables to their terminals L1, L2, L3.
5. Connect neutral conductor to connector (N).
6. Connect earth conductor bolt (PE).
On GA 15 up to GA 22 Full-Feature:
• The voltage supply to the dryer must be 230 V single-phase. The voltage to the dryer is supplied
over the contacts of relay (K11), which close when the compressor is started.

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4.4 Pictographs

Pictographs GA 15 up to GA 22

Reference Designation
1 Warning: before connecting compressor electrically, consult Instruction book for motor
rotation direction
2 Torques for steel (Fe) or brass (CuZn) bolts
3 Warning: suction
4 Lightly oil gasket of oil filter, screw filter on and tighten by hand (approx. half a turn)
5 Consult the instruction book before carrying out maintenance
6 Warning: voltage
7 Warning: hot parts
8 Lock all doors of the bodywork before starting.
• If the sheet is pulled downwards: stop the compressor and switch off the voltage.
• Reverse two incoming lines. Repeat the previous step.
• If the sheet is blown away the motor rotation is correct.

9 Manual condensate drain

10 Automatic condensate drain
11 Warning: switch off the voltage and depressurise compressor before repairing
12 Warning: disconnect electrical supply before opening

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5 Operating instructions

5.1 Before initial start-up

Safety

The operator must apply all relevant safety precautions, including those mentioned in
this book.

Outdoor/altitude operation
If the compressor is installed outdoors or if the air inlet temperature can be below 0 ·C/32 ·F,
precautions must be taken. In this case, and also if operating above 1000 m (3300 ft), consult Atlas
Copco.

Moving/lifting
Floor-mounted unit: the compressor can be moved by a lift truck. Take care not to damage any
installed connections under the frame while moving the truck or compressor. For lifting make sure
that the forks are long enough to give a stable support for the compressor.
Tank-mounted unit: Move the compressor by a lift truck by positioning the forks below the lifting
supports that are mounted between the feet of the air receiver. Make sure that the forks are
positioned in the centre of the air receiver and lift carefully.

Remote starting/stopping on compressors equipped with an Control panel

Have the modifications checked by Atlas Copco. Stop the compressor and switch off the
voltage before connecting external equipment. Only voltage-free contacts are allowed.

Remote starting and stopping:

• Connect a start/programmed stop button between terminals 1 and 2 of terminal strip (X108). See
section Electrical system to locate the connector.

5.2 Initial start-up

Safety

The operator must apply all relevant safety precautions.

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Procedure

For the location of the air outlet valve and the drain connections, see sections
Introduction and Condensate system.

Motor and gear casing transport fixtures

Position of oil level sight-glass

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Electric cubicle

Location of the sheet

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1 Consult the sections Electric cable size,Installation proposals and Dimension drawings
2 The following transport fixtures, painted red, must be removed:
• Bolts (1)
• Bushes (2)
• Supports (3)

3 Check that the electrical connections correspond to the local codes and that all wires are clamped
tight to their terminals.
The installation must be earthed and protected against short circuits by fuses of the inert type in all
phases. An isolating switch must be installed near the compressor.

4 Check the settings of drive motor overload relay (F21).

Check that the motor overload relay is set for manual resetting.
5 Fit air outlet valve (AV); see section Introduction for the location of the valve.
Close the valve.
Connect the air net to the valve.
On compressors equipped with a dryer by-pass, fit the air outlet valve to the dryer by-pass pipe.
6 Connect the condensate drain outlet(s) to a drain collector.
See section Condensate system.
7 Check the oil level. See section Oil and oil filter change.
8 Provide labels, warning the operator that:
• The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco).
• The compressor is automatically controlled and may be restarted automatically.

9 Affix sheet (5) explaining the procedure for checking the motor rotation direction to the cooling air
outlet of the compressor. Consult section Dimension drawings.
Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of
drive motor (M1) while the motor is coasting to a stop.
Check the motor rotation of the motor using sheet (5). If the motor rotation direction is correct, the
label on the top grating will be blown upwards. If the sheet remains in place, the rotation direction is
incorrect.
If the rotation direction of the drive motor is incorrect, open the isolating switch and reverse two
incoming electric lines.
Optional phase sequence relay:
• If the compressor should fail to start, check the display.
• If the display shows the pictograph for motor overload, check the phase sequence relay.
Incorrect rotation direction of the drive motor may cause damage to the compressor.
10 On compressors equipped with an Elektronikon I regulator, check the settings; see section Settings.
11 Start and run the compressor for a few minutes. Check that the compressor operates normally.

