Apf176951 en

GA 160
APF176951
Instruction book
Atlas Copco
GA 160
APF176951
Instruction book
Original instructions
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as identified
in the Declaration of Conformity.
2012 - 09
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................6
1.1 SAFETY ICONS...................................................................................................................................6
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................7
1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................8
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................9
2 General description......................................................................................................11
2.1 INTRODUCTION.................................................................................................................................11
2.2 AIR AND OIL SYSTEM.........................................................................................................................12
2.3 COOLING AND CONDENSATE SYSTEM....................................................................................................15
2.4 REGULATING SYSTEM........................................................................................................................16
2.5 ENERGY RECOVERY SYSTEM...............................................................................................................17
3 Elektronikon regulator.................................................................................................38
3.1 ELEKTRONIKON® REGULATOR.............................................................................................................38
3.2 CONTROL PANEL..............................................................................................................................40
3.3 FUNCTION KEYS...............................................................................................................................41
3.4 SCROLL KEYS..................................................................................................................................42
3.5 EMERGENCY STOP BUTTON................................................................................................................42
3.6 CONTROL PROGRAMS........................................................................................................................43
3.7 CALLING UP MENUS..........................................................................................................................46
3.8 MAIN SCREEN MENU.........................................................................................................................47
3.9 STATUS DATA MENU..........................................................................................................................47
3.10 MEASURED DATA MENU.....................................................................................................................50
3.11 COUNTERS MENU.............................................................................................................................51
3.12 TEST MENU.....................................................................................................................................52
3.13 MODIFY PARAMETERS MENU...............................................................................................................52
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3.14 FAN MOTOR SETTINGS.......................................................................................................................53
3.15 MODIFYING PARAMETERS...................................................................................................................54
3.16 MODIFYING PROTECTION SETTINGS......................................................................................................55
3.17 MODIFYING SERVICE PLANS................................................................................................................56
3.18 PROGRAMMING CLOCK FUNCTION.........................................................................................................57
3.19 MODIFYING CONFIGURATION SETTINGS..................................................................................................61
3.20 SERVICE MENU................................................................................................................................63
3.21 SAVED DATA MENU...........................................................................................................................65
3.22 PROGRAMMABLE SETTINGS.................................................................................................................65
4 Installation.....................................................................................................................69
4.1 DIMENSION DRAWING........................................................................................................................69
4.2 INSTALLATION PROPOSAL...................................................................................................................71
4.3 ELECTRIC CABLE SIZE.......................................................................................................................75
4.4 QUALITY OF SAFETY COMPONENTS.......................................................................................................78
4.5 INSTALLATION INSTRUCTIONS FOR DRYER BY-PASS .................................................................................79
4.6 PICTOGRAPHS.................................................................................................................................80
5 Operating instructions.................................................................................................83
5.1 INITIAL START-UP..............................................................................................................................83
5.2 BEFORE STARTING............................................................................................................................85
5.3 STARTING.......................................................................................................................................86
5.4 DURING OPERATION..........................................................................................................................88
5.5 CHECKING THE DISPLAY.....................................................................................................................89
5.6 MANUAL LOADING/UNLOADING.............................................................................................................91
5.7 STOPPING.......................................................................................................................................93
5.8 TAKING OUT OF OPERATION................................................................................................................94
5.9 USE OF AIR RECEIVER.......................................................................................................................95
6 Maintenance..................................................................................................................96
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6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................96
6.2 MOTORS.........................................................................................................................................97
6.3 OIL SPECIFICATIONS..........................................................................................................................98
6.4 OIL CHANGE....................................................................................................................................98
6.5 STORAGE AFTER INSTALLATION.........................................................................................................103
6.6 SERVICE KITS................................................................................................................................103
7 DD filter........................................................................................................................104
7.1 MAINTENANCE...............................................................................................................................104
7.2 FILTER ELEMENT CHANGE ................................................................................................................104
7.3 SERVICE INTERVALS........................................................................................................................105
7.4 FILTER DISPOSAL............................................................................................................................105
7.5 REFERENCE CONDITIONS.................................................................................................................105
7.6 PRINCIPAL DATA.............................................................................................................................105
8 Integrated dryer..........................................................................................................106
8.1 CONDENSATE DRAIN SYSTEM............................................................................................................106
8.2 MAINTENANCE INSTRUCTIONS...........................................................................................................107
8.3 PROBLEM SOLVING.........................................................................................................................108
9 Adjustments and servicing procedures...................................................................109
9.1 AIR FILTERS..................................................................................................................................109
9.2 COOLERS.....................................................................................................................................111
9.3 SAFETY VALVE...............................................................................................................................113
10 Problem solving..........................................................................................................114
10.1 PROBLEM SOLVING.........................................................................................................................114
11 Technical data.............................................................................................................117
11.1 READINGS ON DISPLAY....................................................................................................................117
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11.2 REFERENCE CONDITIONS.................................................................................................................117
11.3 LIMITS..........................................................................................................................................118
11.4 SETTINGS OF SAFETY VALVE.............................................................................................................118
11.5 SETTINGS FOR OVERLOAD RELAY AND FUSES.......................................................................................118
11.6 SETTINGS OF CIRCUIT BREAKERS.......................................................................................................119
11.7 COMPRESSOR DATA........................................................................................................................119
12 Pressure equipment directives.................................................................................120
13 Documentation............................................................................................................121
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1 Safety precautions
1.1 Safety icons
Explanation
Danger for life
Warning
Important note
1.2 Safety precautions, general
General precautions
1. The operator must employ safe working practices and observe all related work safety requirements and
regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two
shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality,
the compressed air must be adequately purified according to the applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,
press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the
power isolating switch must be opened and locked.
On units powered by a frequency converter, wait six minutes before starting any electrical repair.
If the machine is equipped with an automatic restart after voltage failure function and if this
function is active, be aware that the machine will restart automatically when the power is
restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme
caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall
be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the unit or on its components.
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1.3 Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within
safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction
duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
6. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents, that can lead
to internal fire or explosion.
7. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the electrical isolating
switch is open, locked and labelled with a temporary warning before any maintenance or repair. As a
further safeguard, persons switching on or off remotely controlled machines shall take adequate
precautions to ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and
that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
12. The electrical connections must correspond to the applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed
near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return
valves (check valves) must not be relied upon for isolating pressure systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be
protected by a pressure relieving device or devices as required.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touched
by personnel in normal operation must be guarded or insulated. Other high temperature piping must be
clearly marked.
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17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by
a safety device with set pressure according to the maximum cooling water inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation

