Atlas Copco Bedieiningshandleiding GA-75-90-110 21711600

Translated from Dutch to English - www.onlinedoctranslator.
com
OPERATION MANUAL
OIL-INJECTED ROTARY SCREW COMPRESSORS
GA 75 VSD+, GA 90 VSD+, GA 110 VSD+
Atlas Copco
Oil-injected rotary screw compressors
GA 75 VSD+, GA 90 VSD+, GA 110 VSD+

From the following serial numbers: API 231 035
Operating manual
Translation of the original instructions
NOTE ON COPYRIGHT
Unlawful use or copying of the content, in whole or in part, is prohibited.
This applies in particular to trademarks, type designations, part numbers and drawings.
This operating manual applies to machines with and without CE label. It meets the
requirements for instructions as laid down in the applicable European directives as
stated in the Declaration of Conformity.
2017 - 11
No. 2921 7116 00
www.atlascopco.com
Operating manual
Table of contents
1 Safety regulations ......................................................................................................................5
1.1 SAFETY ICONS ..................................................................................................................................................................................................... 5
1.2 SAFETY REGULATIONS, GENERAL ................................................................................................................................................ 5
1.3 SAFETY INSTRUCTIONS DURING INSTALLATION .......................................................................................................... 6
1.4 SAFETY INSTRUCTIONS DURING OPERATION ................................................................................................................. 7
1.5 SAFETY INSTRUCTIONS DURING MAINTENANCE OR REPAIR ........................................................................ 9
2 General description. ............................................................................................................... 11
2.1 IINTRODUCTION............................................................................................................................................................................................................. 11
2.2 FLOW SCHEDULE ........................................................................................................................................................................................... 14
2.3 CONDENSATE SYSTEM ........................................................................................................................................................................... 16
2.4 CONTROL SYSTEM ....................................................................................................................................................................................... 20
2.5 ELECTRICAL SYSTEM ................................................................................................................................................................................ 20
2.6 lAIR DRYER...................................................................................................................................................................................................................... 21
3 Elektronikon Graphic controller. ......................................................................................... 24
3.1 ELECTRONIKONTM GRAPHIC-CONTROLLER ..................................................................................................................................................... 24
3.2 CONTROL PANEL ............................................................................................................................................................................................ 26
3.3 USED ICONS......................................................................................................................................................................................................... 27
3.4 huhEARTH SCREEN .................................................................................................................................................................................................... 31
3.5 mAND YOU'CALLS S .................................................................................................................................................................................................... 35
3.6 mAND YOU IWAYS ....................................................................................................................................................................................................... 36
3.7 mAND YOU YOUOUTCOMES.................................................................................................................................................................................. 39
3.8 tELLERS............................................................................................................................................................................................................................ 40
3.9 CONTROL MODE SELECTION ........................................................................................................................................................... 42
3.10 mAND YOU sSERVICE................................................................................................................................................................................................. 43
3.11 CHANGE SETPOINT ..................................................................................................................................................................................... 47
3.12 EVENT HISTORY MENU (HISTORY OF OCCURRED EVENTS). ................................................ 50
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3.13 CHANGING GENERAL SETTINGS .................................................................................................................................................. 51
3.14 mAND YOU INFO........................................................................................................................................................................................................... 52
3.15 mAND YOU tTIME CLOCK ........................................................................................................................................................................................... 53
3.16 mAND YOU tEST ........................................................................................................................................................................................................... 62
3.17 MENU PASSWORD USER ....................................................................................................................................................................... 63
3.18 WEBSERVER.................................................................................................................................................................................................................. 64
3.19 PROGRAMMABLE SETTINGS ............................................................................................................................................................. 72
4 Installation. ................................................................................................................................ 74
4.1 DIMENSION DRAWINGS........................................................................................................................................................................... 74
4.2 INSTALLATION PROPOSAL .................................................................................................................................................................. 77
4.3 ELECTRICAL CONNECTIONS ............................................................................................................................................................. 85
4.4 ICONS .......................................................................................................................................................................................................................... 88
5 Options. ...................................................................................................................................... 89
5.1 ENERGY RECOVERY .................................................................................................................................................................................. 89
6 Operating Instructions. ........................................................................................................ 102
7 Maintenance ............................................................................................................................ 108
7.1 PREVENTIVE MAINTENANCE SCHEDULE ......................................................................................................................... 108
7.2 OIL SPECIFICATIONS............................................................................................................................................................................... 111
7.3 aDRIVE MOTOR .......................................................................................................................................................................................................... 112
7.4 lAIR FILTER ................................................................................................................................................................................................................... 113
7.5 CHANGE THE OIL AND REPLACE THE OIL FILTER AND THE OIL SEPARATOR ....................... 113
7.6 kOELERS....................................................................................................................................................................................................................... 116
7.7 MAINTENANCE INSTRUCTIONS FOR THE DRYER................................................................................................... 118
7.8 OMAINTENANCE RELATIVE-HUMIDITY SENSOR (RH). ........................................................................................ 119
7.9 SAFETY VALVES ........................................................................................................................................................................................... 120
7.10 SERVICE INTERVALS FILTERS ..................................................................................................................................................... 121
7.11 sSERVICE KITS ........................................................................................................................................................................................................... 121
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7.12 STORAGE AFTER INSTALLATION .............................................................................................................................................. 121
7.13 DISPOSAL OF USED MATERIALS ............................................................................................................................................... 121
8 To fix an issue. ....................................................................................................................... 123
9 Technical data. ....................................................................................................................... 133
9.1 READINGS ON THE DISPLAY .......................................................................................................................................................... 133
9.2 ELECTRICAL CABLES AND FUSES ........................................................................................................................................... 134
9.3 REFERENCE CONDITIONS AND LIMIT VALUES .......................................................................................................... 140
9.4 COMPRESSOR DATA ............................................................................................................................................................................... 141
9.5 TECHNICAL DATA CONTROLLER ............................................................................................................................................... 143
10 Instructions for use. .............................................................................................................. 145
11 Inspection Guidelines........................................................................................................... 146
12 Pressure Equipment Guidelines ........................................................................................ 147
13 Declaration of Conformity. .................................................................................................. 148
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1 Safety regulations
1.1 Safety icons
Declaration
Danger to life
Warning
Important Note
1.2 Safety instructions, general
General safety regulations

1. The operator must work safely and follow all relevant safety rules and regulations.
2. If one of the following statements does not comply with the applicable regulations, the
stricter of the two must be applied.
3. Installation, operation, maintenance and repair may only be performed by
authorized, trained and skilled personnel.
4. The compressor is not suitable for supplying air intended for inhalation. To make
compressed air suitable for inhalation, it must be purified in accordance with the
applicable regulations and standards.
5. Before performing any maintenance or repairs, adjustments or checks other than the usual
checks, stop the compressor, press the emergency stop button, turn off the power and
release the pressure from the compressor. In addition, you must open and lock the
disconnect switch.
For machines powered by a frequency converter, wait 10 minutes before starting
repair work on electrical equipment.
In a domestic environment this product may cause radio interference in which case
additional mitigation measures may be required.
If the machine is equipped with an automatic restart function after a power cut and if
this function is active, please note that it will restart automatically if the mains power is
restored if it was switched on when the power was cut!
6. Never play with compressed air. Never blow compressed air on the skin or in the direction
of another person. Never use compressed air to remove dirt from clothing. When using
compressed air to clean equipment, extreme caution must be exercised and safety glasses
must be worn.
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7. The owner is responsible for keeping the machine in a safe operating condition. Parts
and accessories must be replaced if they are no longer suitable for safe operation.
8. It is not permitted to walk or stand on the machine or parts thereof.
1.3 Safety Precautions During Installation

Any responsibility for damage or injury resulting from failure to follow these
instructions, or to observe normal caution and care during installation, operation,
maintenance or repairs, even if not expressly stated, shall be disclaimed by the
manufacturer.
Safety Precautions During Installation

1. The machine may only be lifted with suitable equipment that complies with the applicable
safety regulations. Before lifting, all loose or rotating parts must be securely fastened. It is
strictly forbidden to stay under a lifted load in the danger zone. The acceleration and
deceleration of the lifting movement must remain within safe limits. Wear a safety helmet
when working near overhead equipment or hoists.
2. The unit is intended for indoor installation. If the unit is installed outdoors, special
precautions must be taken. Please contact your supplier for this.
3. If the unit is a compressor, it should be installed in a place where the ambient air is as
cool and clean as possible. Install a suction line if necessary. Never obstruct the air inlet.
Make sure that as little moisture as possible penetrates with the intake air.
4. Blind flanges, plugs, caps and desiccant bags must be removed before connecting the
pipes.
5. Air hoses must be of the correct size and suitable for the respective working pressure.
Never use frayed, damaged or worn hoses. Distribution pipes and connections must be
of the correct size and suitable for the respective working pressure.
6. If the appliance is a compressor, the air drawn in must be free of flammable gases, vapors
and particles, for example paint solvents, which could lead to fire or explosion in the
machine.
7. If the device is a compressor, the air inlet should be positioned so that loose clothing
of employees cannot be sucked in.
8. Make sure that the discharge pipe from the compressor to the aftercooler or the air
network can expand freely due to heat influences and is not in contact with or in close
proximity to combustible materials.
9. No external force should be applied to the air outlet valve; the connected pipe must be
installed tension-free.
10. If the machine is equipped with remote control, the following warning text must be clearly
visible: DANGER: this machine is remote controlled and can start without warning.
Before performing any maintenance or repair work, the operator must ensure that the
machine is stopped, depressurized and the electrical disconnect switch is opened, locked
and provided with a temporary warning. As an additional safety measure, remote-
controlled persons should
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switch machines on or off, make sure that no one is carrying out any inspection or other
work on the machine. To this end, a clearly worded warning must be affixed to the starting
equipment.
11. Air-cooled machines must be installed in such a way that there is sufficient
cooling air flow and the exhaust air does not flow back to the compressor air inlet
or the cooling air inlet.
12. The electrical connections must comply with current regulations. The machines must be
earthed and protected against short circuits in all phases by fuses. A lockable disconnect
switch must be installed in the immediate vicinity of the compressor.
13. On machines with an automatic start/stop system or where the automatic restart function
after a power failure has been activated, the following warning text must be affixed to the
instrument panel: 'This machine can start without warning!'
14. In a multi-compressor system, manually operated taps/valves must be installed to shut off
each compressor individually. Non-return valves (check valves) may not be used
exclusively to isolate pressure systems.
15. Safety devices, guards or insulation fitted to the machine must never be removed or
modified. Any pressure vessel or attachment mounted outside the machine and containing
air at superatmospheric pressure must be protected by one or more pressure relief valves.
16. Pipes or other parts with a temperature greater than 70 C (158 ˚F) that could be
accidentally touched by personnel during normal operation must be shielded or insulated.
Other high temperature pipes must be clearly marked as such.
17. On water-cooled machines, the cooling water system mounted outside the machine must
be protected by a safety device with a set pressure according to the maximum cooling
water inlet pressure.
18. Consult the manufacturer if the ground is not level or if there may be variable slopes.
19. If the appliance is a dryer and there is no free extinguishing system in the air network near
the dryer, safety valves must be installed in the boilers of the dryer.
Please also refer to the following safety precautions: Safety regulations during
business and Safety instructions during maintenance.
These safety regulations apply to machines that process or consume air or
inert gases. Handling other gases requires additional safety precautions
specific to the application and not included herein.
Some safety precautions are of a general nature and concern various machine types
and equipment. Therefore, some notices may not apply to your machine.
1.4 Safety regulations during operation

manufacturer.
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Regulations during operation

1. Never touch pipes or parts of the machine during operation.
2. Only use hose couplings and connections of the correct type and dimensions. When
blowing compressed air through a hose or air line, the open end must be tightened
securely. A free end can fly off and cause injury. Before disconnecting a hose, the pressure
must be completely relieved.
3. Persons who switch on remote-controlled machines must first make sure that no one is
carrying out inspection or other work on the machine. To this end, a clearly worded
warning must be affixed to the remote starting equipment.
4. Never operate the machine if there is a possibility that flammable or toxic fumes or
small particles may be drawn in.
5. Never operate the machine below or above the limits.
6. During operation, all housing doors must be kept closed. The doors may only be
opened for a short time, for example to carry out routine checks. Always wear hearing
protection when opening a door.
On machines without housing, wear hearing protection in the vicinity of the machine.
7. Persons staying in an environment or in rooms where the sound pressure level is 80 dB(A)
or more must wear hearing protection.
8. Check regularly whether:
• all guards are in place and securely fastened
• all hoses and/or pipes in the machine are in good condition, tight and do not chafe
• no leaks have occurred
• all fasteners are tight
• all electrical cables are secure and in good condition
• safety valves and other pressure relief devices are not clogged by dirt or paint
• the air exhaust valve and the air network, ie the pipes, couplings, manifolds,
valves/taps, hoses, etc., are in good condition and show no wear or defects
• the cooling air filters of the electrical box are not clogged
9. When warm cooling air from compressors is used for air heating systems, for example for
heating a workspace, measures must be taken against air pollution and possible
contamination of the inhaled air.
10. For water-cooled compressors using open-circuit cooling towers, precautions should be
taken to prevent the growth of harmful bacteria, such as Legionella pneumophila.
11. Do not remove or modify sound dampening material.
12. Safety devices, guards or insulation fitted to the machine must never be removed or
modified. Any pressure vessel or attachment mounted outside the machine containing
air at a pressure above atmospheric pressure must be protected by one or more
pressure relief valves.
13. Check the air reservoir annually. The minimum wall thickness as specified in the manual
must be observed. Local regulations will remain in effect if more stringent.
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Please also refer to the following safety precautions: Safety regulations during
installation and Safety instructions during maintenance.
1.5 Safety instructions during maintenance or repair

manufacturer.
Regulations during maintenance or repair

1. Always use proper safety equipment (such as goggles, gloves, shoes, etc.).
2. Only use tools that are suitable for maintenance and repair work.
3. Use only original parts for maintenance or repair. The manufacturer disclaims any damage
or injury caused by the use of non-genuine parts.
4. Maintenance may only be performed when the machine has cooled down.
5. There should be a warning saying, for example, "Work in progress, do not start!" be
affixed to the starting equipment.
6. Persons who switch on remote-controlled machines must first make sure that no one is
carrying out inspection or other work on the machine. To this end, a clearly worded
warning must be affixed to the remote starting equipment.
7. Before connecting or disconnecting any pipe, close the air outlet valve of the compressor
and release the pressure from the compressor.
8. Before removing a pressurized component, the pressure supply to the machine must be
effectively stopped and the pressure must be released from the entire system.
9. Never use flammable solvents or tetrachloromethane to clean parts. Take safety
precautions against toxic fumes from cleaning fluids.
10. Work extremely cleanly during maintenance and repair work. Stop the dirt by covering the
components and free openings with a clean cloth, paper or tape.
11. Never perform welding or other work in the vicinity of the oil system that generates heat. Oil
tanks must be fully cleaned, e.g. with steam, before carrying out the above work. Pressure
vessels should never be welded or modified in any way.
12. If there is any indication or suspicion that any part in a machine has overheated, the
machine must be stopped. However, inspection hatches may only be opened after a
sufficiently long cooling-off period has been observed.
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This avoids the risk of oil vapors igniting spontaneously as soon as they come into
contact with air.
13. Never use a light source with an open flame to inspect a machine, a pressure vessel, etc.
internally.
14. Make sure that no tools, loose parts or cleaning cloths are left in or on the machine.
15. All control equipment and safety devices must be carefully maintained to ensure proper
operation. These devices must not be taken out of service.
16. Check that the working pressure, temperature and time settings are correct before the
machine is released for use after a service or overhaul. Check that all control and safety
mechanisms are in place and functioning correctly. If the clutch guard has been removed
from the compressor drive shaft, it must be checked to see if it has been reinstalled.
17. Whenever the separator element is replaced, check the drain pipe and the inside of the
oil separator vessel for carbon deposits; if they are excessive, they should be removed.
18. Protect the engine, air filter, electrical and control components, etc. against the ingress
of moisture, for example during steam cleaning.
19. Check that all sound dampening material and vibration dampers, for example on the
housing and in the air inlet and outlet systems of the compressor, are in good condition.
Any damaged material must be replaced with original material from the manufacturer to
prevent the sound pressure level from increasing.
20. Never use caustic solvents that could damage the air network materials, for example the
polycarbonate bowls.
21. If applicable, the following safety regulations must be observed when using
refrigerant:
• Never inhale the refrigerant vapors. Ensure that the workplace is adequately
ventilated; wear a protective mask if necessary.
• Always wear special gloves. If coolant gets on the skin, flush the skin with water. If
liquid refrigerant comes into contact with the skin through the clothing, the clothing
must under no circumstances be torn or removed; rinse the clothing with plenty of
clean water until all the coolant has been washed away; then seek medical attention.
Please also refer to the following safety precautions:Safety instructions during the
installation and Safety regulations during operation.
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2 General description
2.1 Introduction
Introduction
GA 75 VSD+ to GA 110 VSD+ are single-stage oil-injected screw compressors, driven by an
internal permanent magnet (IPM) motor.
The compressors are controlled by the Atlas Copco ElektronikonTM Graphic controller (ER). The
controller is mounted on the front panel. Behind this panel is an electrical box
(1) with the fuses, transformers, relays, etc.
The compressors use VSD (English: Variable Speed Drive) technology. This means: automatic
adjustment of the engine speed, depending on the compressed air requirement.
The compressors are air-cooled and are built into a sound-damped housing.
There are 2 versions of the compressor: Pack (without built-in dryer) and Full-Feature (with
built-in dryer).
GA Pack
Front View, GA VSD+ Pack
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Open Side View, GA VSD+ Pack
GA Full Feature
The Full-Feature compressors are equipped with an air dryer, which is built into the sound-
damped housing. The dryer removes condensate from the compressed air by cooling the air
to just above the freezing point.
Front View, GA VSD+ Full Feature
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Open Side View, GA VSD+ Full-Feature
Reference Name
AF Air filter
AR air receiver
AV Air outlet
ca Air cooler
Co oil cooler
da Automatic condensate outlet
dm Manual Condensate Outlet
DR Refrigerated dryer
E Compressor element
ED Electronic water drain
er Elektronikon® Graphic controller
FN Cooling Fan
IPM Drive motor
OR oil filter
S3 emergency stop button
1 electrical box
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2.2 flow chart
GA 75 VSD+ to GA 110 VSD+ Pack
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GA 75 VSD+ to GA 110 VSD+ Full-Feature
Reference Description
1 Air intake
2 Air/Oil Mixture
3 Oil
4 Humid compressed air
5 Condensate
6 Dry compressed air (Full-Feature)
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Airflow
Air enters through the air filter (AF) and the inlet valve (IV) and is compressed in the
compressor element (E).
A mixture of compressed air and oil flows into the air receiver/oil separator (AR), where oil and air
are separated.
The air flows through the minimum pressure valve (Vp), the air cooler (Ca) and the
condensate trap (MT) to the exhaust valve (AV).
The minimum pressure valve (Vp) prevents the boiler pressure from falling below the set
minimum value and is equipped with a check valve that prevents the return of compressed air
from the mains.
Full-feature compressors are equipped with a dryer (DR) behind the air cooler.
Oil circuit
In the air receiver (AR) most of the oil is removed from the air/oil mixture by centrifugal action.
The oil collects in the lower part of the air reservoir (AR), which serves as an oil tank.
The oil separator (OS) removes the remaining oil.
The oil circuit is fitted with a thermostatic bypass valve (BV) which prevents the oil from flowing
through the oil cooler (Co) when the oil temperature is low.
Compressed air forces the oil from the air reservoir (AR) through the oil filter (OF).
The filtered oil flows through the cooling channels of the internal permanent magnet motor
(IPM) to the compressor element (E).
Cooling
The cooling system consists of an air cooler (Ca) and an oil cooler (Co).
The fan (FN) draws air over the coolers. This fan is switched on and off according to
the operating conditions according to a specific algorithm.
2.3 Condensate System
Drain connections
The compressors are equipped with an electronic water drain (ED).
Location of the electronic water drain (Pack)
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Location of the electronic water drain (Full-Feature)
On Full Feature units, the condensate formed in the dryer collects in the lower portion of the heat
exchanger/evaporator.
When the condensate in the electronic drain (ED) reaches a certain level, it is discharged
through the outlet of the automatic drain (Da).
Connections for condensate drain, Pack
Connections for condensate drain, Full-Feature
Reference name
da Connection for automatic drain
dm Connection for manual drain
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Electronic water drain (ED)
The test button (2) on the top of the drain can be used in three different ways, depending
on the situation:
• When pressed during normal operation, the manual drain test begins.
• If pressed during an alarm, the control logic is reset
• Pressing the test button for at least 5 seconds starts the self-diagnosis routine.
Explanation LED
Green and red LED alternately on/off for 6 seconds after power on.
Drain is fed.
Green LED on
Normal operation, drain is on standby and waiting for condensate.
Green LED flashing