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5.3 Before starting

Procedure

1 Check the oil level, top up if necessary. See section Initial start-up.

5.4 Starting

Controller ES99 - GA15 -GA 22

Procedure
Please check the section Starting from Controller ES99

5.5 During operation

Procedure

The operator must apply all relevant Safety precautions. Also consult section Problem
solving.
Removing the front panel (service panel) during operation will lead to an automatic
shutdown of the unit after a certain time depending of the compressor version.

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Position of oil level sight-glass on GA 15 up to GA 22

Press the stop button, close the air outlet valve and open (if provided) the manual condensate drains.
See section Introduction and section Condensate system for location of the outlet valve and water
drain.
Press the emergency stop button.
Regularly check the oil level. Three minutes after stopping, sight-glass (Gl) should be between 1/4
and 3/4 full. Wait until the compressor has stopped (40 seconds), depressurise the oil system by
unscrewing oil filler plug (FC) one turn and wait a few minutes. Remove the plug and top up oil, until
the sight-glass is full. Fit and tighten the plug (FC).
When automatic operation LED (8) is lit, the regulator is automatically controlling the
compressor, i.e. loading, unloading, stopping of the motors and restarting.

Regularly check that condensate is discharged during operation. See section Condensate system.

5.6 Stopping
Please check the section Stopping from Controller ES99

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6 Maintenance

6.1 Preventive maintenance schedule

Warranty - Product Liability
Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts
is not covered by Warranty or Product Liability.

Service kits
For overhauling or carrying out preventive maintenance, service kits are available (see section Service
kits).

Service contracts
Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance
work. Consult your Atlas Copco Customer Centre.

General
When servicing, replace all removed gaskets, O-rings and washers.

General

Period Operation
Yearly Replace DDx and PDx filters or whenever the pressure indicator points red.
Inspection of the wall thickness of the air receiver. Minimum wall thickness as specified
in respected. Local legislation overrules when more strict.

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For GA 15 upto GA 22

Running hours Operation

4000 (1) Replace the air filter element. (More frequently for dusty environment)
Replace prefilter at suction.
Replace the filter element of the electrical cabinet (where applicable)
Clean coolers
Check pressure and temperature reading.
Carry out a LED/display test.
Check for leakages
Open the manual drain valve (Dm) to clean the filter of the automatic drain. See
section Condensation system.
Test temperature shut-down function.
4000 (1) Change oil filter & Oil separator element.
8000 (2) If Atlas Copco Roto-Xtend fluid is used, change oil
(1): or yearly, witchever comes first
(2): Roto Xtended Duty Fluid

Recommended
Oil temperature End pressure oil service Max. time
(°C) (bar) interval (running interval (years)
hours)
<110 <14 8000 2
>110 <14 6000 2
>105 >14 4000 2
GAR Applications 4000 2

Running hours Operation

8000 On Pack units: remove, dismantle and clean float valve of condensate trap. See
section Condensate system.
8000 Test safety valves.

lmportant

• Always consult Atlas Copco if a timer setting has to be changed.

• For the change interval of oil and oil filter in extreme conditions of temperature,
humidity or cooling air, consult your Atlas Copco Customer Centre.
• Any leakage should be attended to immediately. Damaged flexibles or flexible joints
must be replaced.

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6.2 Drive motor

For GA 15 up to GA 22

The motor bearings are greased for life.

6.3 Oil specifications

Never mix oils of different brands or types.

To assure good oil quality, drain the compressor at all drain locations. Used oils left in the
compressor can contaminate the oil system.

It is strongly recommended to use Atlas Copco Fluid (see section Preventive maintenance schedule).

Atlas Copco Roto-Xtend Duty Fluid

(Special oil, delivered as an option)

Atlas Copco Roto-Xtend Duty Fluid is a high-quality synthetic lubricant for oil-injected scroll and
screw compressors which keeps the compressor in excellent condition. Roto-Xtend Duty Fluid
can be used for compressors operating at ambient temperatures between 0°C and 46°C (see
section Service kits).