manufacturer.
Precautions during operation

1. Never touch any piping or components of the compressor during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure
that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or
particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to
carry out routine checks. Wear ear protectors when opening a door.
On compressors without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• No leaks occur
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free
of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to
avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
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11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be
protected by a pressure relieving device or devices as required.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance.
1.5 Safety precautions during maintenance or repair

manufacturer.
Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the starting
equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or disconnecting
a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify,
pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
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16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that
they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been
reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator
vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering
them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork
and in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by
genuine material from the manufacturer to prevent the sound pressure level from increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use
breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical
first aid.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
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2 General description
2.1 Introduction
General view
General view of air-cooled GA
Description of GA compressors
GA (W) are single-stage, oil-injected screw compressors, driven by an electric motor and enclosed in sound-
insulated bodywork.
GA are air-cooled compressors.
Pipe connections
NPT connections.
Anti-condensation heaters
Electric heaters are installed in the motor windings and connected to the compressor cubicle. When the
compressor is stopped, the heaters are automatically switched on. The heaters in the motor will prevent
condensation during stand-still.
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2.2 Air and oil system
Flow diagrams
Flow diagram of air-cooled GA compressor
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Position of components
Front view
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Rear view of air-cooled GA
Air flow
Air drawn through filter (AF) and unloader (UA) is compressed in compressor element (E). Compressed air
and oil are discharged through check valve (CV) to air receiver/oil separator (AR) where oil is separated from
the compressed air. The air is blown through minimum pressure valve (Vp) to air cooler (Ca).
On GA Pack compressors, the cooled air is discharged through condensate trap (MTa) and outlet (AOw)
towards the air net.
Check valve (CV) prevents blow-back of compressed air.
Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure. The
valve has a built-in check valve.
Oil system
Air pressure forces the oil from receiver (AR) through oil cooler (Co), filters (OF), oil stop valve (Vs) and an
oil injection valve to the compressor element (E) and the lubrication points. The oil injection valve will open
at higher ambient temperatures to keep the element outlet temperature low.
A by-pass valve by-passes the oil cooler (Co) when the injection pressure is low, to ensure a sufficient initial
oil flow to the element when starting the compressor or when switching from unload to load.
For air-cooled units, the oil temperature is controlled by regulating the speed of the fans (FN), to avoid
overcooling and consequently condensation in the air receiver (AR).
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In the air receiver (AR) most of the oil is removed from the air centrifugally. Almost all of the remaining oil
is removed by the separator element.
2.3 Cooling and condensate system
Condensate drain system
Condensate drains of air-cooled GA
Dac Automatic condensate drain, compressor