Normal operation, drain valve is open to drain water.
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Green LED turns on/off

Water does not flow into the tank from the drain. If the float does not reach the upper level for
3 hours, the solenoid is energized for 2 seconds. This cycle is repeated 5 times (so a
maximum of 15 hours). Then the green light turns on/off.
Cause:
• No condensate enters the tank.
• Float incorrectly mounted (upside down).
Controls:
• Is there condensate in the drain? Does the water separation take place
in the heat exchanger?
• Has the float been installed correctly, for example after
maintenance? Solution:
• Although this LED symbol does not indicate a malfunction, the drain can be reset by
pressing the test button (T) for 5 seconds.
Red LED flashes slowly: cleaning routine 1
The drain tank is full and the water cannot be drained or can only be drained very slowly.
In normal operation, the drain has 20 seconds to drain all the water. If the drain is not
emptied within this time frame, a (first) cleaning routine is activated ie the valve is opened
and closed alternately for 2 seconds, for a maximum of 30 cycles. This procedure is started
to try to unblock the drain. If this first unblock routine fails, a second routine is started.
Cause:
• Filter screen clogged.
• Insufficient pressure on drain.
• Internal drain problem.
Controls:
• Is the filter clean and in good condition?
• Is there a minimum pressure of 0.2 bar (2.8 psi) in the drain?
Press the test button (T) for at least 5 seconds to reset the drain.
Red LED flashes quickly

If cleaning routine 1 is completed (after 30 cycles) but still fails, cleaning routine 2 is
activated. This routine opens (3 sec) and closes (60 sec) the drain valve until a float is in the
lower position, allowing the water to drain completely.
Meanwhile: The external alarm signal is activated.
Cause:
• Filter screen clogged.
• Insufficient pressure on drain.
• Internal drain problem.
Controls:
• Is the filter clean and in good condition?
• Is there a minimum pressure of 0.2 bar (2.8 psi) in the drain?
From this point on, the drain remains in this routine even after a reboot. Press the test button
(T) for at least 5 seconds to reset the drain.
Red LED on
An unrecoverable error has occurred. Replace the drain and keep the defective one for
further analysis.
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2.4 Control system
Description
When the compressor is started and the mains pressure is lower than the set value, the motor
speed increases until the mains pressure reaches the set value or until the maximum motor
speed is reached.
If the air consumption is lower than the air output of the compressor, the mains pressure rises further.
When the line pressure reaches the set point (desired line pressure) and continues to
rise, the controller decreases the motor speed.
If the pressure continues to increase even though the motor is already running at minimum
speed, the motor is stopped by the controller as soon as the mains pressure reaches a value
equal to the set point plus the indirect stop level (usually 0.3 bar above the set value , see
paragraph Programmable Settings).
If the mains pressure rises very quickly to a value equal to the set point plus the immediate stop
level (usually 1 bar above the set value, see paragraph Programmable institutions), the
compressor is stopped immediately (without the engine speed being reduced first).
No compressed air is lost when the compressor is stopped in automatic mode, saving
valuable energy.
If the compressor has been stopped in automatic mode and the mains pressure approaches
the set point, the controller will restart the motor. The faster the mains pressure drops, the
faster the compressor restarts.
The pressure in the oil separator vessel is only released to atmosphere when the
compressor is stopped manually or in case of an emergency stop (see the Stopping
section in the chapter Operating Instructions).
2.5 Electrical System
Electrical parts
The electrical system includes the following parts:
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Electrical cabinet, typical example
Reference name
T1 Transformer
Q15 Circuit breaker
Q1 Circuit breaker
K15 Switch
Z1 EMC filter
U1 Frequency converter
Electrical Schematics
The complete electrical diagram is located in the electrical control box and on the CD-ROM,
DVD or USB supplied with the machine.
2.6 Air dryer

(only for compressors with built-in dryer)
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flow chart
Air dryer
Reference Name
AI Air intake
AO Air outlet
1 Air/air heat exchanger
2 Air/refrigerant heat exchanger/evaporator
3 Condensate separator
4 Automatic Drain / Condensate Outlet
5 Refrigerant compressor
6 Refrigerant Condenser
7 Coolant dryer/filter
8 Capillary tube
9 Bypass valve
10 Condenser Cooling Fan
11 Pressure switch, fan control
12 Liquid separator
Compressed air circuit

The compressed air flows into the heat exchanger (1) and is cooled by the outgoing cold, dried
air. The water in the incoming air begins to condense. The air then flows through the heat
exchanger/evaporator (2), where the refrigerant evaporates and the air cools further to close to
the evaporating temperature of the refrigerant. More moisture condenses from the air. The cold
air then flows through the separator (3), where all the condensate is separated from the air.
The condensate is automatically drained through the condensate drain (4).
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The cold, dried air flows through the heat exchanger (1) and is heated by the incoming air.
Refrigerant circuit
The compressor (5) supplies hot, high-pressure gaseous refrigerant, which flows through the
condenser (6), where most of the refrigerant condenses.
The liquid refrigerant flows through the refrigerant dryer/filter (7) to the capillary tube (8). The
refrigerant exits the capillary tube at approximately the evaporation pressure.
The refrigerant flows into the evaporator (2), where it extracts heat from the compressed air
through further evaporation at approximately constant pressure. The heated refrigerant leaves
the evaporator and is drawn into the compressor (5) through a liquid separator (12).
The bypass valve (9) controls the refrigerant flow. Depending on the pressure value of
the condensate, the fan (10) is switched on or off by the switch (11).
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3 Elektronikon Graphic controller
3.1 ElektronikonTM Graphic controller
Control panel
Display of the ElektronikonTM Graphic Control
Introduction
The ElektronikonTMcontroller has the following functions:
• Controlling the compressor
• Securing the compressor
• Monitor parts that need maintenance
• Automatically restart after a power interruption (this function has been made
inactive)
Automatic control of compressor operation

The controller maintains mains pressure within programmable limits by automatically adjusting
the motor speed. This takes into account a number of programmable settings, such as the set
point, the minimum stop time and the maximum number of motor starts and several other
parameters.
The controller stops the compressor whenever possible to reduce energy consumption and
restarts it automatically when the mains pressure decreases. If there is a risk of condensation
in the oil, the compressor activates the condensate prevention cycle and continues to operate
for a certain time.
A number of time-based automatic start/stop commands can be programmed. Please

note that a start command is always executed (if programmed and activated), even if the
compressor has been stopped manually.
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Protecting the compressor

Alarm stop
Various sensors are mounted on the compressor. If any of the measured signals exceed the
programmed decommissioning level, the compressor is stopped. This is indicated on display
(1), and LED (2) 'general alarm' will flash.
Clear the error and reset the message.
Please refer to the applicable safety regulations before troubleshooting.
Shutdown Alert
The decommissioning warning level is a programmable level below the decommissioning
level.
If any of the measured signals exceeds the programmed decommissioning warning level, a
message is shown on the display (1) and the 'general alarm' LED (2) illuminates to alert the
operator that the decommissioning warning level has been exceeded.
The message disappears as soon as the trigger for the warning disappears.
Warning
A warning message appears on the display when the dew point temperature is too high
relative to the ambient temperature on Full-Feature compressors.
Service Alert
A number of service activities are grouped together (these groups are referred to as 'service
plans'). Each service plan has a programmed time interval. If a time interval is exceeded, a
message appears on the display (1) to warn the operator that the service work of the
respective service plan must be performed.
Automatically restart after a power failure

The controller has a built-in function to automatically restart the compressor when power is
restored after a power cut. All compressors leaving the factory have this function disabled. This
function can be activated if desired. The ARAVF label 1079 9932 74 (see the Icons section)
must be glued to the controller. Consult the Atlas Copco Customer Center.
If this function is enabled and the controller was in automatic mode, the compressor will
restart automatically when mains power is restored to the module.
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3.2 Control panel
Elektronikon controller
Control panel
Parts and Functions
Reference name Function

1 Display Shows the operating status of the compressor and a
number of icons to navigate through the menu.
2 Icon Automatic operation

3 Icon General alarm
4 Alarm LED Flashes in the event of an alarm stop, illuminates in
the event of a warning condition.
5 Icon Service
6 Service LED Lights up when service is required
7 LED 'automatic operation' Indicates that the controller automatically controls
compressor operation.
8 LED 'power on' Indicates that power is on.
9 Icon Voltage
10 Enter key Use this key to confirm your last action.
11 Escape key Use this key to go to the previous screen or to

end the current action.
12 Scroll keys Keys to scroll through the menu.
13 stop button Button to stop the compressor. LED (7) goes out.
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Reference name Function

14 Start button Button to start the compressor. LED (7) lights up to
indicate that the Elektronikon controller is turned
on.
3.3 Icons used
Status icons
Name Icon Description

Stopped / Running When the compressor is stopped, the icon is stopped.
When the compressor is running, the icon rotates.
Compressor status Engine stopped
Runs no load
Running under load
Machine Control Mode Local start/stop
or
Remote start/stop
Network control
Automatically restart after a Automatic restart after a power

power failure failure is active
time clock Timer is active
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Name Icon Description

Active protection functions Emergency stop
Alarm stop
Warning
Service Service Needed
Main screen Value rule display icon
Graph view icon
General icons No communication / network problem
Invalid
Input icons
Icon Description
Busy
Temperature
Digital input
Special security
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System icons
Icon Description
Compressor element (LD, HD, ...)
Dryer
Fan
Frequency converter
drain
Filter
engine
Expansion module failure
Network problem
General alarm
Menu icons
Icon Description
Inputs
outputs
Alarms (warnings, decommissioning)
Counters
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Icon Description
Test
or
Institutions
Service
Event History (saved data)
Access Key / User Password
Network
Set point
Info
Navigation arrows (cursor)
Icon Description
Upwards
down
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3.4 Main screen
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Function
The main screen is the screen that is automatically displayed when the power is turned on and
one of the keys is pressed. It will turn off automatically after a few minutes if no key is pressed.
By default, 5 different main screens can be selected:
1. Two Value Rules
2. Four Value Rules
3. Chart (High Resolution)
4. Graph (Average Resolution)
5. Graph (Low Resolution)
Screens with two and four value rules

This type of main screen displays the value of 2 or 4 parameters (see section Menu
Inputs).
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Typical main screen (2 value lines)
Text in images
(1) Exhaust Compressor

(2) flow
(3) Load, Alarm stop, ... (text depends on the current compressor operating state)
(4) Menu
(5) No-load, ES, ... (text depends on the current compressor operating status)
Text in images

(2) flow
(3) Off, Alarm stop, ... (text depends on the current compressor operating state)
(4) Menu
(5) Operating hours
(6) Exhaust element
(7) Loaded, Unloaded, ... (text depends on the current compressor operating status)
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• Field A shows information about compressor operation (e.g. outlet pressure or

temperature at the compressor outlet). For compressors with a frequency converter, the
load (flow) is indicated in % of the maximum flow.
• Field B shows the status icons. The following icons are displayed in this field:
• Fixed icons
These icons are always shown in the main screen and cannot be selected
with the cursor (eg Compressor stopped or running, Compressor status
(running, running no load or motor stopped)).
• Optional icons
These icons are only shown if the corresponding function is activated (e.g. Weekly
schedule clock, Automatic restart after a power cut, etc.)
• Pop-up icons
These icons are displayed when an abnormal condition occurs (warnings, alarm
stops, service, etc.)
To call up more information about the icons shown, select the appropriate icon using
the scroll keys and press the Enter key.
• Field C is called the status bar.
This bar shows the text associated with the selected icon.
• Field D shows the action buttons. These buttons are used to:
• Call up or program settings
• Resetting an engine overload, service message or emergency stop
• Accessing all data stored in the controller's memory The functions of the buttons vary
depending on the menu displayed. The most common functions are:
name Function
Menu Go to the menu
Change Changing Programmable Settings
Reset Resetting a counter or message
To activate an action button, highlight the button with the scroll keys and press the Enter
key.
Press the Escape key to return to the previous menu.
Chart view
Instead of values, a graph of one of the input signals as a function of time can also be shown
(see section Menu Inputs).
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When Graph (High Resolution) is selected, the graph shows the variation in the selected input
(in this case the pressure) per minute. The current value is also shown. The screen shows the
last 4 minutes.
The toggle button (icon) for selecting other screens is displayed as a small graph marked
(active).
When the Graph (Average Resolution) is selected, the graph shows the variation in the
selected input per hour. The screen shows the last 4 hours.
When the Graph (Low Resolution) is selected, the graph shows the variation in the selected input per
day. The screen shows the development during the last 10 days.
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Choice of a main screen display

To switch between the different screen layouts, select the icon on the far right of the control icon
line (see Value Line View icon or Graph View icon in section Icons used) and press the Enter
key. A screen like the one shown below will appear:
Select the desired format and press the Enter key. See also the paragraphMenu Inputs.
3.5 Calling up menus
Control panel
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Description
When the power is turned on, the main screen is automatically displayed (see paragraph
Main screen):
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• Highlight <Menu> (3) using the scroll keys to enter the menu screen.
• Press the Enter key to select the menu. the next screen appears:
• The screen shows a number of icons. Each icon indicates a menu option. By default,
the Pressure Settings (Control) icon is selected. The status bar shows the name of the
menu associated with the selected icon.
• Use the scroll keys to select an icon.
• Press the Escape key to return to the main screen.
3.6 Menu Inputs
Menu Icon, Inputs
Function
• Display of the currently measured values (analog inputs) and the status of the digital
inputs (e.g. emergency stop contact, motor overload relay, etc.).
• Selection of the digital input shown in the graph on the main screen.
Procedure
From the main screen:
• Move the cursor to the Menu action button and press the Enter key. the next screen
appears:
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Text in image
(1) Menu
(2) Regulation
• Use the scroll keys to move the cursor to the Inputs icon (see Menu Icon section
above).
• Press the Enter key. A screen like the one shown below will appear:
Text in image
(1) Inputs
(3) Exhaust Element
(4) Ambient air
(5) Emergency stop
• The screen displays a list of all inputs and their icons and readings.
• If a zone has a warning or decommissioning condition, the original icon is replaced by the
Warning or Decommissioning icon (in this case the stop icon and the warning icon in the
screen shown above).
A small graph icon displayed below an item in the list means that this input signal is displayed
in the graph on the main screen. Any analog input can be selected.
Selecting a different input signal as the signal to display on the main screen graph
With the Edit button active (light gray background in the screen above), press the Enter key
on the controller. A screen like the one shown below will appear:
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The first option in the list is highlighted. In this example, the Net Pressure is selected
(graph icon).
To change it, press the Enter key again: a pop-up window appears:
press the Enter key again to remove this entry from the graph. Another pop-up window will
appear:
select Yes to delete, or select No to exit the current screen.