47 9095 0503 04
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6.4 Oil and oil filter change

Warning

The operator must apply all relevant Safety precautions.

Procedure

Oil system components of GA 15 up to GA 22

9095 0503 04 48
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1 Run the compressor until warm. Stop the compressor after 3 minutes of unloaded operation.
Close the air outlet valve and switch off the voltage. Wait a few minutes and depressurise by
unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape.
Also open (if provided) the manual condensate drains.
2 Remove oil drain plug (DP1). Drain the oil by opening valve (Vd). Also remove the drain plug on
the flexible (1) near the element and the vent plug on the oil cooler. Close the valve and fit the
plugs after draining.
3 Collect the oil in a collector and deliver it to the local collection service. Refit and tighten the drain
and vent plugs after draining.
4 Remove the oil filter (OF). Clean the seat on the manifold. Oil the gasket of the new filter and
screw it into place. Tighten firmly by hand.
5 Remove filler plug (FC).
On GA 15 up to GA 22, insert an elbow coupling in the filler plug (FC) for easy filling. Fill the oil
tank (OT) with oil until the level reaches the middle of sight-glass (Gl).
Take care that no dirt drops into the system. Refit and tighten filler plug (FC).
6 Run the compressor loaded for a few minutes. Stop the compressor and wait a few minutes to
allow the oil to settle.
7 Depressurise the system by unscrewing filler plug (FC) just one turn to permit any pressure in the
system to escape. Remove the plug.
On GA 15 up to GA 22, fill the oil tank with oil until the sight-glass (Gl) is 3/4 full.
Tighten the filler plug.
8 • Reset the service timer:
• For compressors equipped with an Elektronikon I regulator, see section Calling up resetting
service timer

6.5 Oil separator change

Warning

The operator must apply all relevant Safety precautions.

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Procedure

Oil system components of GA 15 up to GA 22

1 Run the compressor until warm. Stop the compressor, close the air outlet valve and
switch off the voltage. Wait a few minutes and depressurise by unscrewing oil filler plug
(FC) just one turn to permit any pressure in the system to escape.
2 Wait 5 minutes and remove the oil separator (OS). Clean the seat on the manifold. Oil
the gasket of the new separator and screw it into place. Tighten firmly by hand.
3 Run the compressor loaded for a few minutes. Stop the compressor and wait a few
minutes to allow the oil to settle.
4 Depressurise the system by unscrewing filler plug (FC) just one turn to permit any
pressure in the system to escape. Remove the plug.
Fill the oil tank with oil until the sight-glass (Gl) is 3/4 full.
Tighten the filler plug.
5 • Reset the service timer:
• For compressors equipped with an Elektronikon I regulator, see section Calling up
resetting service timer

6.6 Storage after installation

Procedure
Run the compressor, e.g. twice a week, until warm. Load and unload the compressor a few times

If the compressor is going to be stored without running from time to time, protective
measures must be taken. Consult Atlas Copco

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6.7 Service kits

Description
Service kits are available offering the benefit of genuine Atlas Copco parts while keeping the
maintenance budget low. The kits comprise all parts needed for servicing.

Service kit for oil filters and air filters

Service kit for oil filters and air filters Ordering number
GA 15 up to GA 22 for 4000 running hours (filters 2901 0866 01
and oil separator)
For GA 15 up to GA 22, cubicle filter element 1089 9556 23

Service kits GA 15 up to GA 22

Service kits Ordering number

Minimum pressure valve for 7.5 bar, 10 bar, 2901 1399 00
compressors
Minimum pressure valve for 13 bar 2901 1411 00
compressors
Float kit 2901 0712 00
PDX filter kit 2901 1212 00
DDX filter kit 2901 1214 00

Atlas Copco Roto-Xtend Duty Fluid

Also consult section Oil specification.

Ordering number
5-litre can 2901 1700 00
20-litre can 2901 1701 00
209-litre drum 2901 1702 00

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7 Adjustments and servicing procedures

7.1 Air filter

Location of air filter

Air filter, GA 15 up to GA 22

Recommendations
1. Never remove the element while the compressor is running.
2. For minimum down-time, replace the dirty element by a new one.
3. Discard the element when damaged.