Dmc Manual condensate drain
A condensate trap is installed downstream of the air cooler to prevent condensate from entering the air outlet
pipe. The trap is provided with a float valve for automatically draining condensate and with a manual drain
valve.
Cooling system
On air-cooled compressors, the air and oil coolers are cooled by fans.
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2.4 Regulating system
Flow diagrams
Flow diagram
Reference Designation
A To air cooler
B To/from oil cooler
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Regulating system
The compressor is controlled by Elektronikon® regulator (1)
The regulator keeps the net pressure within programmable pressure limits by automatically loading and
unloading the compressor depending on the air consumption. It also protects the compressor and monitors
components subject to service.
Unloading
If the air consumption is less than the air delivery of the compressor, the net pressure increases. When the net
pressure reaches the upper limit of the working pressure (unloading pressure), solenoid valve (5) is de-
energised by Elektronikon regulator (1). The plunger of solenoid valve (5) moves downwards by spring force:
Phase Description
1 The plunger of solenoid valve (5) shuts off the supply of receiver pressure towards
chamber (2).
2 Control pressure present in chamber (2) is vented to atmosphere. Plunger (3) of blow-off
valve (4) is moved by air receiver pressure allowing air receiver pressure to chamber (6).
3 Valve (7) is pushed upwards closing off the air inlet.
4 A small flow of air remains drawn in via channel (8), and is finally blown from receiver via
channel (10) to the air inlet.
5 Air delivery is stopped (0%), the compressor runs unloaded while chamber (6) contains a
steady overpressure (receiver unload pressure minus Blow Off valve (4) pressure drop).
Loading
When the net pressure decreases to the lower limit of the working pressure (loading pressure), solenoid valve
(5) is energised. The plunger of solenoid valve (5) moves upwards against spring force:
Phase
1 The plunger of solenoid valve (5) opens the supply of receiver pressure towards chamber
(2). Plunger (3) of blow-off valve (4) moves, closing off the air pressure supply towards
chamber (6).
2 Valve (7) moves downwards since the pressure in chamber (6) drops below atmospheric
pressure, opening the air inlet to the compressor element.
3 Air delivery is resumed (100%), the compressor runs loaded while the piston-rod-valve
assembly is only surrounded by atmospheric pressure.
2.5 Energy recovery system
General description
The maximum allowed pressure at the water side of the heat exchanger is 10 bar (145 psi).
The energy required in any compression process is mainly transformed into heat. The major part of the
compression heat is dissipated through the oil system. The Atlas Copco energy recovery systems are designed
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to recover most of the above-mentioned heat as warm or hot water without any adverse influence on the
compressor performance.
After the compression stage, the oil is separated from the compressed air. The compressed air flows to the
aftercooler and the oil flows to the oil cooler. The energy in the oil can be recovered by installing a heat
exchanger in front of the oil cooler.
The energy recovery systems can be applied as low temperature rise / high water flow systems (e.g. central
heating in closed water circuits) or as high temperature rise / low water flow systems (e.g. pre-heating of
boiler feed water in open water circuits).
Main components
The system mainly comprises:
• Oil/water heat exchanger (HE)
• Energy recovery valve (Y152)
• Oil by-pass valve (Y151)
• Temperature sensors for water inlet and outlet
• The necessary pipes, brackets, bolts, etc.
Installation
The package includes:
• a general by-pass system, to shut down the energy recovery system
• a by-pass system to prevent the oil outlet temperature from dropping below the minimum value.
When the Energy Recovery system is working, this by-pass system makes the oil flow through the Energy
Recovery heat exchanger instead of the normal oil cooler
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Energy recovery system
Pressure drop, water side
Text on figure
(1) Pressure drop (kPa)