Similarly, another input signal can be highlighted and selected as Signal Main Screen
Graph:
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(1): Set Signal Main Screen Graph
3.7 Menu Outputs
Menu Icon, Outputs
Function
Retrieving information about the current status of a number of outputs, such as the state of the
fan overload contact (for air-cooled compressors), the emergency stop contact, etc.
Procedure
From the Main screen,
appears:
Text in image
(1) Menu
(2) Regulation
• Use the scroll keys to move the cursor to the Outputs icon (see Menu Icon section
above).
• Press the Enter key. A screen like the one shown below will appear:
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Display Outputs (default)
Text in image
(1) outputs
(2) Fan motor
(3) blow off
(4) General alarm stop
(5) Automatic operation
• The screen shows a list of all outputs and their icons and readings.
If an output has a warning or decommissioning, the original icon is replaced by the
Warning or Decommissioning icon.
3.8 Counters
Control panel
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(1) Scroll keys

(2) Enter key
(3) Escape key
Menu Icon, Counters
Function
Calling up:
• the operating hours
• run the number of hours charged
• the number of engine starts
• the number of hours that the regulator has been energized
• the number of load cycles
• the number of recirculation cycles
• the number of recirculation cycle failures
Procedure
Starting from the main screen (see Main screen):
appears:
Text in image
(1) Menu
(2) Regulation
• Use the scroll keys to move the cursor to the Counters icon (see Menu Icon section
above).
• Press the Enter key. the next screen appears:
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Text in image
(1) Counters
(2) Operating hours
(3) Engine Starts
(4) Load relay
(5) VSD 1-20% rpm in % (the percentage of time during which the engine speed was
between 1 and 20%)
(6) Recirculation Cycles
(7) Recirculation Failures
A list of all counters and current readings is shown on the screen.
3.9 Control mode selection
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Function
Selecting the control mode, ie whether the compressor is controlled locally, remotely or via a
local area network (LAN).
Procedure
From the main screen, select the Menu button (1):
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Then use the scroll keys to move to the Control icon (2) and press the Enter key:
There are 3 options:

• Local Control
• remote control
• LAN control (network)
After selecting the desired control mode, press the Enter button on the controller to confirm your
selection. The new setting is now visible on the main screen. See the paragraphIcons used for
the meaning of the icons.
3.10 Service menu
Menu icon, Service
Function
• Resetting the service plans that have been executed.
• Check when the following service plans are due.
• Find out which service plans have already been implemented.
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• Change the programmed service intervals.
Procedure
appears:
Text in image
(1) Menu
(2) Regulation
• Use the scroll keys to move the cursor to the Service icon (see Menu Icon section
above).
Text in image
(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History
• Scroll through the options to select the desired option and press the Enter key to view the
details as described below.
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Overview
Text in image
(1) Overview
(2) Operating hours
(3) Hours Real-time
(4) Reset
Example for service level (A):

The numbers on the left refer to the programmed service intervals. For Service Interval A, the
programmed number of operating hours is 4000 (top row) and the programmed number of
actual hours is 8760, which corresponds to one year (second row). This means that the
controller will issue a service warning when it reaches 4000 operating hours or 8760 actual
hours, whichever comes first. Note that the actual hours timer continues to count even when the
controller is not powered up.
The numbers between the bars indicate the number of hours remaining until the next service. In
the example above, the compressor has just started up, which means it can run for 4000 hours
or 8280 actual hours before the next service is due.
Service plans
A number of service activities are grouped (named Level A, Level B etc...). Each level represents
a number of service operations that must be performed according to the time intervals
programmed in the Elektronikon® controller.
Once a service plan interval is reached, a message will appear on the screen.
After the service work corresponding to the indicated levels has been carried out, the counters
must be reset.
From the Service menu above, choose Service Plan (3) and press Enter. the next screen
appears:
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Text in image
(1) Service plan

(2) Level
(3) Operating hours
(4) Actual Hours (hours)
(5) Change
Changing a service plan

Depending on the operating conditions, it may be necessary to change the service intervals. To
do this, use the scroll keys to select the value to be changed. A screen like the one shown
below will appear:
Press the Enter key. the next screen appears:
Change the value using the ↑ or ↓ key and press the Enter key to confirm.
Remark: operating hours and actual hours can be changed in 100 hour increments.
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Next service
Text in image
(1) Next Service

(2) Level
(3) Operating hours
(4) Topical
In the example above, service level A is programmed to 4000 operating hours, of which 0
hours have elapsed.
History
The History screen shows a list of all service work performed in the past, sorted by date. The
top date is the most recent service activity. To view details of a service activity performed (eg
service level, operating hours, or actual hours), use the scroll keys to select the desired activity
and then press the Enter key.
3.11 Change setpoint
Control panel
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(1) Scroll keys

(2) Enter key
(3) Escape key
Menu icon, Set point
Function
For compressors with a frequency converter-driven main motor two different setpoints
can be programmed. This menu is also used to choose the active set point.
Procedure
From the main screen:
• Highlight the Menu action key using the scroll keys and press the Enter key. the next
screen appears:
Text in image
(1) Menu
(2) Regulation
• Activate the menu by pressing the Enter key. A screen like the one shown below will
appear:
Text in image
(1) Regulation
(2) Set point 1
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(3) Indirect Stop Level 1

(4) Instant Stop Level 1
(5) Set point 2
(6) Change
• The screen shows the current settings.

To change settings, move the cursor to the Change action button and press the Enter
key. the next screen appears:
• The first line in the screen is highlighted. Use the scroll keys (1) to highlight the setting to be
changed and press the Enter key (2). the next screen appears:
The upper and lower limits of the setting are shown in gray and the current setting is
shown in black. Use the ↑ or ↓ scroll key to change the settings as required and press the
Enter key to confirm the change.
If necessary, change the other settings as desired as described above.
Indirect stop: occurs when the pressure rises to the preset indirect stop set point (= set point plus
indirect stop level). The motor slows down to minimum speed and the compressor switches to
no-load operation.
Immediate stop: occurs when the compressor is running at a speed between the minimum
and maximum speed, and the pneumatic pressure rises above the instant stop set point (=
instant stop set point plus level).
Both settings (indirect stop level and direct stop level) are programmable; see the
Programmable Settings section.
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3.12 Event History menu (history of events that

occurred)
Menu Icon, Event History
Function
Recalling the latest shutdown and emergency stop data.
Procedure
• In the Main screen, move the cursor to the Menu action button and press the Enter key.
the next screen appears:
Text in image
(1) Menu
(2) Regulation
• Use the scroll keys to move the cursor to the Event History icon (see Menu Icon
section above).
• The list of the latest shutdowns and emergency stops is displayed.
Example of the Event History screen
• Scroll through the items and select the desired shutdown or emergency stop.
• Press the Enter key to recall the date, time and other compressor status data at the time
of the last shutdown or emergency stop.
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3.13 Change general settings
Menu icon, Settings
Function
View and change some settings.
Procedure
appears:
Text in image
(1) Menu
(2) Regulation
• Then move the cursor to the Settings icon (see the Menu Icon section above),
using the scroll keys.
This screen also shows a number of icons. By default, the User Password icon is
selected. The status bar shows the description associated with the selected icon.
Each icon includes one or more items, such as
• Access code
• User password
• Main screen graph
• General
• Automatic restart after a power failure (ARAVF)
• Network
• Regulation
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A password may be required to adjust certain parameters. Example: By selecting the

General Settings icon you can change e.g. language, date, date format, etc.:
Text in image
(1) General
(2) Active Language
(3) Time
(4) Date
(5) Format Date
(6) Change
• To change the setting, select the Change button using the scroll keys and press the
Enter key.
• A screen like the one shown above will appear; the first option (Language) is
highlighted. Use the scroll key ↓ to select the setting you want to change and press the
Enter key.
• A pop-up screen will appear. Use the ↑ or ↓ key to select the desired value and press the
Enter key to confirm.
3.14 Menu Info
Menu icon, Info
Function
View Atlas Copco's Internet address.
Procedure
appears:
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Text in image
(1) Menu
(2) Regulation
• Use the scroll keys to move the cursor to the Info icon (see Menu Icon section
above).
• Press the Enter key. Atlas Copco's Internet address appears on the screen.
3.15 Menu Timer
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Menu Icon, Time Clock
Function
• Programming compressor start/stop commands on a time basis
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• Programming commands to switch network pressure bandwidth on a time basis

• Four different weekly schedules can be programmed.
• A weekly cycle can be programmed; a weekly cycle includes 10 consecutive weeks. One of
four programmed weekly schedules can be selected for each week in the cycle.
Important Note:
In the Elektronikon you can select different time clocks in one day (up to 8 actions).
However, it is not possible to program 2 actions simultaneously. The solution: leave at
least 1 minute between 2 actions.
For example, Start Compressor: 5.00 AM, Pressure Set Point 2: 5.01 AM (or later).
Procedure
Starting from the main screen (see Main screen):
• Move the cursor to the Menu action button and press the Enter key. Use the scroll
keys to select the Timer icon.
Text in image
(1) Menu
(2) time clock
• Press the Enter key on the controller. the next screen appears:
(1) time clock

(2) Week Action Schedules
(3) Week cycle
(4) Status
(5) Timer is not active
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(6) Remaining Operating Time
The first option in this list is shown in red. Select the desired option and press the Enter
button on the controller to change the setting.
Programming weekly schedules

• Select Week Action Schedules and press Enter. A new window will appear. The first option
in the list is shown in red. Press the Enter key on the controller to change Week Action
Schedule 1.

(2) Week Action schedule 1
(3) Week Action Schedule 2
• A week list appears. Monday is automatically selected and shown in red. Press the Enter
key on the controller to set an action for this day.

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
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• A new window will appear. The Edit action button is selected. Press the Enter key on the
controller to create an action.
(1) Monday
(2) Change
• A new pop-up window will appear. Use the scroll keys on the controller to select an action
from this list. When you are ready, press the Enter key to confirm the action.
(1) Monday
(2) Actions
(3) remove
(4) Start
(5) Stop
(6) Pressure Setpoint 1
(7) Change
• A new window will appear. The promotion is now visible in the first day of the week.
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(1) Monday
(2) Start
(3) Save
(4) Change
• Use the scroll buttons on the controller to change the time and press the Enter button to
confirm the change.
(1) Monday
(2) Start
(3) Save
(4) Change
• A pop-up window will appear. Change the value of the hours with the scroll keys ↑ and ↓.
Use the scroll buttons ← and → to move to the minutes.
(1) Monday
(2) Time
(3) Save
(4) Change
• Press the Escape key on the controller. The Edit action button is selected. Use the scroll
keys to select the Save action.
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(1) Monday
(2) Start
(3) Save
(4) Change
• A new pop-up window will appear. Use the scroll keys on the controller to select the
appropriate actions. Press the Enter key to confirm these actions.
(1) Monday
(3) Are you sure ?
(4) new
(5) Yes
(6) Save
(7) Change
Press the Escape key to exit this window.

• The action is shown below the day on which the action is scheduled.
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(2) Monday - Start

(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
Press the Escape key on the controller to exit this screen.
Programming the weekly cycle

A weekly cycle consists of 10 consecutive weeks. One of four programmed weekly schedules
can be selected for each week in the cycle.
• Select Week Cycle from the menu list of the main menu Timer.
(1) time clock

(3) Week cycle
(4) Status
• A list of 10 weeks is displayed.
(1) Week cycle

(2) Week 1
(3) Week 2
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(4) Week 3
(5) Week 4
(6) Change
Press the Enter key on the controller twice to change the first week.
• A new window will appear. Select the action, for example: Week Action schedule 1
(1) Week cycle

(2) Week 1
(6) Change
• Check the status of the Time Clock.

Use the Escape key on the controller to return to the main Timer menu. Select the
status of the Time Clock.
(1) time clock

(3) Week cycle
(4) Status
• A new window will appear. Select Week 1 to activate the Timer.
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(1) time clock

(2) Week
(4) Week 1
• Press the Escape key on the controller to exit this window. The status shows that week 1
is active.
(1) time clock

(3) Week cycle
(4) Status
• Press the Escape key on the controller to go to the main Timer menu. Select Remaining
Operating Time from the list and press the Enter button on the controller to change the
setting.
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(1) time clock

(3) Week cycle
(4) Status
• This timer is used when setting the timer. For example, if the compressor has to run for
1 hour for some reason, you can set that in this screen. This time clock takes
precedence over the actions of the Time clock.
(1) time clock

3.16 Menu Test
Menu icon, Test
or
Functi
on
• Performing a display test, ie checking that the display and LEDs are still functioning.
Procedure
• Move the cursor to the Menu action button and press the enter key (2); the next screen
appears.
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• Use the scroll keys (1) to move the cursor to the Test icon (see Menu Icon section
above)
• Press the Enter key (2); the next screen appears:
Text in image
(1) Test
(2) Safety valve test
(3) Not allowed
(4) Audit Data
• Testing of the safety valve should only be performed by authorized personnel and this
function is protected by a safety code.
• Choose the Display Test option and press the Enter key. A screen for inspection of the
display will appear and at the same time all the LEDs will light up.
3.17 Menu Password User
Menu icon, Password
Function
If the Password option is activated, unauthorized persons cannot change any settings.
Procedure
Outgoing from the main screen (see section Main screen):
• Move the cursor to Menu and press the Enter key (2). the next screen appears:
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• Use the scroll keys to select the Settings icon (see section Generalchange settings)
• Move the cursor to the Password icon (see Menu Icon section above)
• Use the scroll keys to select <Edit> and press the Enter key. Then change the password
as desired.
3.18 web server

All controllers feature a built-in web server, so they can be connected directly to the corporate
network or via a local area network (LAN) on a dedicated PC. This allows you to consult
certain data and settings via a PC, instead of via the controller display.
To work
Make sure you are logged in as an administrator.
• Use your computer's internal network card or a USB LAN adapter.
• Use a UTP cable (CAT 5e) for connection to the controller (see figure below).
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Configure the network card

• Go to Network and Sharing Center (1).
• Click on Change adapter settings (1).
• Select the Local Area Connection connected to the controller.
• Right click on Properties (1).
• Use the checkbox Internet Protocol version +4 (TCP/IPv4) (1) (see picture). Deselect the
other properties to avoid conflicts. After selecting TCP/IPv4, click the Properties button (2)
to change the settings.
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• Use the following settings:

• IP Address 192.168.100.200 (1)
• Subnet Mask 255.255.255.0 (2)
Click OK (3) and close the network connections.
Configure a connection to a corporate network (LAN)

• Ask your IT department to generate a fixed IP address in your company network.
• That IP address is excluded from the DNS server, so it is reserved for the controller.
• Also make sure that the gateway and subnet mask settings are correct. For example:
• IP = 10.25.43.200
• Gateway = 10.25.42.250
• Subnet Mask = 255.255.254.0
• Connect your controller to the company network (LAN) using a UTP cable (min. CAT
5e).
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• Adjust the controller network settings:

• Go to Main Menu
• Go to Settings (1)
• Go to Network (1)
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• Go to Ethernet (1)
• Turn off the Ethernet communication (Off) (1) so that the settings can be edited
• Change the IP Address (1)

• Adjust the Gateway IP (2)
• Adjust the Subnet Mask (3)
• Enable Ethernet communication (On) (4)
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• Wait a few minutes for the LAN network to connect to the controller
Configure the web server

The internal web server is designed and tested for Microsoft® Internet Explorer.
Also "Opera", "Mozilla Firefox", "Safari" and "Chrome" should work. View
controller data
All screenshots are indicative. The number of fields displayed depends on the options
selected.
• Open your browser and type the IP address of the controller whose data you want to view
into your browser (in this example http://192.168.100.100). The interface appears on the
screen:
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Screenshot (example!)
Navigation and options

• The banner shows the unit type and the language selection window. In this example, three
languages are available in the controller.
• On the left side of the interface you will find the navigation menu.
If the ESi has been licensed, the menu contains 3 buttons.
• Machine: Shows all generator settings.
• ES: Shows the status of the ESi (if licensed).
• Preferences: Here you can change the pressure and temperature units.
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Unit settings
All unit settings can be shown or hidden. Place a checkmark in front of each desired item and it
will be displayed. Only the machine status is fixed and cannot be removed from the main screen.
Analog inputs
Shows all current values of the analog inputs. The units of measure can be changed via the
Preferences button in the navigation menu.
Counters
Displays all controller and unit counter values.
Status info
The machine status is always visible on the web interface.
Digital inputs
Shows all digital inputs and their status.
Digital outputs
Shows all digital outputs and their status.
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Special protections.
Shows all special protections of the unit.
Service Plan
Shows all levels of the service plan and their status. The screenshot below only shows the
operating hours. It is also possible to display the current status of the maintenance interval.
3.19 Programmable Settings
Protections
Minimum Factory Maximum

setting setting setting
Compressor element outlet C 50 110 119
temperature (decommissioning
warning level)
Compressor element outlet F 122 230 246
temperature (decommissioning
warning level)
Compressor element outlet C 111 120 120
temperature (decommissioning level)
Compressor element outlet F 232 248 248
temperature (decommissioning level)
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Specific Protections for Full-Feature Compressors:
Minimum Factory Maximum

setting setting setting
Dew point warning temperature °C 10 25 99
Dew point warning temperature °F 10 77 210
Service Plan
The built-in service counters show a service warning message when the pre-
programmed time interval in the counter has elapsed.
For specific details, see the Preventive Maintenance section.
Contact Atlas Copco if a counter setting needs to be changed. The intervals must not exceed
the normal intervals and must logically coincide. See the paragraphChange general settings.
Terminology
Term Declaration
Mains This is the period within which the mains voltage must be restored for an automatic
recovery restart. This option is accessible if the auto-restart feature is enabled. Refer to Atlas
time Copco to activate the auto-restart feature.
Restart This parameter makes it possible to program the system so that not all compressors are
Delay restarted simultaneously after a power failure (ARAVF active).
Compressor The recommended minimum setting is 70 C (158 ˚F). To test the temperature sensor,
element outlet this set point can be reduced to 50°C (122 ˚F). Reset the value after testing.
The controller does not accept illogical settings. For example, if the warning level is
programmed to 95 °C (203 °F), the minimum limit for the decommissioning level is
changed to 96 °C (204 °F). The recommended difference between the warning level
and the decommissioning level is 10
°C (18 °F).
Signal delay This is the period during which the warning signal must be active before the warning
message appears.
Start delay This is the period after startup that must elapse before an alert is generated. This set
point must be less than the signal delay set point.
Minimum stop Once the compressor has stopped automatically, it will remain stopped for the duration
time of the minimum stop time, regardless of the course of the air pressure in the network.
Proportional The settings for Proportional band and Integration time have been determined
band and experimentally. Changing these settings can damage the compressor. Consult Atlas
integration Copco.
time
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4 Installation
4.1 Dimension Drawings