Procedure
1. Stop the compressor. Switch off the voltage.
2. On Pack units: remove the side panel.
On Full-Feature units: remove the front panel.
3. Remove the air filter assembly.
4. Remove the cover of air filter (AF) by turning it anti-clockwise. Remove the filter element. If
necessary, clean the cover.
5. Fit the new element and the cover.
6. Reset the air filter service warning.
Consult section Calling up/resetting service timer to reset the service warning on Elektronikon I
regulators.

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7.2 Coolers
Cleaning
Keep the coolers clean to maintain efficiency

On air-cooled compressors:
• Stop the compressor, close the air outlet valve and switch off the voltage.
• Cover all parts under the coolers.
• Remove any dirt from the coolers with a fibre brush. Never use a wire brush or metal objects.
• Then clean with an air jet in the reverse direction to normal flow.
• If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco.

Never use a high pressure water cleaner to clean the compressor

7.3 Safety valves

Location of safety valve

GA 15 up to GA 22

Safety valve air recei1er on Tank-mounted units

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Operating
Operate the safety valve by unscrewing the cap one or two turns and retightening it.

Testing
Before removing the valve, depressurise the compressor.
See section Problem solving
Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure
stamped on the valve, consult Atlas Copco.
Valve (SV1) is fitted on tank-mounted versions. The valve can be tested on a separate air line. If
the valve does not open at the set pressure stamped on the valve, consult Atlas Copco.

Warning
No adjustments are allowed. Never run the compressor without safety valve.

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8 Problem solving

8.1 Problem solving

Warning
Before carrying out any maintenance, repair work or adjustment, press the stop button,
wait until the compressor has stopped (approx. 30 seconds), press the emergency stop
button and switch off the voltage. Close the air outlet valve, open manual drain (Dm) on
Pack units and also open the manual condensate drain (Dm1) on Tank-mounted units.
Depressurise the compressor by opening the oil filler plug (FC) one turn.
For location of components, see sections:
• Introduction
• Condensate system
• Initial start-up

Open and lock the isolating switch.

The air outlet valve can be locked during maintenance or repair as follows:
• Close the valve.
• Remove the screw fixing the handle with the wrench delivered with the compressor.
• Lift the handle and turn it until the slot of the handle fits over the blocking edge on
the valve body.
• Fit the screw.

The operator must apply all relevant Safety precautions.

Faults and remedies

On compressors equipped with an Elektronikon I regulator, if the alarm LED is lit or flashes, consult
section Shut down warning.

- Condition Fault Remedy

Compressor starts running, but
does not load after a delay time
Solenoid valve out of order Replace valve
Inlet valve stuck in closed Have valve checked
position
Leak in control air flexibles Replace leaking flexible
Minimum pressure valve leaking Have valve checked
(when net is depressurised)

- Condition Fault Remedy

Compressor does not unload, Solenoid valve out of order Replace valve
safety valve blows
Inlet valve does not close Have valve checked

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- Condition
Condensate is not discharged
from condensate separator
during loading
- Condition
Compressor air output or
pressure below normal
- Condition
Excessive oil consumption; oil
carry-over through discharge line
- Condition
Safety valve blows after loading
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Fault
Discharge flexible clogged
On Pack units: float valve
malfunctioning
On Full-Feature units: electronic
drain malfunctioning
Fault
Air consumption exceeds air
delivery of compressor
Choked air filter element
Solenoid valve malfunctioning
Leak in control air flexibles
Inlet valve does not fully open
Oil separator clogged
Air leakage
Safety valve leaking
Compressor element out of order
Fault
Incorrect oil causing foam
Oil separator defective
Malfunctioning of the scavenge
line
Fault
Inlet valve malfunctioning
Minimum pressure valve
malfunctioning
Safety valve out of order
Compressor element out of order
Oil separator element clogged
Remedy
Check and correct as
necessary
Remove float valve assembly,
clean and check
Press test button, replace if
necessary
Remedy
Check equipment connected
Replace filter element
Replace valve
Replace leaking flexibles
Have valve checked
Have oil separator replaced
Have leaks repaired
Have valve replaced
Consult Atlas Copco
Remedy
Change to correct oil
Have separator checked.
Replace if necessary
Replace non-return valve in
the scavenge line
Remedy
Have valve checked
Have valve checked
Have valve replaced
Consult Atlas Copco
Have oil separator replaced
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- Condition Fault Remedy