(2) Pressure drop (bar)
(3) Water flow (l/s)
For GA 90-132:
• pd = 6.96 F2 + 2.71 F
For GA 160:
• pd = 4.23 F2 + 1.62 F
With:
• pd = pressure drop in kPa
• F = water flow in L/s
The pressure drops calculated with the formulas above are indicative.
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Flow diagram
The recovery water enters the unit at the heat exchanger inlet connection (Wi). In the heat exchanger the
compression heat is transferred from the compressor to the water. The water leaves the heat exchanger via
the outlet connection (Wo).
Installation
The compressor frame is prepared for the Energy Recovery system. Before mounting the installation, the two
laser prepared holes in the frame must be cut out.
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Air-cooled compressors
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Water-cooled compressors
Operation
The compressor oil flow is controlled by two by-pass valves (Y152 and Y151 ), ensuring reliable compressor
operation and optimum energy recovery.
Recoverable Energy
The graphs of section Principal data below represent the performance for each power variant of GA90-160+
at reference working pressure. The curves represent the limits of the energy recovery area and were obtained
with the temperature of the element outlet as indicated in the graph. All points below the curve with Tc=85
°C are possible working points where the recovered energy is maximized for lower element outlet
temperatures.
The formula to calculate the amount of recovered energy is:
Q (kW) = 4.2 x q (l/s) x dT (°C)
with
• q = water flow in l/s
• dT = temperature difference between water at inlet and outlet
For a VSD compressor, when running at a lower motor speed, the recoverable energy will be lower, because
the dT that can be reached is smaller. This can be calculated by using the graph for maximum speed (see
“performance curves”) and then recalculating the dT:
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dTv=dT x (RPMv/RPMmax)
dTv = the lower temperature rise that can be reached at lower motor speed
RPMv = the lower motor speed
RPMmax = the maximum motor speed that can be reached by the GA VSD
Settings
Fixed speed compressors
For Full-Feature compressors or if a separate dryer is installed the "Lowest dewpoint mode" (See section
Modifying fan motor settings) is recommended to reduce the load to the dryer.
For Pack compressors the "Economy mode" (See section Modifying fan motor settings) will result in higher
oil temperatures and consequently also higher water outlet temperatures. The vessel temperature setting has
to be set by an Atlas Copco service technician.
VSD compressors
The machine should be running in "Lowest dewpoint mode” (See section Modifying fan motor settings) to
avoid too high oil temperatures at low compressor speeds.
Regulation
The element outlet temperature must always be higher than the condensation temperature (see section
Starting). The software in the Elektronikon regulator of GA90-160+ compressors prevents the outlet
temperature of the compressor element from dropping below the condensation temperature. Electronic valve
(Y152) will be used to switch the Energy Recovery system on or off and to regulate the energy recovery.
Electronic valve (Y151) is used to regulate the oil flow through the heat exchangers and consequently the
compressor element outlet temperature. The regulation will aim for an element outlet temperature of 90 °C /
194 °F.
Start status
Compressor stopped, Energy Recovery 0%, all oil goes through normal oil cooler.
Unloaded operation
No Energy Recovery, oil flows through the regular oil cooler and is PI-regulated.
Loaded operation
• Compressor loads, cooling doesn’t change
• Cooling stabilizes through regular oil cooler with PI-regulation, no Energy Recovery yet
• Electronic valve (Y152) starts opening, the Energy Recovery is started. The flow through the oil cooler
is PI-regulated
• Depending on the needed cooling:
• Less cooling is needed: flow through Energy Recovery cooler is PI-regulated, flow through oil cooler
is minimum
• More cooling is needed: flow through Energy Recovery cooler is maximum, flow through oil cooler
is PI-regulated
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Calculation examples
Example point X
High temperature rise, low water flow application, e.g. pre-heating of boiler feed water in open circuit:
• Compressor unit: GA160-50Hz
• Working pressure: 14 bar / 200 psi
• Water flow: 0.6 l/s / 1.27 cfm
• Water inlet temperature: 36°C / 97 °F
• Water outlet temperature: 90 °C / 194 °F
The formula to calculate the amount of recovered energy results in (2):
• 4.2 x 0.6 x (90 - 36) = 136 kW ( ± as indicated on the curve)
The outlet temperature for a water flow of 0.6 l/s can be calculated backwards from formula (2):
• Toutlet = 36 + (136 / (4.2 x 0.6)) = 90 °C
Total pressure drop on waterside is (1):
• pd = (4.23 x 0.6²) + (1.62 x 0.6) = 2.5 kPa = 25 mbar
Example point Y
Low temperature rise, high water flow application, e.g. central heating in closed circuit:
• Water flow: 4 l/s / 0.87 cfm
• Water inlet temperature: 55.8°C / 132.4 °F
• Water outlet temperature: 64.2 °C / 147.6 °F
• 4.2 x 4 x (64.2-55.8) = 141 kW ( ± as indicated on the curve of 85°C)
The outlet temperatures for a water flow of 6 l/s can be calculated backwards from formula (2):
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Instruction book
• Toutlet = 55.8 + (141 / (4.2 x 4)) = 64.2°C