The dimension drawing can be found on the CD-ROM, DVD or USB stick supplied with the unit.
Dimension drawing Fashion model

9820 3001 17 GA 75 VSD+, GA 90 VSD+, GA 110 VSD+ Pack, Metric/British
Units
9820 3001 18 GA 75 VSD+, GA 90 VSD+, GA 110 VSD+ Full-Feature, Metric/British
Units
Text in drawings Translation or explanation

emergency stop switch Emergency stop switch
Electrical cable passage Lead-through hole for electrical cable
Air inlet or compressor Compressor air inlet
Cooling air inlet or compressor Compressor cooling air inlet
Cooling air inlet of cubicle and converter Cooling air inlet of electrical box and inverter
Compressed air outlet Compressed air outlet
Cooling air outlet of compressor, cubicle and Cooling air outlet from compressor, electrical box
converter and inverter
Manual drain or compressor Compressor Manual Drain
Automatic drain or compressor Automatic compressor drain
Service panel Service panel
Compressor mounting holes Compressor mounting holes
front side Front
Bottom view Bottom view
Cooling air inlet or transformer Transformer Cooling Air Inlet
Cooling air inlet or dryer Dryer Cooling Air Inlet
Cooling air outlet or dryer Dryer Cooling Air Outlet
Dryer service panel Dryer Service Panel
Manual drain or dryer Manual Dryer Drain
Automatic drain or dryer Dryer Auto Drain
Water inlet (Option Energy recovery) Water inlet (energy recovery option)
Water outlet (Option Energy recovery) Water outlet (energy recovery option)
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Reference point, center of gravity
Reference Name
1 Reference point
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Center of gravity and weight GA 75 VSD+
Frequency Model variant Voltage (V) L (mm) W (mm) H (mm) Weight (kg)
(Hz)
50 pack 200 860 515 800 1867
400 660 510 890 1552
500 820 500 860 1773
Full Feature 200 960 520 820 1825
400 800 520 910 1545
500 905 520 870 1766
60 pack 200 835 530 780 1867
230 820 500 860 1867
380/460V 660 510 890 1552
575 V 820 500 860 1773
Full Feature 200 960 520 820 1825
230 905 520 870 1860
380/460V 800 520 910 1545
575 V 905 520 870 1766
(Hz)
50 pack 200 860 515 800 1952
400 660 510 890 1602
500 820 500 860 1832
Full Feature 200 960 520 820 1969
400 800 520 910 1619
500 905 520 870 1849
60 pack 200 835 530 780 1910
230 820 500 860 1952
380/460V 660 510 890 1602
575 V 820 500 860 1832
Full Feature 200 960 520 820 1929
230 905 520 870 1969
380/460V 800 520 910 1619
575 V 905 520 870 1849
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(Hz)
50 pack 200 860 515 800 2127
400 660 510 890 1692
500 820 500 860 1917
Full Feature 200 960 520 820 2109
400 800 520 910 1724
500 905 520 870 1949
60 pack 200 835 530 780 2077
230 820 500 860 2127
380/460V 660 510 890 1692
575 V 820 500 860 1917
Full Feature 200 960 520 820 2109
230 905 520 870 2159
380/460V 800 520 910 1724
575 V 905 520 870 1949
Dimensions +/- 10 mm
Weights (including oil) +/- 10 kg
4.2 Installation proposal
Safety
The operator must observe all applicable safety regulations, including those stated in this
manual.
• Read the manual before installing the compressor. The instruction manual contains
the necessary information regarding the values described.
• Check the situation.
• Use the right tools.
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Example of a compressor room
Foundation, positioning the compressor unit

Place the compressor on a solid level floor that can support the weight of the compressor. It is
not allowed to place extra (damping) material between the floor and the base frame, so that the
base frame is not supported over the entire surface.
Ensure adequate space is available for proper maintenance and service. All dimensions
can be found in the example of the compressor room in the drawing above.
Transport brackets
Before using the compressor for the first time, make sure all red shipping brackets/bolts are
removed. They may be located under the drive train, separator vessel and compressor of the
integrated dryer (option).
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Electrical connections
• The supply voltage at the compressor terminals must not deviate by more than 10% from
the rated voltage. It is strongly recommended that the voltage drop across the power supply
cable at rated current is kept below 5% of the rated voltage.
• The power supply cable cross-section and cable installation should be performed by a
qualified electrician. Examples of cable cross-sections according to IEC and UL can be
found in the Technical Data section of the Atlas Copco Owner's Manual. If cables are
grouped together with other power cables, it may be necessary to use cables with a cross
section greater than that calculated for standard operating conditions. Local regulations
remain in force if they are stricter than the suggested values.
• A main switch and fuses are not included in the compressor and must be fitted by a
qualified electrician. To select the correct fuse type and size, refer to the electrical diagram
or the Technical Data section of the owner's manual. Note that different sizes are for
compressors with or without integrated dryer.
• Always check the fuse capacity twice in relation to the calculated cable cross-section.
Decrease the fuse rating or increase the cable cross-section if necessary.
• In order to maintain the degree of protection of the electrical connection box and to
protect its components from environmental dust, it is essential to use a well-sealing
cable thimble when connecting the power supply cable to the compressor.
• For VSD compressors, fast acting fuses must be fitted as stated in the instruction book.
The use of circuit breakers is not allowed.
• Electrical connections must be checked and tightened prior to commissioning. Tightening
torques can be found in the electrical diagram.
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Checking direction of rotation

At first start-up, the direction of rotation must be checked to check the phase direction of the
input power cables.
Incorrect phase direction of the input power cables can cause irreparable damage to the
compressor element.
• Fixed Speed Compressors

• Turn on the power. Start the compressor and turn it off immediately. Check the
direction of rotation of the drive motor while the motor is coasting. The correct
direction of rotation of the drive is indicated by an arrow on the motor fan housing.
If the direction of rotation of the drive motor is not correct, open the
disconnect switch and swap two wires on the input power cables.
• VSD compressors
• Air-cooled versions: check the direction of rotation of the main fan. The cooling fan
switch (commonly labeled Q15 or K15, see electrical diagram) must be switched
manually for a short period of time. The correct direction of rotation of the fan motor is
indicated by arrows on the plate under the fan, which are visible through the roof grille.
If the direction of rotation of the fan motor is not correct, open the disconnect switch
and swap two wires on the input power cables.
• Water Cooled Versions: Check the dryer's direction of rotation (only required for Full-
Feature versions, Pack versions will run correctly). The dryer switch (usually labeled
K11, see electrical diagram) must be switched manually for a short period of time.
Arrows are provided to indicate the correct direction of rotation of the dryer condenser
fan. Open the disconnect switch and swap two wires on the input power cables if the
dryer condenser fan direction is not correct.
Condensate collection
The drain pipes to the condensate collector must not hang in the water of the collector.
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Atlas Copco uses oil-water separators (OSD or OSCi type) that separate oil from the
condensate to comply with applicable environmental regulations. Discharge lines from
different compressors should not be interconnected before the (atmospheric) sump, as this
may damage the electronic drains.
Ventilation
The compressor room must be adequately ventilated to control the compressor air inlet
temperature. The maximum air temperature at the compressor inlet is 46°C (115°F), the
minimum temperature is 0°C (32°F). If the temperature in the room exceeds these limits, the
compressor will switch off automatically.
If the machine is equipped with the "High Ambient Temperature Version" option, it is
allowed to use the unit up to 55 °C (131 °F). This option comes with a refill of RXD
oil. A compressor with the optional freeze protection will shut down at temperatures
below -10 °C (14 °F).
The inlet grilles, ducts and external fan must always be installed in such a way that recirculation
of cooling air to the integrated dryer and/or the engine compartment is prevented. In order to
prevent the return of exhaust air to the cooling air inlet, there must be sufficient space above the
compressor for the exhaust air to be exhausted. Otherwise a pipe for the exhaust air must be
installed.
If piping is required, a different cooling capacity may be required, depending on the four possible
piping configurations:
The direction of cooling flows should never be reversed.

The maximum air speed through the ventilation grilles is 5 m/s (16.5 ft/s). The maximum
allowed pressure drop across the line before or after the compressor is 30 Pa. If there is a
leadership
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is present at the air inlet, the ambient temperature sensor should be positioned so as to
properly monitor the inlet temperature.
If the pressure drop across the ducts is too great to be overcome by the standard
fan, it is recommended to equip the unit with the optional "Powered Duct Fan".
This option increases the total allowable pressure drop across the pipes without
the need to install an additional external fan.
For air-cooled compressors and ventilation alternatives 1 and 3
The required ventilation capacity to limit the temperature in the compressor room can be
calculated as follows:
• For compressors without dryer:
Qv = 1.06 N/T
• For compressors with dryer:
Qv = (1.06 N + 1.2 D)/T
Qv = required ventilation capacity in m3/s
N = nominal compressor motor power in kW D =
electrical power of the dryer in kW
T = temperature rise in the compressor room in °C
For air-cooled compressors and the ventilation alternatives 2 and 4
The ventilation capacity must correspond to the capacity of the compressor fan at a pressure
head equal to the pressure drop caused by the cooling air outlet ducts.
For water-cooled compressors
The required ventilation capacity to limit the temperature in the compressor room can be
• For compressors without dryer:
Qv = 0.13 N/T
• For compressors with dryer:
Qv = (0.13 N + 1.2 D)/T
Qv = required ventilation capacity in m3/s
N = nominal compressor motor power in kW D =
electrical power of the dryer in kW
T = temperature rise in the compressor room in °C
The dryer's cooling air can be directed outside
Air Filtration
Filter DD must be installed for general use (repels solid particles down to 1 micron, with a
maximum oil transfer of 0.5 mg/m³). Downstream of a DD filter, a high efficiency filter of type PD
can be installed. This filter retains solid particles from 0.01 microns, with a maximum oil carry-
over of 0.01 mg/m3. A UD+ filter provides the same air purity as a DD filter in combination with a
PD. If oil vapor and odors are undesirable, a QD type filter can be installed downstream of the PD
filter. All filters must be preceded by a water separator if no
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water separator is built into the aftercooler of the compressor. If the filter is preceded
by a dryer, a water separator is no longer necessary.
We recommend installing ball valve bypass lines around each filter to isolate the filters during
service work without interfering with the compressed air flow.
The pipes for collecting condensate may only be connected to each other after a minimum of
two metres. After the point where they are connected, the diameter of the drain pipe should be
twice the diameter of the original pipes.
It is not allowed to connect pressurized electronic drains to the drain lines of the filters.
Air delivery pipe

The pressure drop across the air outlet pipe can be calculated as
follows: p = (L x c450 x Q 1,85) / (d5 x P)
d = inner diameter of the pipe in mm
p = pressure drop in bar (recommended maximum: 0.1 bar
(1.5 psi)) L = length of pipe in m
P = absolute pressure at the compressor outlet in bar(a) Qc
= free air delivery from the compressor in l/s
It is recommended to connect the compressor air outlet pipe above the main air line to
minimize the entrainment of any residual condensate.
For proper maintenance, a manually controlled valve should be installed on the

compressed air outlet to isolate the compressor from the compressed air network.
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air receiver
Install the air receiver (purchased separately) in a frost-free area and on a solid, level floor
that can support its weight.
The air receiver must be equipped with an approved safety valve of the correct capacity, which
is connected directly to the receiver. A drain must be installed at the bottom of the boiler to
collect the condensate.
With normal air consumption, the volume of the air network (boiler plus pipes) can be
V = (0.25 x Qc x P1 x T0) / (fmax x P x
T1) V = volume of the air network in l
Qc = free air delivery from the compressor in l/s
P1= compressor air inlet pressure in bar (a)
fmax = maximum cycle frequency (recommended: 1 cycle/30 seconds)
P = difference between relief pressure and load pressure in bar
T1 = compressor air inlet temperature in K
T0 = air receiver temperature in K
Moving/lifting
The compressor can be moved with a forklift using the slots in the frame. Make sure that the
housing is not damaged during lifting or transport. The transit bolts must not be removed until
the unit is in its fixed and final position. Apply it every time the unit is moved.
Make sure the fork sticks out on the other side of the frame. The compressor can also be lifted
after beams have been fitted in the slots. Make sure that the beams cannot shift and that they
extend the same length on each side of the frame. The chains must be kept parallel to the
housing using chain spreaders to avoid damaging the compressor. The hoist must be
positioned in such a way that the compressor can be lifted vertically. Lift evenly and avoid
twisting movements.
On units with the optional lifting device, it is not allowed to lift the compressor if the housing
or lifting supports are not fully installed. No persons may be under the load or perform
maintenance on the compressor while lifting the compressor.
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Safety Precautions for Water Cooled Compressors

The water flow and pressure must be set according to the local conditions.
For the quality of the cooling water, see the section Required quality of the cooling water in
this instruction manual.
A water shut-off valve and a water drain valve must be installed by the customer in the water inlet
pipe and outlet pipe of the compressor. If water shut-off valves are installed in the compressor
water inlet pipe and outlet pipe, a safety device with a pressure setting according to the
maximum cooling water inlet pressure (see Reference Conditions and Limits section in this
instruction manual) must be installed between the compressor water outlet pipe and the shut-off
valve.
When operating the unit, the operator must ensure that the cooling water system cannot be
blocked. The above also applies to the cooling water system with energy recovery. Remove
the plastic plugs (if present) from the water pipes of the compressor and connect the pipes to
the cooling water circuit.
Outdoor/High Altitude Operation

Compressors are available with the option of rain protection. This allows the compressor to be
installed outdoors under a shelter under frost-free conditions.
If there is a risk of frost, suitable measures must be taken to prevent damage to the machine and
attachments. In combination with the Frost Protection option, the unit can start up at ambient
temperatures down to minus 20 °C (-4 °F) and can run continuously at minus 10 °C (14 °F). This
option comes with a refill of RXD oil.
The maximum altitude above sea level at which the unit can operate is 1000 m (3000 ft).
Intake air quality

The inlet air of the compressors must be clean, free from solid contaminants and gaseous
contaminants must be prevented. Dirt particles that cause wear and corrosive gases (SO2, NOx,
chlorides, H2S, NH3,...) can be particularly harmful. Make sure that as little moisture* as
possible enters with the intake air. No water droplets should enter the air inlet.
Maximum allowed relative humidity in combination with ambient temperature
100% RH 35°C (95°F)

70% RH 40°C (104°F)
30% RH 46°C (115°F)
4.3 Electrical connections

Special safety precautions must be taken when working with machines controlled by
a frequency converter. These security measures depend on the type of network (TN,
TT or IT system). Consult Atlas Copco.
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Most compressors are designed for use in TT/TN networks and are intended for
industrial environments where the electrical supply is separated from the supply
network for residential/commercial premises.
To use the machine in light industrial, commercial or residential areas where there is a
shared power supply network or in an IT network, additional measures may be
required: contact Atlas Copco.
Electrical connections for the GA VSD+
Diagram electrical connections, typical example
Reference name
(1) Installation by the customer
(2) Circuit
(3) engine
Remark
The complete electrical diagram is located in the electrical connection box.
Electric scheme 9820 3000 22
Description
You will find the correct position for the electrical connection on the dimension drawings.
1. Install a disconnect switch.

2. Check that the motor cables and wires in the electrical box are securely attached to
the terminals.
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3. Check the fuses. See the paragraphCross-section of electrical cables andfuses.

4. Connect the power cables to the terminals of the EMC filter (Z1).
5. Connect the ground wire to the ground bolt (PE).
In order to maintain the degree of protection of the electrical connection box and to
protect its components from environmental dust, it is essential to use a suitable cable
thimble when connecting the power supply cable to the compressor.
Compressor Control Modes

See also the paragraph Control mode selection.
The following control modes can be selected:
• Local Control: the compressor will respond to commands entered via the buttons on the
control panel. Compressor start/stop commands via the timer function are active, if
programmed.
• Remote Control: the compressor will respond to commands given through external
switches. The emergency stop button remains active. Compressor start/stop commands
via the timer function remain possible.
Have the changes checked by Atlas Copco.