Compressor element outlet
temperature or delivery air
temperature above normal
Oil level too low
On air-cooled compressors,
insufficient cooling air or cooling
air temperature too high
Oil cooler clogged
By-pass valve malfunctioning
Air cooler clogged
Compressor element out of order
Check and correct
Check for cooling air
restriction or improve
ventilation of the compressor
room. Avoid recirculating of
cooling air. If installed, check
capacity of compressor room
fan
Clean cooler
Have valve tested
Clean cooler
Consult Atlas Copco
Customer Centre

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9 Technical data
9.1 Electric cable size

Attention

Local regulations remain applicable if they are stricter than the values proposed below.
The voltage drop must not exceed 5% of the nominal voltage. It may be necessary to
use cables of a larger size than those stated to comply with this requirement

Cable size

GA 15 GA 18 GA 22
Frequency Hz Voltage (V} Cable size Cable size Cable size

Star-delta mm2 mm2 mm2

Pack Full Pack Full Pack Full
version Feature version Feature version Feature
version version version
50 400 4 x 10 4 x 16 4 x 16 4 x 25 4 x 25 4 x 35

9.2 Settings for overload relay and fuses

Backup fuse selection

Model name SDF rating Fuse rating Fuse link

GA15 80NHC00G 80A NX80

GA18 80NHC00G 80A NX80

GA22 100NHG00B 125A NX125

9.3 Dryer switches (IFD)

General
The regulating and safety devices are factory-adjusted to give optimum performance
of the dryer. Do not alter the setting of any of the devices.

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9.4 Reference conditions and limitations

Reference conditions

Air inlet pressure (absolute) bar 1

Air inlet pressure (absolute) psi 14.5
Air inlet temperature ·C 20
Air inlet temperature ·F 68
Relative humidity % 0
Working pressure for GA 15 up to GA 22 See section Compressor data for
GA 15 up to GA 22

Limits

Maximum working pressure for GA 15 up to GA 22 See section Compressor data for

GA 15 up to GA 22
Minimum working pressure bar(e) 4
Minimum working pressure psig 58
Maximum air inlet temperature ·C 46
Maximum air inlet temperature ·F 115
Minimum air inlet temperature ·C 0
Minimum air inlet temperature ·F 32

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9.5 Compressor data for GA 15 up to GA 22

Reference conditions

All data specified below apply under reference conditions, see section Reference
conditions and limitations

GA 15

Units 7.5 bar 8.5 bar 10 bar 13 bar

Frequency Hz 50 50 50 50
Maximum (unloading) pressure bar(e) 7.5 8.5 10 13

Maximum (unloading) pressure, bar(e) 7.25 8.25 9.75 12.75

Full- Feature units

Nominal working pressure bar(e) 7 8 9.5 12.5

Pressure drop over dryer, Full- bar(e) 0.25 0.25 0.25 0.25
Feature units

Motor shaft speed r/min 2940 2940 2940 2940

Set point, thermostatic valve ·C 40 40 40 65

Temperature of air leaving ·C 28 28 28 28

outlet valve (approx.)

Temperature of air leaving ·C 20 20 20 20

outlet valve (approx.), Full-
Feature units

Pressure dew-point, Full-Feature ·C 5 5 5 5

units
Power consumption (dryer at full kW 0.7 0.7 0.7 0.7
load), Full-Feature units

Power consumption (dryer at no kW 0.5 0.5 0.5 0.5

load), Full-Feature units

Refrigerant type, Full-Feature R404A R404A R404A R404A

units
Total amount (refrigerant), kg 0.38 0.38 0.38 0.38
Full- Feature units

Oil capacity l 6.75 6.75 6.75 6.75

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10 Instructions for use of air receiver

10.1 Instructions for use

Instrictions

4
5

6
7

8 Yearly service inspection of the air receiver by a notified body is needed, as internal
corrosion can reduce the steel wall thickness with the consequent risk of bursting.
Minimum wallthickness as specified in the instruction book should be respected. Local
legislation overrules when more stric. The use of the air receiver is forbidden once the wall
thickness reaches the minimum value as indicated in the service manual of the air receiver
(part of the documentation delivered with the unit).

For tank mounted units also

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