Stop the compressor and turn off the power before connecting any external equipment.
Only potential-free contacts are allowed.
• LAN control: the compressor is controlled via a local network. Consult Atlas Copco.
Compressor status indication

The Elektronikon controller is equipped with potential-free NO auxiliary contacts (NO =
normally open) (K07, K08 and K09) for external indication of:
• Manual or automatic mode (K07)
• Reason for warning (K08)
• Alarm stop condition (K09)
Maximum load on this contact: 10 A / 250 V AC.
Stop the compressor and turn off the power before connecting any external equipment.
Consult Atlas Copco.
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4.4 Icons
Icons
Reference name
1 Lock/label the compressor before performing any maintenance or repair work
2 Automatic condensate drain

3 Manual condensate drain
4 Lightly oil the oil filter gasket, screw on the filter and tighten by hand (about half a turn)
5 Automatic restart after a power failure (ARAVF)

6 Stop the compressor before cleaning the coolers
7 Warning: voltage
8 Turn off the power and wait at least 10 minutes before starting any
maintenance work
9 The compressor remains pressurized for 180 seconds after the power is turned off
10 Keep the doors closed during operation

11 Cooling water inlet
12 Cooling water outlet
13 EWD installation
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5 Options
5.1 Energy recovery

5.1.1 Energy recovery unit
Description
In every compression process, a large part of the required energy is converted into heat. With oil-
injected GA screw compressors, most of the heat of compression is dissipated by the oil system.
Atlas Copco's energy recovery systems (ER) are designed to recover most of the heat of
compression by converting it into warm or hot water, without adversely affecting compressor
efficiency. The water can be used for various applications.
Components
The energy recovery system is fully integrated and mainly includes:
• stainless steel oil/water heat exchanger
• Thermostatic bypass valve for energy recovery heat exchanger (BV2)
• Two temperature sensors for water inlet and outlet control (3 and 4)
• The necessary bolts, hoses, etc.
• Pressure relief valve with pressure setting of 10 bar
• oil drain valve
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Energy recovery unit (ER unit)
Main parts of the ER unit (standard installation)
Reference name
1 Water inlet pipe
2 water outlet pipe
3 Temperature sensor, water inlet pipe
4 Temperature sensor, water outlet pipe
6 Oil line from oil separator barrel from compressor to ER unit
7 Oil line from ER unit to oil filter housing
BV2 Location of the bypass valve of the heat exchanger (BV2)
HEY Heat exchanger
AR Oil separator vessel
OR Oil filter housing
BV1 Location of the oil cooler bypass valve (BV1)
Assembly at the customer

The main parts are assembled at the factory into a compact unit that fits into the compressor
housing. Contact Atlas Copco for installation and connection of the energy recovery unit.
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5.1.2 Energy recovery systems
General
Energy recovery systems can be applied as systems with limited temperature rise and
high water flow, or as systems with high temperature rise and limited water flow.
Systems with limited temperature rise and high water flow

In this type of application, the temperature difference between the water in the energy
recovery system and the compressor oil is small. Therefore, for maximum energy
recovery, a high water flow is required.
Example: the heated water is used to keep another medium at a moderately high temperature
in a closed circuit, such as with central heating.
Systems with high temperature rise and limited water flow

In this type of application, a large water temperature rise is obtained in the energy recovery
system, resulting in a low flow.
Example: An open circuit in which cold water from a main supply is heated through the energy
recovery system for use in a factory, for example to preheat boiler feed water.
Recovery water flow

The recovery water enters the unit through the inlet connection (1). In the heat exchanger (HE),
the heat of compression is transferred from the compressor oil to the water. The water leaves
the heat exchanger (HE) through the outlet connection (2).
Required water quality for closed water circuits.

The use of a closed water circuit reduces the requirements for the make-up water to a minimum.
The use of softened or even demineralized water is therefore economically feasible and prevents
problems due to scaling. Although the heat exchanger is made of stainless steel, it may be
necessary to add anti-corrosive agents to the water circuit connected to the compressor.
Add an antifreeze product, such as ethylene glycol, to the water in the correct amount for the
expected temperature to prevent freezing.
Required water quality for open water circuits

In open circuits that do not contain recirculated water, the main problems are usually caused by
insufficient control of deposits, corrosion and bacterial growth. To keep these problems to a
minimum, the water must meet a number of requirements.
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5.1.3 Operation
Description
The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), which
guarantee reliable operation and optimum energy recovery.
The bypass valve (BV1) is integrated into the compressor oil filter housing and controls the oil
flow to the compressor's heat exchanger (HE) and main oil cooler (Co). The bypass valve
(BV2) controls the oil flow through the oil/water heat exchanger (HE) of the ER unit. Both
bypass valves consist of an element (thermostat) mounted in a housing.
Flow Chart of Compressor with Energy Recovery System
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Reference name Reference name

BV2 ER unit thermostatic bypass OR oil filter
valve
HEY Oil/water heat exchanger (ER AR Oil separator vessel
unit)
E Compressor element BV1 Thermostatic bypass valve in
oil filter housing
Co Oil cooler (compressor) ca Aftercooler (compressor)
1 water inlet 2 water outlet
BV1 starts to close the oil cooling circuit bypass line at 70°C. At 85°C the bypass line
will be completely closed so that all oil flows through the oil cooling circuit.
BV2 begins to close the heat exchanger bypass (HE) at 60°C. At 75°C the bypass line is
completely closed and all oil flows through the main oil cooler (Co).
The energy recovery system can be equipped with water side bypass valves
When the ball valves are in position (A), as shown on the energy recovery label, the energy
recovery unit is integrated into the water circuit and will recover energy.
When the ball valves are in position (B), the heat exchanger (HE) is bypassed and no energy
is recovered.
Position of Bypass Ball Valves
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ER label
Attention: it is NOT allowed to put the ball valves in an intermediate position!
BV1 must have a higher opening temperature (set point) than BV2 to avoid transferring the heat
to the compressor oil cooler (Co) instead of going to the oil/water heat exchanger when the heat
of compression is used as a source for heat recovery.
Energy recovery system in use (see drawing)

Bypass valves in position (A): the heat exchanger (HE) is integrated in the water side of the
energy recovery
• Start up the compressor
When starting the compressor cold, the oil temperature will be low. Bypass valve (BV1) shuts
off the oil supply to the oil cooling system to prevent the compressor oil from being cooled. The
oil flows from the oil separator vessel (AR) through the oil filter(s) (OR) back to the compressor
element (E).
All the energy supplied is used to quickly heat up the compressor oil. No energy is recovered.
• Maximum energy recovery
Once the oil temperature reaches the set point (opening temperature) of the bypass valve (BV1),
the valve begins to shut off the bypass through the oil line from the heat exchanger (HE). This
allows the oil to gradually flow through the heat exchanger (HE). If the oil temperature reaches
approximately 75
C (167 ˚F) has risen, all oil will flow through the cooling system. The transfer of heat between
the compressor oil and the heat recovery water is maximum. The oil from the outlet of the heat
exchanger flows through the oil filter (OF), the compressor element (E) and the separator (AR)
back to the inlet of the heat exchanger (HE).
As long as the oil temperature remains below the 70°C set point, the bypass valve (BV1) will
cause the oil to bypass the main oil cooler (Co).
Principle of operation at different loads:
• Low consumption of recovered energy
The temperature of the oil leaving the heat exchanger (HE) rises. If the oil temperature rises
above the set point, the oil cooler bypass valve (BV2) will gradually cool the oil in the oil
cooler (Co).
• Recovery water flow too high/temperature too low
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In this case, the bypass valve (BV1) will open the bypass line, allowing the oil from the heat
exchanger (HE) to mix with the oil from the separator (AR). Energy is transferred from the
compressor oil to the water, but at a relatively low temperature level.
Energy recovery system not in use

Bypass valves in position (B): the heat exchanger (HE) is bypassed on the water side of the
energy recovery.
The oil circuit is the same as without installed energy recovery system. No energy
is recovered.
This situation should be regarded as an exception, for example during maintenance work
on the energy recovery system or when no energy is required for a longer period of time.
Taking the unit out of service for an extended period

In case of an open water system and/or expected temperatures below freezing, the compressor
water system must be insulated and purged with compressed air.
5.1.4 Maintenance
Compressor oil
See Energy Recovery Unit section for references used.
Change oil:
1. Let the unit warm up. Stop the unit, turn off the disconnect switch and close the
compressor air outlet valve.
2. Release the pressure from the compressor and drain the oil by opening the drain valve.
Also drain the oil in the heat exchanger by opening the heat exchanger drain valve (HE).
Close the tap after draining.
3. Resume the oil change as described in the Oil and Oil Filter Replacement section of this
manual.
Thermostatic Bypass Valves

Replace the energy recovery system thermostat at the same interval as the unit thermostat.
Heat exchanger (HE)

If the temperature rise across the energy recovery system decreases over a period of
constant basic operating conditions, the heat exchanger should be inspected. Immerse the
heat exchanger in a degreasing solution to clean the oil side. A suitable method must be
used for the removal of scale in the water compartment. Consult Atlas Copco.
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5.1.5 Required cooling water quality
General
Cooling water must meet certain requirements to avoid problems with scaling,
contamination, corrosion or bacterial growth.
In open-circuit cooling towers, precautions should be taken to prevent the growth of
harmful bacteria, such as Legionella pneumophila, when there is a risk of inhalation of
water droplets.
It is impossible to formulate a general recommendation for the effects of the interaction between
all combinations of the different compounds, solids and gases that may be present in the
cooling water, and the different materials. Therefore, the recommendations made in our Cooling
Water Specifications are only a general guideline for acceptable coolant quality. However,
where severe restrictions apply, a corresponding note is included in the specification.
The required water quality applies to untreated water. When the water has been treated, certain
parameters deviate. The water treatment must be carried out by a specialized water treatment
company, which accepts responsibility for the proper functioning of the treated cooling water
and its suitability for the materials in the cooling circuit. This includes not only choosing the right
additives, but also their correct administration, monitoring concentrations and properties,
preventing sludge formation and maintaining the system. The same applies to treatment with
frost-resistant products. These should be combined with suitable stabilizers and inhibitors. The
specifications also depend on the type of refrigerant circuit (open,
Consult the manufacturer if the water does not meet the recommended values, or if in doubt.
Cooling water parameters

1. pH
The pH effect has already been taken into account in the Ryznar Stability Index (RSI -
see point 4 below), but there are also limitations for pH:
pH
Cooling system type materials Default Energy recovery
single pass copper-containing 6.8 - 9.3 6.8 - 9.3
Stainless steel with 6.8 - 9.3 6.8 - 9.3
carbon steel and/or cast
iron
Stainless steel only 6 - 9.3 6 - 9.3
Recirculation (with cooling copper-containing 6.8 - 9.3 does not apply
tower) Stainless steel with 6.8 - 9.3
iron
Stainless steel only 6 - 9.3
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pH
Cooling system type materials Default Energy recovery
Closed circle copper-containing 7.5 - 9.3 7.5 - 9.3
Stainless steel with 7.5 - 9.3 7.5 - 9.3
iron
Stainless steel only 6 - 9.3 6 - 9.3
Values in bold are rejection limits.

When the system contains Zn or Al, the pH should be < 8.5.
2. Total dissolved solids (TDS) and conductivity
The conductivity is expressed in μS/cm, the TDS in ppm.
Both parameters are related to each other. The conductivity is convenient for a quick
check of the general water quality, but the TDS is needed to calculate the RSI. If only one
of the two parameters is measured, an estimate can be obtained by applying a theoretical
conversion factor (0.67):
TDS = conductivity x 0.67
3. Hardness
Different types of hardness are related to each other and together with the pH and
alkalinity of the water, these determine the equilibrium situation of the water, which
is established and specified by the RSI.
In addition, the calcium hardness must not exceed:
Ca (ppm CaCO3)
Cooling system type Default Energy recovery
single pass < 500 <2
Recirculation (with cooling tower) < 500 does not apply
Closed circle < 1000 < 50
4. The Ryznar Stability Index (RSI)

The Ryznar Stability Index is a parameter to predict whether water will tend to dissolve or
precipitate calcium carbonate. The adhesion of scaling and its effect varies according to the
material, but the equilibrium of the water (scaling or corrosive) is determined solely by the
actual acidity (pH) and the saturation acidity (pHs). The acidity at saturation is
determined by the relationship between calcium hardness, total alkalinity, total solids
concentration and temperature.
The Ryznar Stability Index is calculated as follows:
RSI = 2*pHs -
pH, where
• pH = measured pH (at room temperature) of the water sample
• pHs= pH at
saturation pHs is
calculated from:
pHs = (9.3 + A + B) - (C + D),
at which
• A: Depends on the total solids concentration
• B: depending on the water temperature at the outlet of the heat exchanger
• C: depending on the calcium hardness (CaCO3)
• D: depending on the HCO3-concentration or M-alkalinity
The values for A, B, C and D can be found in the table below:
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Total a Temperature B Ca hardness C M- d

dissolved (°C) (ppm alkalinit
solids CaCO3) y (ppm
(mg/l) CaCO3)
< 30 0.1 0-1 2.3 9 - 11 0.6 10 - 11 1.0

30 - 320 0.2 2-6 2.2 12 - 14 0.7 12 - 14 1.1
> 320 0.3 7 - 11 2.1 15 - 17 0.8 15 - 17 1.2
12 - 16 2.0 18 - 22 0.9 18 - 22 1.3
17 - 22 1.9 23 - 28 1.0 23 - 28 1.4
23 - 27 1,8 29 - 35 1.1 29 - 35 1,5
28 - 32 1.7 36 - 44 1.2 36 - 44 1.6
33 - 38 1.6 45 - 56 1.3 45 - 56 1.7
39 - 43 1,5 57 - 70 1.4 57 - 70 1,8
44 - 49 1.4 71 - 89 1,5 71 - 89 1.9
50 - 55 1.3 90 - 112 1.6 90 - 112 2.0
56 - 61 1.2 113 - 141 1.7 113 - 141 2.1
62 - 67 1.1 142 - 177 1,8 142 - 177 2.2
68 - 73 1.0 178 - 223 1.9 178 - 223 2.3
74 - 79 0.9 224 - 281 2.0 224 - 281 2.4
80 - 85 0.8 282 - 355 2.1 282 - 355 2.5
86 - 91 0.7 356 - 446 2.2 356 - 446 2.6
92 - 95 0.6 447 - 563 2.3 447 - 563 2.7
564 - 707 2.4 564 - 707 2.8
708 - 892 2.5 708 - 892 2.9
893 - 1000 2.6 893 - 1000 3.0
Interpretation of the obtained values:

• RSI < 6: scale formation
• 6 < RSI < 7: neutral water
• RSI > 7: corrosive water
As a general rule, the RSI index should be between 5.6 and 7.5. If this is not the case,
please contact an expert.
5. Free chlorine (Cl2)

In closed systems and in energy recovery systems, no disinfected with chlorine.
A constant level of 0.5 ppm should not be exceeded. For shock treatments, a maximum
limit of 2 ppm applies for a maximum of 30 minutes/day.
6. Chlorides (Cl-)
Chloride ions are the cause of pitting corrosion in stainless steel. Depending on the RSI
value, its concentration should be limited.
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RSI < 5.5 5.6 < RSI < 6.2 6.3 < RSI < 6.8 6.9 < RSI < 7.5 7.6 < RSI
Cl- (ppm) 200 350 500 350 200
A limit value of 100 ppm applies for energy recovery systems.

7. Sulfates (SO 42-)
Sulfate (ppm)
single pass < 1000 < 200
Closed circle < 400 < 200
8. Iron and Manganese
Dissolved Iron (ppm) Dissolved manganese (ppm)

Cooling system Default Energy recovery Default Energy recovery
type
single pass <1 < 0.2 < 0.2 < 0.05
Recirculation <1 does not apply < 0.2 does not apply
(with cooling
tower)
Closed circle <1 < 0.2 < 0.2 < 0.05
Values in bold are rejection limits.

9. Buyer
Copper (ppm)
single pass <1 < 0.2
Recirculation (with cooling tower) <1 does not apply
Closed circle <1 < 0.2
10. Ammonium
The limit value 0.5 ppm is a rejection limit.
The restriction only applies to copper containing systems.
11. Suspended Solids
No large particles (size > 10 µm) should be present as they can be filtered out.
Small particles (< 0.5 µm) are not taken into account.
The following limit values apply for particles between 0.5 µm and 10 µm:
Suspended solids (ppm)

single pass < 10 <1
Closed circle < 10 <1
12. oil or fat

< 1 ppm (rejection value)
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13. Biology
If biology is present, it must be aerobic. Anaerobic biology (in closed systems) should
be avoided.
Biology (CFU/ml)
single pass < 105 / < 107 < 103 / < 105
Recirculation (with cooling tower) < 105 / < 107 does not apply
Closed circle < 103 / < 105 < 103 / < 105
The table shows the recommended values. Values in bold are rejection limits.
When using additives in the cooling water, keep in mind that the cooling capacity
changes.
Δm = ((Cpw - Cpa) * X) / (Cpw * (1-X) + X*Cpa) *
100% where
Δm: change in the mass flow of the refrigerant
Cpw: specific thermal capacity of water
Cpa: specific thermal capacity of the additives X: the
percentage of additives
5.1.6 Energy recovery data
Reference conditions
See the paragraph Reference conditions and limit values.
Effective working pressure

See the Compressor Data section for normal working pressure.
Maximum allowable pressure in the heat exchanger
Oil side 15 bar (217 psi)

Waterside 10 bar (145 psi)
Read settings
In addition to other data, the following temperatures can be read on the display of
the Elektronikon:
For air-cooled units:
• The water inlet temperature of the energy recovery system.
• The water outlet temperature of the energy recovery system.
Changing settings
If the programmed water temperature warning settings are exceeded, a warning
indication is displayed on the Elektronikon:
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Temperature input Minimum Nominal Maximum

setting institutio setting
n
Water inlet temperature, energy recovery C 0 70 99
Water inlet temperature, energy recovery F 32 158 210
Water outlet temperature, energy recovery C 0 90 99
Water outlet temperature, energy recovery F 32 194 210
To change a setting, see the appropriate section in the Elektronikon controller description.
Reclaimable energy
The renewable energy can be calculated as follows:
REWINDABLE ENERGY (kW) = 4.2 x water flow (l/s) x water temperature rise (˚C) The
tables below contain typical examples.
Data for systems with limited temperature rise and high water flow
Parameter unit d GA 75 VSD+ GA 90 VSD+ GA 110 VSD+
Renewable Energy kW 69.9 85.8 97.7

Renewable Energy pk 93.7 115.1 131.0
water flow l/min 65.5 80.5 91.6
water flow cfm 2.31 2.84 3.23
Temperature at inlet C 55 55 55
Temperature at inlet F 131 131 131
Temperature at outlet C 70 70 70
Temperature at outlet F 158 158 158
Data for systems with high temperature rise and limited water flow
Parameter unit d GA 75 VSD+ GA 90 VSD+ GA 110 VSD+
Renewable Energy kW 53.7 73.4 87.8

Renewable Energy pk 72.01 98.43 117.74
water flow l/min 11.5 15.1 17.7
water flow cfm 0.4 0.5 0.6
Temperature at inlet C 20 20 20
Temperature at inlet F 68 68 68
Temperature at outlet C 87 90 90
Temperature at outlet F 189 194 194
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6 Operating Instructions
First usage
The operator must comply with all applicable Safety regulations consider. See also the
paragraphTo fix an issue.
See the paragraphs Introduction and Condensate System for the location of the air exhaust
valve and the drain connections.
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Step Action
1 Remove the panel(s) from the enclosure to gain access to the internal components.
Remove the red spacers (1) for transport and the corresponding bolts under the
engine.
Remove the red spacers (2) for transport and the corresponding bolts under the air
reservoir.
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Step Action
2 Check that the electrical connections comply with local codes and that all wires are securely
attached to the terminals.
The installation must be earthed and protected against short circuits in all phases with slow-
blow fuses. An isolation switch must be installed near the compressor.
3 Check the voltage select wires on the primary side of transformer T1.
4 Install the air exhaust valve (AV); see paragraphIntroduction for the valve location.
Close the cover.
Connect the air network to the valve.
5 Install the manual condensate drain valve (Dm).
Close the cover.

6 Check the oil level. The oil should reach the bottom of the oil filler neck (FC).
The minimum level should reach the oil level sight glass (GI) when the compressor is
stopped.
Top up oil if necessary.
Make sure that no dirt gets into the oil system. Reinstall
and tighten the fill plug (FC).
7 Post warnings so that the operator is aware of the following:
• The compressor can restart automatically after a power cut (contact Atlas Copco if this
option is enabled).
• The compressor is automatically controlled and can restart automatically.
• The compressor can be controlled remotely.
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Step Action
8 Check the direction of rotation of the fan motor.
1. Turn on the power.
2. For Full-Feature compressors: Apply power and energize contact K12 (dryer fan) on
the dryer rail for a few seconds (e.g. with a screwdriver) to check the direction of
rotation. The direction of rotation of the fan also indicates the direction of rotation of the
dryer's compressor.
If the direction of rotation is wrong, swap two phases of the mains supply.
If the dryer turns in the wrong direction, it will be damaged!
3. For air-cooled compressors, check the direction of rotation of the fan motor. The
correct direction of rotation of the fan motor is indicated by arrows on the plate under
the fan, which are visible through the roof grille.
9 Check the programmed settings. See the paragraphProgrammable Settings.
10 Open the air outlet valve.
Start the compressor and let it run for a few minutes. Check if the compressor is working
normally.
Start
Control panel, Elektronikon® Graphic
Step Action
1 Open the air outlet valve.
2 Turn on the power. Check whether the 'power on' LED (6) lights up.
3 Press the start button (1) on the control panel. The compressor starts running and the LED
(8) 'automatic operation' lights up.
During business
Keep the panels closed during operation.
When the motors have stopped and the 'automatic run' LED (8) is lit, the motors can restart
automatically.
When the 'automatic run' LED (8) is lit, the compressor operation, ie load, unload, stop the
motors and restart, is automatically controlled by the controller!
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Check the oil level regularly:
A few minutes after stopping, the oil level should reach the bottom of the oil filler neck (FC).
If the oil level is too low, wait until the compressor is completely depressurized. Press the
emergency stop button (10) to prevent the compressor from starting unexpectedly. Then close
the air outlet valve and open the manual drain valve (Dm) until the pressure in the air system
between the oil separator/air receiver and the outlet valve is completely relieved. See the
paragraphCondensate System for the location of the exhaust valve and the water drain.
Loosen the oil fill plug (FC) one turn to release any remaining pressure in the system. Wait a
few minutes. Remove the fill plug and add oil up to the fill hole. Reinstall and tighten the fill
plug (FC).
Unlock the emergency stop button (10), select the STOP icon on the display and press
Reset before restarting the machine.
Check regularly whether condensate is discharged during operation. See the
paragraphCondensate System. The amount of condensate depends on the ambient
and operating conditions.
Check the Elektronikon® display regularly:
Control panel, Elektronikon® Graphic
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Check the display (2) regularly for readings and messages. Usually the display shows the
compressor outlet pressure, while the compressor status is shown by icons. If alarm LED (7) is lit
or flashing, rectify the fault, see sectionIcons used. The display (2) shows a service message
when a service plan interval or service level for a monitored component has been exceeded.
Carry out the service work according to the indicated plans or replace the part and reset the
relevant timer. See the paragraphMenu Service.
Fuses
Step Action
1 Press the stop button (9). The LED 'automatic operation' (8) goes out and the compressor
stops.
2 Close the air outlet valve.
3 Press the test button on top of the electronic water drain(s) to release the pressure in the line
between the air receiver and the exhaust valve. Then open the manual drain valve (Dm). See
the paragraphCondensate System.
Turn off the power.
If you need to stop the compressor in an emergency, press the emergency stop button
(10). The alarm LED flashes (7).
• Fix the cause of the problem.
• Then unlock the button by pulling it out.
• Then navigate to the Stop icon on the display using the navigation buttons (3/4) and
press the Select button.
Press Reset.
Do not use the emergency stop button (10) for a normal stop!
Decommissioning
Step Action
1 Disconnect the compressor from the mains.
2 Loosen the oil fill plug one turn to release any pressure remaining in the system.
3 Shut off the part of the air network connected to the exhaust valve and release the pressure.
Disconnect the compressor air outlet line from the air mains.
4 Drain the oil.
5 Drain the condensate circuit and disconnect the condensate pipes from the condensate
network.
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7 Maintenance
7.1 Preventive Maintenance Schedule
Control panel Warning
Before carrying out any maintenance, repair or adjustment work, proceed as

follows:
• Stop the compressor.
• Close the air outlet valve and open the condensate drain valve to relieve
pressure from the air system between the air receiver and the outlet valve.
• Press the emergency stop button (10).
• Turn off the power.
• Release the pressure from the compressor.
See the paragraph To fix an issue for detailed instructions.
The operator must comply with all applicable Safety regulations consider.
Warranty - Product Liability

Use only approved parts. Any damage or malfunction of any kind caused by the use of non-
approved parts is not covered by the warranty or product liability.
service kits
Service kits are available for overhaul or preventive maintenance (see section service kits).
Service contracts
Atlas Copco can offer you various service contracts that take all preventive maintenance work
off your hands. Consult the nearest Atlas Copco Customer Center.
General
During service, all removed O-rings and shims should be replaced.
Intervals
The local Atlas Copco Customer Center can adapt the maintenance schedule, especially
the maintenance intervals, to the environmental and operating conditions of the
compressor.
In the case of long-term inspections, the short-term inspections must also be carried out.
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Service Plans for Compressors with an ElektronikonTM Graphic Controller

In addition to the checks that must be carried out daily and every 3 months, there are the
preventive service activities listed in the following schedule.
Each plan has a programmed time interval within which all service activities associated with
that plan must be performed. When the interval has elapsed, a message will appear on the
screen indicating which maintenance plans must be performed. After performing the service
work, the intervals must be reset. See the paragraphService menu.
Preventive Maintenance Schedule

Checklist for checks to be performed daily or every 3 months
Period Action
Daily Check oil level. Top up oil if necessary (see sectionOperating instructions — during
business)
Check the values on the display.
Check whether condensate is discharged by waiting some time during operation. You
can use the test button on the top of the electronic water drain to check the drain
function.
Every 3 Check the coolers and clean them if necessary.
months (1) Remove the air filter element and inspect the element. Replace damaged or heavily
soiled elements.
Check the filter elements of the electrical box. Replace if necessary.
Checklist for Compressors with Dryer
Period Action
Daily Check that the dryer drains condensate by waiting some time during operation.
You can use the test button on the top of the electronic water drain to check the drain
function.
Monthly (1) Cleaning the condenser:
• Stop the compressor, close the air exhaust valve and turn off the power.
• Remove any debris on the condenser inlet with a vacuum cleaner.
• Then clean by blowing compressed air through it in the opposite direction to the
normal flow. Use compressed air with a low pressure for this. Keep the
compressed air nozzle more than 12 inches (30 cm) from the condenser to avoid
damaging the condenser fins.
• Remove dust from the dryer, eg with a vacuum cleaner.
Do not use water or solvents to clean the condenser.
(1): Check more often if working in a dusty environment. Preventive

maintenance schedule programmed into the Elektronikon
A maintenance B maintenance D maintenance

every 4000 every 8000 every 24000 hours
operating hours (1) operating hours (2)
Replace the air filter X X X
Replace the electrical X X X
box filter mats
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A maintenance B maintenance D maintenance

every 4000 every 8000 every 24000 hours
operating hours (1) operating hours (2)
Replace the filter screen X X X
of the drain(s)
Change the oil x (3) X X
Replace the oil filter x (3) X X
Replace the oil X X
separator element
Overhaul the purge X X
line check valve
Overhaul the X X
minimum
pressure valve
Overhaul the X X
thermostatic valve
Overhaul the X X
condensate drain(s)
Replace the motor x (4)
top bearing
Overhaul the x (4)
compressor
element
Intake valve x (5)
(1) : or yearly (indicated by real-time counter), whichever comes first

(2) : or every 2 years (indicated by real-time counter), whichever comes first
(3) : if Roto-Xtend Duty Fluid is used, changing the oil and replacing the oil filter are part
of the B maintenance.
(4) : For compressor elements used at operating pressures less than or equal to 10 bar (145 psi),
overhaul may be delayed up to 32000 hours of operation.
(5) : When the unit has had more than 300,000 starts/stops (more than 10 starts per hour) it is
recommended to service the inlet valve and solenoid block.
Change Interval for Roto-Inject Fluid Ndurance
Ambient temperature Exhaust temperature of Refresh interval * Maximum time interval *

element
up to 30 °C up to 95 °C 4000 1 year
between 30°C and 35°C between 95 °C and 100 3000 1 year
°C
between 35 °C and 40 °C between 100 °C and 105 2000 1 year
°C
higher than 40 °C higher than 105 °C use ROTO-Xtend use ROTO-Xtend
Change Interval for Roto-Xtend Duty Fluid
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Ambient temperature Exhaust temperature Refresh interval * Maximum time interval *

of element
up to 35 °C up to 100 °C 8000 2 years
between 35 °C and 40 °C between 100 °C and 105 6000 2 years
°C
higher than 40 °C higher than 105 °C 5000 2 years
Change Interval for Roto-Foodgrade Fluid
Ambient temperature Exhaust temperature of Refresh interval * Maximum time interval *

element
up to 35 °C up to 100 °C 4000 1 year
°C
°C
higher than 45 °C higher than 110 °C use not recommended use not recommended
* Whichever expires first.
Important
• Always contact Atlas Copco if a counter setting needs to be changed.

• Contact the nearest Atlas Copco Customer Center for information on the oil and
oil filter change interval under extreme temperature, humidity or cooling air
conditions.
• Any leakage must be rectified immediately. Replace damaged hoses or gaskets.
7.2 Oil Specifications

It is strongly recommended to use genuine Atlas Copco lubricants. These lubricants are the
result of years of practical experience and research. Refer to the Preventive Maintenance
Schedule section for recommended drain intervals and refer to the spare parts list for part
numbers.
Avoid mixing different brands or types of lubricants. Because these may not be
compatible, the resulting oil mixture may be of inferior quality. There is a plate on the air
receiver or oil tank that indicates which type of oil has been used at the factory.
Only Atlas Copco oils may be used.

The oil level should be checked on a regular basis.
Roto-Inject Fluid Ndurance

Atlas Copco Roto-Inject Fluid Ndurance is a specially developed lubricant for use in single-
stage oil-injected screw compressors. Due to the special composition of this
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lubricant keeps the compressor in optimum condition. Roto-Inject Fluid Ndurance can be used
for compressors operating at ambient temperatures between 0˚C (32˚F) and 46˚C (115˚F). If
the compressor operates regularly at ambient temperatures above 35
°C (95°F), the life of the engine oil is significantly reduced. In that case, use Roto-Xtend Duty
Fluid for a longer oil change interval.
Roto-Xtend Duty Fluid

Atlas Copco Roto-Xtend Duty Fluid is a high performance synthetic lubricant for oil-injected screw
compressors and keeps them in optimum condition. Due to its excellent oxidation stability, Roto-
Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 C
(32 F) and 46 ˚C (115 F).
Roto-Xtend Duty Fluid is the standard oil for high ambient compressor
versions.
If the compressor is operated regularly at ambient temperatures above 40 °C (104 °F), the oil life
is limited (see oil life table Preventive Maintenance Schedule).
Roto Food Grade Fluid

Special oil, available as an option.
Atlas Copco Roto-Foodgrade Fluid is a unique and high performance synthetic lubricant,
specially developed for oil-injected screw compressors that supply air to the food industry.
This lubricant keeps the compressor in optimum condition. Roto-Foodgrade Fluid can be used
for compressors operating at ambient temperatures between 0 C (32 ˚F) and 40 ˚C (104 F).
If the compressor is operated regularly at ambient temperatures above 95 °F (35 °C), the oil life
is limited (see oil life table Preventive Maintenance Schedule).
7.3 Drive motor
Maintenance of the bearings

The motor bearing is lubricated by oil injection. Re-lubrication is not necessary.
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7.4 Air filter
Location of the air filter
Procedure
1. Stop the compressor. Turn off the power.
2. Remove the air filter cover (AF) by opening the clamping system. Remove the filter
element.
3. Install the new element and replace the cover.
7.5 Changing the oil and replacing the oil filter and oil
separator
Warning
Always drain the compressor oil at all drain points. Used oil left in the compressor can
contaminate the oil system and shorten the life of the fresh oil.
Never mix different brands or types of lubricants. Because these may not be
compatible, the resulting oil mixture may be of inferior quality. There is a plate on the
air receiver or oil tank that indicates which type of oil has been used at the factory.
Also see Maintenance of energy recovery systems if the compressor is
equipped with an energy recovery unit.
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Only Atlas Copco oils may be used. The oil level

should be checked regularly. Timely service of
consumables is needed.
Use appropriate personal protective equipment (gloves).
Procedure
Pressure draining is available on this unit and should only be performed by authorized
personnel and is protected by a security code.
Consult Atlas Copco.
1. Warm up the compressor and stop the compressor.

• Close the air outlet valve.
• Wait 10 minutes until the compressor depressurizes the air receiver.
• Open the condensate drain valve to release the pressure from the
cooler (see condensate system) and close the valve again.
• Turn off the power.
• Loosen the oil fill plug (FC) one turn to release any remaining pressure in the system.
• Cover the heat sink channel on the electrical box.
2. Remove the breather plug (VP) from the oil cooler.
Vent plug, oil cooler
3. Open the oil drain valve (Do).
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4. Open the oil drain valve on the element outlet hose (DO1).
• Remove the oil filter (OR). Note that this filter has a left-hand threaded
connection.
• Collect the oil in a container and hand it in at the local waste depot. Reinstall the vent
plugs after draining.
5. Close the oil drain valves (Do, Do1).
6. Clean the seat on the manifold. Lubricate the gasket of the new oil filter and screw it in
place. Tighten them firmly by hand.
7. Remove the fill plug (FC).
Fill the air reservoir with oil until the level reaches the filler neck.
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Make sure that no dirt gets into the system. Reinstall and tighten the fill plug (FC).
8. Let the compressor run under load for a few minutes. Stop the compressor.
9. Close the air exhaust valve and turn off the power.
• Wait 3 minutes until the compressor depressurizes the air receiver.
• Open the condensate drain valve (Dm) to depressurize the cooler.
(SeeCondensate System) and close the tap again.
• Loosen the oil fill plug (FC) one turn to release any remaining pressure in the system.
10. Fill the air reservoir (AR) with oil until the level reaches the filler neck. (seeOperating
Instructions/During business)
• Reinstall and tighten the fill plug (FC). If the oil level
is too low, go back to step 7.
7.6 Coolers
General
Keep the coolers clean so that the cooling efficiency is not adversely affected.
Procedure
• Stop the compressor, close the air exhaust valve and turn off the power.
• Cover all parts under the cooler.
• Remove the maintenance plate (1) from the fan compartment.
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• Remove any dirt on the coolers with a synthetic fiber brush. Move the brush in the direction
of the cooling fins.
Remove any dirt on the fan with a synthetic fiber brush.
• Clean by blowing compressed air through it in the opposite direction to normal flow.
• Contact Atlas Copco if the coolers require cleaning with a cleaning agent.
After servicing the fan and coolers: Remove the

material used as cover.
• Install the maintenance plate (1) on the fan compartment.
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Procedure for compressors with dryer.
Dryer condenser location
• Remove dirt on the condenser inlet (6) with a synthetic fiber brush.
• Clean by blowing compressed air through it in the opposite direction to normal flow.
• Clean the condenser section with a synthetic fiber brush.
7.7 Dryer Care Instructions
Safety regulations
Type ID refrigeration dryers contain the refrigerant HFC.
When handling the refrigerant, all applicable safety regulationsare complied with. In
particular, keep the following in mind:
• Contact of the refrigerant with the skin will cause frostbite injuries. Special gloves must be
worn. If the refrigerant has come into contact with the skin, rinse the skin with water. Under
no circumstances remove any items of clothing.
• Liquid coolant can also cause frostbite in the eyes. Therefore always wear safety
glasses.
• Refrigerant is harmful. Never inhale refrigerant vapors. Check that the workplace is
adequately ventilated.
Be aware that certain components, such as the refrigerant compressor, and the discharge
pipe can become quite hot (up to 110°C - 230°F). Therefore, wait until the dryer has cooled
down before removing the panels.
Turn off the power and close the air inlet and air outlet valves before performing any
maintenance or repair work.
Local Regulations
Local regulations may include the following provisions:
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• Work on the refrigerant circuit of the refrigerant dryer or on any equipment that affects the
operation of the dryer should be performed by an authorized inspection body.
• The installation must be checked annually by an authorized inspection body.
7.8 Maintenance Relative Humidity Sensor (RH)
Cleaning
The relative humidity sensor should be cleaned monthly.
1. Remove the front service panel using the wrench supplied with the compressor.
Location of the relative humidity (RH) sensor on the compressor
Reference Name
RH Relative Humidity Sensor
2. Clean the relative humidity sensor with isopropanol (quick solution) or demineralised water
and let it dry.
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7.9 Safety valves
Location of the safety valve
To
test
Testing of the safety valve (SV) should only be performed by authorized personnel and
this function is protected by a security code. Refer to Elektronikon® Graphic
controller,menu Test
If the safety valve does not open at the set pressure engraved on the valve, the valve must be
replaced.
Warning
It is not allowed to change the settings. Never run the compressor without a safety
valve.
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7.10 Service intervals filters
UD+ filters
The filter elements of oil mist filters (UD+) should be replaced after 4000 hours. The gauge or
pop-up window does not provide a clear indication, as a standard oil mist filter operates in a
steady state of eg 200-250 mbar throughout its life.
Note that the indicator or gauge will not move to the red area, but will remain yellow or orange
during operation.
In summary, the following service intervals must be observed (depending on which situation
occurs first):
• 4000 operating hours
• after 12 months of use
• Pressure drop: 350 mbar
7.11 service kits
service kits
A wide range of service kits are available for overhauls and preventive maintenance. Service kits
contain all the parts needed for maintenance, offer the advantage of genuine Atlas Copco parts
and also help keep your maintenance budget low.
A full range of rigorously tested lubricants are also available, tailored to your specific needs, to
keep the compressor in excellent condition.
See spare parts list for part numbers.
7.12 Storage after installation
Procedure
Warm up the compressor regularly, for example twice a week.
If the compressor is stored and will not run on a regular basis, extra precautions must
be taken. Contact the supplier.
7.13 Dispose of used materials
Used filters or other used materials (e.g. desiccants, lubricants, cleaning cloths, machine
parts, etc.) must be disposed of in an environmentally sound and safe manner in
accordance with local recommendations and environmental legislation.
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Be careful when removing the electric motor. The rotor contains magnetic parts.
Electronic components are covered by the EU Directive 2002/96/EC for Waste Electrical and
Electronic Equipment (WEEE). These parts may therefore not be returned to a municipal waste
collection point. Consult your local regulations for further instructions on how to dispose of this
product in an environmentally sound manner.
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8 To fix an issue
Warning
Before performing any maintenance, repairs or adjustments, stop the compressor, wait 3
minutes and close the air outlet valve.
Press the test button on top of the electronic water drain until the pressure in the air
system between the air reservoir and the exhaust valve is completely relieved.
Press the emergency stop button and turn off the power.
Release the pressure from the compressor by loosening the oil fill plug one turn.
For the location of the parts, see the paragraphs:
• Introduction
• Condensate System
• Operating Instructions
• Maintenance.
Open and lock the disconnect switch.
During maintenance or repair, lock the air exhaust valve as follows:
• Close the cover.
• Remove the screw securing the handle using the wrench supplied with the
compressor.
• Lift the handle and turn it until the slot fits over the abutment on the valve body.
• Tighten the screw again.
Before electrical maintenance
Wait at least 10 minutes before starting repair work on electrical equipment, because
the capacitors of the starter and speed control unit are still at dangerously high
voltages for several minutes after the power is turned off.
Faults and solutions, compressor

If the alarm LED is on or flashing, refer to paragraphs Event History or Service menu.
Status Malfunction Solution

No condensate is discharged from Drain hose clogged Check and remedy if
the separator during loading necessary

Compressor flow or pressure Air consumption exceeds the air Check the connected equipment
lower than normal output of the compressor
Air filter element clogged Replace the filter element
Solenoid valve defective Replace the valve
Oil separator clogged Have the element replaced
Air leakage Have the leaks fixed
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Safety valve is leaking. Have the valve replaced.
Compressor element defective. Contact Atlas Copco

Safety valve blows off Minimum pressure valve defective Check and have defective
parts replaced
Oil separator clogged Have the element replaced
Safety valve defective Have the valve checked
Replace if necessary.
On Full-Feature Compressors: Have the system checked by
Dryer Lines Clogged Due to Ice Atlas Copco
Formation

Compressor element outlet Oil level is too low Check and repair, see Operating
temperature or outlet air instructions/during business
temperature higher than normal
For air-cooled compressors: Check if the cooling airflow is
insufficient cooling air or cooling impeded, or improve the
air temperature or relative ventilation in the compressor
humidity is too high room. Avoid recirculating
cooling air.
Check the capacity of the fan
in the compressor room, if
installed
Oil cooler clogged Clean the cooler

Bypass valve defective Have valve tested
Air cooler clogged. Clean the cooler
Compressor element defective. Contact Atlas Copco
Oil of reduced quality Check maintenance intervals,

see Preventive Maintenance
Schedule

Low load alarm enabled: Solenoid valve defective Replace the valve
compressor has been running with
too low oil temperature for an
extended period
Extremely low Increase load profile (longer
compressor usage and/or more load cycles are
required)
If this is not possible,
consult Atlas Copco
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Inverter error codes

If a problem is detected by the drive, a specific code (main motor drive alarm) will appear on the
Elektronikon display, along with an error code. The table below lists the main error codes. If a
new code appears, please contact Atlas Copco.
Default display when the compressor is stopped by an alarm stop
(1) Alarm stop
Navigate to the Stop icon or to the Protections icon and press Enter.
(1) Protections
(1) General
The display shows the problem (Main motor inverter alarm) and an error code (31 in this
case).
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(1) Main motor inverter alarm

(2) Malfunction
Error Codes for NEOS Inverter
electro Error Description Cause Actions

nic code of the
nikon mistake
4369 0x1111 Voltage Mains voltage too low or missing Check that the mains voltage
too low circuitry in the control panel meets the specifications. Check
the main fuses.
Check for loose connectors on
the drive control unit and the
Elektronikon controller.
Check for blown fuses on the
secondary side of the transformer
T1 in the electrical panel.
8978 0x2312 Motor Overcurrent detected on Check that the mains voltage
8980 0x2314 overcurrent motor side meets the specifications.
8981 0x2315 Motor Short circuit detected in U

overcurrent phase
Try to reset the error.
8982 0x2316 Motor Short circuit detected in V phase
If the error returns, contact Atlas
overcurrent
Copco.
8983 0x2317 Motor Short circuit detected in W
overcurrent phase
12816 0x3210 Overvoltage Overvoltage detected
Check that the mains voltage
12833 0x3221 Voltage Mains voltage too low.
meets the specifications. Check
too low
the main fuses.
12835 0x3223 Voltage Phase Loss Detected
too low
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nic code of the
nikon mistake
12836 0x3224 Overvoltage Maximum allowable voltage of the Allow the drive to cool
DC link has been exceeded; Check for excessive
threshold value is lowered in case ambient temperature Clean
of higher temperature the heat sink with
compressed air
Clean the inlet filter housing
Ensure good cooling air
flow in the compressor
room Check that the
supply voltage is within
the specifications
12837 0x3225 Voltage Undervoltage detected Check that the mains voltage
too low meets the specifications.
Check the main fuses.
12838 0x3226 Overvoltage Over voltage or over temperature Let the drive cool down. Check for
detected in IGBT (U phase) excessive ambient temperature.
12839 0x3227 Overvoltage Over voltage or over temperature Clean the heat sink with
detected in IGBT (V phase) compressed air.
Clean the inlet filter housing.
12840 0x3228 Overvoltage Over voltage or over temperature Ensure good cooling
detected in IGBT (W phase) air flow in the
compressor room.
Check whether the
supply voltage meets the
specifications.
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nic code of the
nikon mistake
17169 0x4311 Drive Overtemperature detected in an
overheated IGBT
17170 0x4312 Drive Overtemperature detected in the
overheated heat sink
17172 0x4314 Drive Overtemperature detected in
overheated IGBT junction box UH
overheated IGBT junction box UL
overheated IGBT junction box VH Let the drive cool down. Check for
excessive ambient temperature.
17175 0x4317 Drive Overtemperature detected in Clean the heat sink with
overheated IGBT junction box VL compressed air.
17176 0x4318 Drive Overtemperature detected in Clean the inlet filter housing.
overheated IGBT junction box WH Ensure good cooling
17177 0x4319 Drive Overtemperature detected in air flow in the
overheated IGBT terminal box WL compressor room.

overheated power supply board
overheated switchboard
17180 0x4322 Drive Overtemperature detected in U
overheated phase of IGBT board
17181 0x4323 Drive Overtemperature detected in V
17182 0x4324 Drive Overtemperature detected in W
20512 0x5020 Emergen Emergency stop circuit open
cy stop Check the emergency stop
(ST) button. Check for loose
20513 0x5021 Emergen Emergency stop circuit open connectors on the drive control
cy stop unit.
(ST)
20514 0x5022 Emergen Emergency stop circuit open
cy stop Hardware failure detected
(ST)
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nic code of the
nikon mistake
20756 0x5114 Drive Internal power is turned off
failure
(hardware)
20757 0x5115 Drive Internal power is turned off
failure
(hardware)
21505 0x5401 Drive General fault detected in power
failure section
(hardware)
21506 0x5402 Drive General fault detected in power
failure section
(hardware)
24833 0x6101 Drive EEPROM read error
failure Communication
(hardware) timeout
24834 0x6102 Drive Power board temperature
failure reading failed
(hardware) Communication timeout
on initialization
24835 0x6103 Drive General fault detected
failure
(hardware)
Try to reset the error.
24836 0x6104 Drive Internal checksum
failure error detected
Copco.
(hardware)
24837 0x6105 Drive Internal communication timeout
failure
(hardware)
(hardware)
failure
(hardware)
failure
(hardware)
(hardware)
24842 0x610A Drive Internal
failure communication
(hardware) overload
24843 0x610B Drive Internal control overload
failure
(hardware)
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nic code of the
nikon mistake
24844 0x610C Drive CAN communication timeout Check CAN cable connection
failure between Elektronikon and inverter.
(hardware) Check the position of the CAN
terminator switch on both sides
of the CAN cable. Both should
be OFF.
24845 0x610D Drive Firmware not compatible

failure
(hardware)
24846 0x610E Drive Power supply board not recognized
failure
(hardware) Try to reset the error.
24847 0x610F Drive IGBT module not recognized Copco.
failure
(hardware)
24848 0x6110 Drive Power supply board not
failure compatible with IGBT modules
(hardware)
24849 0x6111 Drive Internal CAN status machine fault Check CAN cable connection
(software) Check the position of the CAN
be OFF.
24850 0x6112 Drive Requested command cannot Try to reset the error.
failure be executed due to limited If the error returns, contact Atlas
(software) access level Copco.
24851 0x6113 Drive CAN communication overload Check CAN cable connection
(software) Check the position of the CAN
be OFF.
24852 0x6114 Drive The firmware version is not Try to reset the error.
failure compatible with the parameter If the error returns, contact Atlas
(software) version Copco.
28976 0x7130 Engine Motor overheating detected Let the engine cool down. Check
overheat that the main fan and airflow in
ed and out of the compressor room
are not blocked or clogged.
Provide a good flow of cool air in
the compressor room.
Check for loose connectors on
the drive control unit.
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nic code of the
nikon mistake
33793 0x8401 Overvoltage Motor maximum speed Try to reset the error.
exceeded If the error returns, contact Atlas
Copco.
12817 0x3211 Overvoltage Engine start failed; desired Wait until the boiler is
21507 0x5403 speed not reached pressureless by blowing it off. (by
33794 0x8402 not resetting the fault
immediately). If the problem
persists, contact Atlas Copco.
33795 0x8403 Negative Electrical connection not Swap the two power cables
speed correct; wrong direction of
rotation of the motor
36865 0x9001 Enable Hardware release signal is Check for loose connectors on
hardware missing the drive control unit and the
release is Elektronikon controller.
missing Check for blown fuses on the
secondary side of the transformer
T1 in the electrical panel.
From: From: Drive Error attempting to write parameter Try to reset the error.
36965 0x9065 failure Pyyy out of range If the error returns, contact Atlas
To: To: (software) Copco.
37364 91F4
Malfunctions and solutions, dryer

See the paragraph Air dryer for all subsequent references.

Pressure dew point is too high Air inlet temperature is too Check and remedy; clean the compressor
high aftercooler if necessary
Ambient temperature is too Check and remedy; if necessary, suck in
high cooling air through a duct from a cooler
place or relocate the compressor
Refrigerant Shortage Have the circuit checked for leaks and
topping up
Refrigerant compressor does See below.
not work.
Evaporator pressure is too See below.
high
Condenser pressure is too See below.
high
Condenser pressure is too Fan switch is defective To replace
high or too low
Fan blades or fan Have the fan/fan motor checked,
motor defective replace if necessary
Ambient temperature is too Check and remedy; if necessary, suck in
high cooling air through a duct from a cooler
place or relocate the compressor
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Condenser clogged on the Clean the condenser
outside
Compressor stops, or does Power to the compressor is Check and remedy if necessary
not start interrupted
Thermal protection of the The motor will restart when the motor
refrigerant compressor motor windings have cooled down
is activated
Electronic condensate Electronic drain system is Have the system inspected

drain does not work clogged Clean the automatic drain filter by opening
the manual drain valve. Check the operation
of the drain by pressing the test button
Condensate trap Automatic drain defective. Have the system checked. If

continuously separates air necessary, replace the automatic drain
and water
Evaporator pressure is too Hot gas bypass valve Have hot gas bypass valve adjusted
high or too low at no load misadjusted or defective
Condenser pressure is too See above.
high or too low
Refrigerant Shortage Have the circuit checked for leaks and
top up if necessary
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9 Technical data
9.1 Display readings
Elektronikon® Graphic controller
Important
The values below are valid under the reference conditions (see section Reference
conditions and limit values).
Reference Reading
Air outlet pressure Dependent on set point (desired mains pressure)
Compressor Approx. 80 °C (176 °F) (ambient temperature 20 °C + 60 °C)
element outlet
temperature
Dew point temperature Approx. 4˚C (39˚F).
(with Full-Feature
compressors)
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9.2 Cross section of electrical cables and fuses
Important
• The voltage at the compressor terminals must not deviate more than 10% from the
rated voltage.
However, it is strongly recommended that the voltage drop across the power
supply cables at rated current is kept below 5% of the rated voltage (IEC
60204-1).
• If cables are grouped together with other power cables, it may be necessary to
use cables with a cross section greater than that calculated for standard
operating conditions.
• Please use the original cable entry. See the paragraphDimension Drawings. In
order to maintain the IP degree of protection of the electrical connection box and
to protect its components from environmental dust, it is imperative to use a
suitable cable thimble when connecting the power supply cable to the compressor.
• Local regulations remain in force if they are stricter than the values
suggested below.
• Carefully:
• Always check the fuse capacity twice in relation to the calculated cable
cross-section. Decrease the fuse rating or increase the cable cross-section if
necessary.
• The cable length must not exceed the maximum length according to
IEC60204 table 10.
The correct tightening torque must be applied to the power cables.
Leakage current switch (option)

If a residual current circuit breaker is required for installation, always use a residual current circuit
breaker sensitive to all currents, RCM or RCD type B (according to IEC/EN 60755) with adequate
undervoltage tripping.
Currents and fuses

IEC approval
Type Imax(1) max. secured imax(2) max. secured

power (1) power (2)
aR gL/gG aR gL/gG
V Hz a a a a a a
GA 75 VSD+ 200 50 324 2x200 339 2x200
GA 75 VSD+ 400 50 157 200 165 200
GA 75 VSD+ 500 50 130 200 136 200
GA 75 VSD+ 200 60 326 2x200 343 2x200
GA 75 VSD+ 380 60 166 200 175 200
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power (1) power (2)
aR gL/gG aR gL/gG
V Hz a a a a a a
GA 75 VSD+ 460 60 138 160 147 160
IEC approval

power (1) power (2)
aR gL/gG aR gL/gG
V Hz a a a a a a
GA 90 VSD+ 200 50 367 2x224 383 2x224
GA 90 VSD+ 400 50 178 200 186 250
GA 90 VSD+ 500 50 146 200 153 200
GA 90 VSD+ 380 60 187 250 197 250
GA 90 VSD+ 200 60 367 2x224 386 2x224
GA 90 VSD+ 460 60 156 200 163 200
IEC approval

power (1) power (2)
aR gL/gG aR gL/gG
V Hz a a a a a a
GA 110 VSD+ 200 50 424 2x250 443 2x250
GA 110 VSD+ 400 50 208 250 217 250
GA 110 VSD+ 500 50 171 200 179 200
GA 110 VSD+ 200 60 428 2x250 450 2x250
GA 110 VSD+ 380 60 219 250 230 315
GA 110 VSD+ 460 60 182 200 191 250
UL/cUL Approval

power (1) power (2)
JJS K5/ JJS K5/
HRC HRC
form II form II
V Hz a a a a a a
GA 75 VSD+ 230 60 283 2x175 301 2x175
GA 75 VSD+ 460 60 137 250 146 175
GA 75 VSD+ 575 60 114 125 120 150
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UL/cUL Approval

power (1) power (2)
JJS K5/ JJS K5/
HRC HRC
form II form II
V Hz a a a a a a
GA 90 VSD+ 230 60 319 2x200 334 2x200
GA 90 VSD+ 460 60 155 200 162 200
GA 90 VSD+ 575 60 128 150 133 150
UL/cUL Approval

power (1) power (2)
JJS K5/ JJS K5/
HRC HRC
form II form II
V Hz a a a a a a
GA 110 VSD+ 230 60 367 386 2x225
GA 110 VSD+ 460 60 180 200 189 225
GA 110 VSD+ 575 60 149 175 157 175
Imax: current in power cables at maximum load and rated voltage (1):
compressors without built-in dryer
(2) : compressors with built-in dryer
Circuit Breaker Setting
frequency (Hz) voltage (V) GA 75 VSD+ GA 90 VSD+ GA 110 VSD+

Q15 (A) Q15 (A) Q15 (A)
IEC 50 200 4.0 5.0 7.7
50 400 4.0 5.0 7.7
50 500 4.0 5.0 7.7
60 200 5.0 5.0 8.0
60 380 5.0 5.0 8.0
60 460 5.0 5.0 8.0
UL/cUL 60 230 5.0 5.0 7.3
60 460 5.0 5.0 7.3
60 575 5.0 5.0 7.3
Fuse calculations for IEC be carried out in accordance with IEC 60364-4-43 Electrical
installations of buildings, part 4: Protective measures - section 43: Protection against
overcurrent. Fuse capacities are calculated to protect the cable against short circuits.
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Fuse calculations for cUL and UL: to protect the motor against short circuits, the specified
fuse rating is the maximum fuse rating.
Grounding
The ground cable connected to the compressor (PE) must be at least 10 mm2 (according to
EN 60204-1 section 828).
Cable capacities according to IEC

The tables below indicate the current carrying capacities of cables for 3 commonly used
installation methods, calculated according to standard 60364-5-52 - Electrical installations of
buildings, part 5 - Selection and installation of electrical equipment and paragraph 52 - Current
carrying capacities in wiring systems.
The permitted currents are valid for cables with PVC insulation and three loaded copper
conductors.
max. current IEC 70 °C 90 °C

75 kW 190 X X
(95mm2)
90 kW 217 X X
(150mm2)
110 kW 253 X X
(150mm2)
Installation method F according to table B.52.1. 1-

core cables touching each other in the free space
Distance to wall not less than one cable cross section
Maximum allowable current as a function of ambient temperature for installation method F,

conductor temperature 70 °C
Ambient temperature
Cable cross 30°C 40 °C 45 °C 50°C 55 °C
section
25mm² < 110 A < 96 A < 87 A < 78 A < 67 A
35mm² < 137 A < 119 A < 108 A < 97 A < 84 A
50mm² < 167 A < 145 A < 132 A < 119 A < 102 A
70mm² < 216 A < 188 A < 171 A < 153 A < 132 A
95mm² < 264 A < 230 A < 209 A < 187 A < 161 A
120mm² < 308 A < 268 A < 243 A < 219 A < 188 A
150mm² < 356 A < 310 A < 281 A < 253 A < 217 A
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Maximum allowable current as a function of ambient temperature for installation method F,

conductor temperature 90 °C
Ambient temperature
Cable cross 30°C 40 °C 45 °C 50°C 55 °C
section
25mm² < 135 A < 123 A < 117 A < 110 A < 103 A
35mm² < 169 A < 154 A < 147 A < 139 A < 128 A
50mm² < 207 A < 188 A < 180 A < 170 A < 157 A
70mm² < 268 A < 244 A < 233 A < 220 A < 204 A
95mm² < 328 A < 298 A < 285 A < 269 A < 249 A
120mm² < 383 A < 349 A < 333 A < 314 A < 291 A
150mm² < 444 A < 404 A < 386 A < 364 A < 337 A
Calculation method for IEC:

• Single power cables (3 phases + PE - configuration (1)):
• Add 10% to the total compressor current (ItotPack or ItotFF in the tables)
• Fit the specified fuse to each cable
• Parallel power cable (2 x 3 phases + PE - configuration (2)):
• Add 10% to the total compressor current (ItotPack or ItotFF in the tables) and divide
by 2
• Multiply the load capacity of the cables by 0.8 (see table A.52.17 (52-E1))
• Fuse each cable with half the recommended maximum fuse rating.
• Cross section of the PE cable:
• For power cables up to 35 mm²: same cross section as power cables
• For power cables larger than 35 mm²: half the cross-section of the power
cables
Always check the voltage drop across the cable (less than 5% of the rated voltage is
recommended).
Example 1: Itot = 178 A, maximum ambient temperature is 45 °C, recommended fuse = 200 A
• I = 178 A + 10% = 178 x 1.1 = 196 A
• The table for method F is at conductor temperature 70 °C and ambient temperature 45
°C allows a maximum current of 209 A for a 95 mm² cable.
Therefore use a cable of 3 x 95 mm² + 50 mm².
If method F conductor temperature 90 °C is used, 70 mm² is sufficient.
Therefore, 3 x 50 mm² + 25 mm² can be used.
Example 2: Itot = 178 A, 424 A, maximum ambient temperature is 45 °C, recommended
fuse = 500 A
With transformer
• Single power cables with a maximum cross section of 150 mm² (3 phases + PE -
configuration (1)):
• I = 424 A + 10% = 424 x 1.1 = 466 A
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• The table for method F allows a maximum current of 386 A for a 150 mm² cable at
conductor temperature 90 °C and ambient temperature 45 °C.
• 150 mm² is the maximum cable cross-section that can be connected. Therefore
we have to use configuration (2)
• Parallel power cable (2 x 3 phases + PE - configuration (2)):
• I = (424 A + 10%)/2 = (424 x 1.1)/2 = 233 A
• With a 120 mm² cable, method F 90 °C conductor at 45 °C, the maximum current is
333 A x 0.8 = 266 A. So 2 parallel cables of 3 x 120 mm² + 70 mm² are sufficient.
• Install a 250 A fuse on each cable.
Cable capacities according to UL/cUL

Calculation method according to UL 508A, Table 28.1, Column 5: Allowable
load capacities of insulated copper conductors (75 °C (167 °F)).
Maximum allowable current as a function of the wire cross-section
AWG or kcmil Maximum current

10 < 30 A
8 < 50 A
6 < 65 A
4 < 85 A
3 < 100 A
2 < 115 A
1 < 130 A
1/0 < 150 A
2/0 < 175 A
3/0 < 200 A
4/0 < 230 A
250 < 255 A
300 < 285 A
350 < 310 A
Calculation method for UL:

• Single power cables (3 phases + 1 PE - configuration (1)):
• Add 25% to the total current in the tables (see UL 508A 28.3.2: "Ampacity shall have
125% of the full load current")
• Fit the specified maximum fuse on each cable
• Parallel power cable (2 x 3 phases + 2 PE - configuration (2)):
• Add 25% to the total flow in the tables and divide by 2
• Multiply the load carrying capacity of the cables by 0.8 (see UL 508A, Table 28.1
continued)
• Fuse each cable with half the recommended maximum fuse rating.
• When using 2 x 3 phases + 2 PE as in (3):
• Add 25% to the total flow in the tables and divide by √3
• Multiply the load carrying capacity of the cables by 0.8 (see UL 508A, Table 28.1
continued)
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• Fuse Capacity: For each cable, the recommended maximum fuse capacity
divided by √3.
• PE cable cross section:
• For power cables up to AWG8: same cross section as the power cables
• For power supply cables larger than AWG8: use the maximum allowable load
carrying capacity of the selected supply cables and compare with the value in
the table below (see CEC, part 1, table 17)
< 100 A: Use AWG8

< 200 A: Use AWG6
< 300 A: Use AWG4
Always check the voltage drop across the cable (less than 5% of the rated voltage is
recommended).
Example 3: Itot = 189 A, maximum ambient temperature is 45 °C, recommended fuse = 225 A
• I = 189 A + 25% = 189 x 1.25 = 207 A
• For AWG 4/0, the maximum current is 230 A, which is sufficient.
• Install the specified maximum fuse (225 A) on each cable.
9.3 Reference conditions and limit values
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
Workload See the Compressor data section.
Limits
Maximum working pressure See the Compressor data section.
Minimum working pressure bar(e)

Minimum working pressure psig
Maximum air inlet temperature C 46
Maximum air inlet temperature F 115
Minimum ambient temperature C 0
Minimum ambient temperature F 32
140 2921 7116 00

Operating manual
9.4 Compressor data
All data listed below are under the reference conditions. See the paragraphReference
conditions and limit values.
GA 75 VSD+
Normal effective working pressure bar(e) 4 7 9.5 12.5

Normal effective working pressure psig 58 102 138 181
Maximum effective working pressure, bar(e) 13 13 13 13
Pack
Maximum effective working pressure, psig 189 189 189 189
Pack
Maximum Effective Working bar(e) 12.75 12.75 12.75 12.75
Pressure, Full-Feature
Maximum Effective Working psig 185 185 185 185
Maximum motor shaft speed rev/min 3150 3150 2817 2417
n
Minimum motor shaft speed rev/min 600 600 780 850
n
Rated motor power kW 75

Rated motor power pk 100
Total Refrigerant Amount, Full-Feature kg 1.30
Total Refrigerant Amount, Full-Feature lb 2.9
Oil capacity l 54
Oil capacity US gal 14.3
Oil capacity Imp. gal 11.9
Oil capacity cu. ft. 1.9
Sound pressure level (according to ISO 2151 (2004)) dB(A) 70
GA 90 VSD+

Pack
Pack
2921 7116 00 141

Operating manual

n
142 2921 7116 00

Operating manual

n

Oil capacity l 54
GA 110 VSD+

Pack
Pack
n
n

Oil capacity l 54
2921 7116 00 143

Operating manual
9.5 Controller technical data
General
mains voltage 24 VAC/16 VA 50/60 Hz (+40%/-30%)

24VDC/0.7A
Degree of protection IP54 (front)
IP21 (rear)
Ambient conditions and IEC60068-2
temperature
• Operating temperature • -10 °C…..+60 °C (14 °F ...... 140°F)
range k • -30 °C…..+70 °C (-22 °F ...... 158°F)
• Storage temperature
range k
Permissible humidity Relative humidity 90%
Non-condensing
noise emission IEC61000-6-3
noise immunity IEC61000-6-2
Confirmation On door of electrical cabinet
Digital outputs
Number of outputs 9 (Elektronikon™ Graphic Controller - Part No. 1900 5200 10 to 1900
5200 19)
9 (Elektronikon™ IO2 Module - Part No. 1900 5200 33)
Type Relay (voltage free contacts)
Rated voltage AC 250 V AC / 10 A max.
Rated voltage DC 30 V DC / 10 A max.
Digital inputs
Number of inputs 10 (Elektronikon™ Graphic Controller - Part No. 1900 5200 10 to 1900
5200 19)
Controller power 24 V DC
Power supply protection Protected against short circuit to ground
Security entrance Not isolated
144 2921 7116 00

Operating manual
Analog inputs
Number of pressure inputs 2 (Elektronikon™ Graphic Controller - Part No. 1900 5200 10 to 1900
5200 19)
Number of temperature inputs 5 (Elektronikon™ Graphic Controller - Part No. 1900 5200 10 to 1900
5200 19)
2921 7116 00 145

Operating manual
10 Instructions for use
Air/oil separator boiler
- This boiler may contain compressed air and present a potential hazard if misused.
- This boiler may only be used as a compressed air/oil separator and within the limits stated
on the rating plate.
- No changes may be made to this boiler by welding, drilling or other mechanical means
without the written permission of the manufacturer.
- The safety valve must be designed for pressure surges of 1.1 times the maximum
allowable working pressure. This ensures that the pressure does not permanently exceed
the maximum allowable working pressure of the boiler.
- Only use oil specified by the manufacturer.
- This boiler has been designed and built in such a way that an operational life of more than
20 years can be guaranteed.
The boiler must be visually inspected annually.
However, national legislation may require an in-service inspection.
146 2921 7116 00

Operating manual
11 Inspection Guidelines
Guidelines
The Declaration of Conformity / Manufacturer's Declaration lists and/or refers to the
harmonized and/or other standards used in the design.
The Declaration of Conformity / Manufacturer's Declaration is part of the documentation supplied
with this compressor.
Local regulations and/or use of the dryer outside the limits and/or conditions specified by
the manufacturer may require inspection periods other than those specified below.
2921 7116 00 147

Operating manual
12 Pressure Equipment Guidelines
Parts covered by the Pressure Equipment Directive 2014/68/EU

The following table contains the necessary information for inspecting all pressure equipment
of category II and above according to the Pressure Equipment Directive 2014/68/EU, and for
inspecting all pressure equipment according to the Simple Pressure Vessels Directive
2014/29/EU.
Compressor Component Description Numbe Minimum Frequency Frequency of

type e r of wall of visual hydrostatic
cycles thickness inspection inspection (2)
(1) (2)
GA 75 VSD+ to 1649 8001 01 Boiler 2 x 106 8mm 1 year Every 10 years
GA 110 VSD+
1649 8003 90 Safety valve - - - -
1202 5401 00 Safety valve - - - -
Compressor type Component Description Volume design Minimum and PED-

pressure maximum class
design
temperature
GA 75 VSD+ to 1625 4815 01 Boiler 100 l 15 bar(e) -8˚C/ 120C III
GA 110 VSD+ 1625 4815 01 Safety valve - - - IV
0830 1009 98 Safety valve - - - IV
The compressors comply with a PED category lower than category III.
(1) The number of cycles is the number of cycles from 0 bar(e) to the maximum pressure.
(2) Other inspection techniques, such as ultrasonic or X-ray examination, are equivalent to
hydrostatic testing of this equipment.
148 2921 7116 00

Operating manual
13 Declaration of Conformity
Typical example of a declaration of conformity
(1) : Contact address:

Atlas Copco Airpower nv
PO Box 100
B-2610 Wilrijk (Antwerp)
Belgium
(2) : Applicable guidelines (3):
Standards used
The Declaration of Conformity/Manufacturer's Declaration lists and/or refers to the
harmonized and/or other standards used in the design.
The Declaration of Conformity / Manufacturer's Declaration is part of the documentation
supplied with this device.
2921 7116 00 149

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150 2921 7116 00

no. 2921 7116 00 / 2017 - 11 - Printed in Belgium Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.
DEDICATED, SUSTAINABLE AND PRODUCTIVE
We stand by our responsibility to our customers, the environment and
the people around us. We ensure that performance stands the test of
time. That's what we mean by Sustainable Productivity.
www.atlascopco.com

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Translated from Dutch to English - www.onlinedoctranslator.

GA 75 VSD+, GA 90 VSD+, GA 110 VSD+

1 Safety regulations ......................................................................................................................5

1.1 SAFETY ICONS ..................................................................................................................................................................................................... 5

1.2 SAFETY REGULATIONS, GENERAL ................................................................................................................................................ 5

1.3 SAFETY INSTRUCTIONS DURING INSTALLATION .......................................................................................................... 6

1.4 SAFETY INSTRUCTIONS DURING OPERATION ................................................................................................................. 7

1.5 SAFETY INSTRUCTIONS DURING MAINTENANCE OR REPAIR ........................................................................ 9

2 General description. ............................................................................................................... 11

2.2 FLOW SCHEDULE ........................................................................................................................................................................................... 14

2.3 CONDENSATE SYSTEM ........................................................................................................................................................................... 16

2.4 CONTROL SYSTEM ....................................................................................................................................................................................... 20

2.5 ELECTRICAL SYSTEM ................................................................................................................................................................................ 20

2.6 lAIR DRYER...................................................................................................................................................................................................................... 21

3 Elektronikon Graphic controller. ......................................................................................... 24

3.1 ELECTRONIKONTM GRAPHIC-CONTROLLER ..................................................................................................................................................... 24

3.2 CONTROL PANEL ............................................................................................................................................................................................ 26

3.3 USED ICONS......................................................................................................................................................................................................... 27

3.4 huhEARTH SCREEN .................................................................................................................................................................................................... 31

3.5 mAND YOU'CALLS S .................................................................................................................................................................................................... 35

3.6 mAND YOU IWAYS ....................................................................................................................................................................................................... 36

3.7 mAND YOU YOUOUTCOMES.................................................................................................................................................................................. 39

3.9 CONTROL MODE SELECTION ........................................................................................................................................................... 42

3.10 mAND YOU sSERVICE................................................................................................................................................................................................. 43

3.11 CHANGE SETPOINT ..................................................................................................................................................................................... 47

3.12 EVENT HISTORY MENU (HISTORY OF OCCURRED EVENTS). ................................................ 50

3.13 CHANGING GENERAL SETTINGS .................................................................................................................................................. 51

3.14 mAND YOU INFO........................................................................................................................................................................................................... 52

3.15 mAND YOU tTIME CLOCK ........................................................................................................................................................................................... 53

3.16 mAND YOU tEST ........................................................................................................................................................................................................... 62

3.17 MENU PASSWORD USER ....................................................................................................................................................................... 63

3.19 PROGRAMMABLE SETTINGS ............................................................................................................................................................. 72

4.1 DIMENSION DRAWINGS........................................................................................................................................................................... 74

4.2 INSTALLATION PROPOSAL .................................................................................................................................................................. 77

4.3 ELECTRICAL CONNECTIONS ............................................................................................................................................................. 85

4.4 ICONS .......................................................................................................................................................................................................................... 88

5.1 ENERGY RECOVERY .................................................................................................................................................................................. 89

6 Operating Instructions. ........................................................................................................ 102

7 Maintenance ............................................................................................................................ 108

7.1 PREVENTIVE MAINTENANCE SCHEDULE ......................................................................................................................... 108

7.2 OIL SPECIFICATIONS............................................................................................................................................................................... 111

7.3 aDRIVE MOTOR .......................................................................................................................................................................................................... 112

7.4 lAIR FILTER ................................................................................................................................................................................................................... 113

7.6 kOELERS....................................................................................................................................................................................................................... 116

7.7 MAINTENANCE INSTRUCTIONS FOR THE DRYER................................................................................................... 118

7.8 OMAINTENANCE RELATIVE-HUMIDITY SENSOR (RH). ........................................................................................ 119

7.9 SAFETY VALVES ........................................................................................................................................................................................... 120

7.10 SERVICE INTERVALS FILTERS ..................................................................................................................................................... 121

7.11 sSERVICE KITS ........................................................................................................................................................................................................... 121

7.12 STORAGE AFTER INSTALLATION .............................................................................................................................................. 121

7.13 DISPOSAL OF USED MATERIALS ............................................................................................................................................... 121

8 To fix an issue. ....................................................................................................................... 123

9 Technical data. ....................................................................................................................... 133

9.1 READINGS ON THE DISPLAY .......................................................................................................................................................... 133

9.2 ELECTRICAL CABLES AND FUSES ........................................................................................................................................... 134

9.3 REFERENCE CONDITIONS AND LIMIT VALUES .......................................................................................................... 140

9.4 COMPRESSOR DATA ............................................................................................................................................................................... 141

9.5 TECHNICAL DATA CONTROLLER ............................................................................................................................................... 143