• pd = (4.23 x 4²) + (1.62 x 4) = 74 kPa = 0.74 bar
Example point Y for a GA VSD working at 1500 RPM, when max RPM is 3000:
dT = 90-36 = 54°C
RPMv = 1500
RPMmax = 3000
dTv = 54 x (1500/3000) = 27 °C
Q = 4.2 x 0.6 x 27 = 68 kW
Example point Z
• Water flow: 1 l/s / 2.12 cfm
• Water inlet temperature: 60°C / 140 °F
• Water outlet temperature: 87.8°C / 190 °F
• 4.2 x 1 x (87.8-60) = 117 kW
The outlet temperatures for a water flow of 1 l/s can be calculated backwards from formula (2):
• Toutlet = 60 + (117 / (4.2 x 1)) = 87.8°C
• pd = (4.23 x 1²) + (1.62 x 1) = 5.85 kPa = 58.5 mbar
This proves that it is possible to work at higher temperatures, but with less heating power.
The temperature of the vessel can be set to 100°C as well. The installation can work in a higher curve,
to obtain a higher water outlet temperature. This setting must be done by a service technician of Atlas
Copco.
Example point below the lowest curve
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• Compressor unit: GA 160 VSD

• Water inlet temperature: 30 °C / 86 °F
• Water outlet temperature: 60 °C / 140 °F
The lowest curve is the maximum energy that can be recovered. If it is necessary to work in the area below
the lowest curve, you have to calculate with the 140.5kW anyway.
dT=30 °C/ 54 °F (60 °C - 30 °C / 140 °F - 86 °F)
c = 4.2 J/kgK (for water)
Q= 140.5 kW (lowest curve)
Formula for recovered energy is : ==> Q = m x c x dT
==> m = Q / (c x dT)
==> m = 140.5 / (4.2 x 30)
==> m = 1.115 l/s
Additional safety precautions

• The parts must only be lifted using suitable equipment in accordance with the applicable safety regulations.
Loose or pivoting parts must be securely fastened before lifting.
• Wear a safety helmet when working in the area of overhead or lifting equipment.
• Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
• Protection caps, bags, etc. must be removed before connecting the pipes.
• Water hoses must be of correct size and suitable for the working pressure.
• The water connections must be free of strain.
• Pipe work or other parts with a temperature in excess of 80˚C (176˚F) must be guarded or insulated. Other
high-temperature pipe work must be clearly marked.
26 APF176951
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• The water system installed outside the machine has to be protected by a safety device with set pressure
according to the maximum cooling water inlet pressure.
• All maintenance work shall only be undertaken when the machine has cooled down.
• Never weld or perform any operation involving heat near the oil system.
Principal data
Performance curves
The given curves show only indicative values. Some deviations may be possible,
depending on the circumstances. The fine tuning of the installation must be done on site,
by a service technician of Atlas Copco.
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Spare parts list
Ref Qty Partnumber Name Extra info

1 1 1623 2823 00 Pipe
1 0147 1322 03 Bolt, M8 x 16 Pipe to frame
2 0147 1362 03 Bolt, M10 x 25 Pipe to block
2 0301 2344 00 Washer Pipe to block
1 0663 2107 77 O-ring Pipe to block
2 1 1623 2824 00 Pipe
1 0147 1322 03 Bolt, M8 x 16 Pipe to frame
2 0147 1362 03 Bolt, M10 x 25 Pipe to block
2 0301 2344 00 Washer Pipe to block
1 0663 2107 77 O-ring Pipe to block
1623 1346 00 or 1623
3 1 2779 00 Block
2 0211 1375 03 Screw, M10 x 90 Block to cooler
1 0663 2107 77 O-ring
1623 1404 00 or 1623
4 1 2755 00 Heat exchanger
2 0211 1375 03 Screw, M10 x 90 Block to cooler
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Instruction book

1623 1347 00 or 1623
5 1 2780 00 Block
1 0663 2107 77 O-ring
6 1 1623 1245 00 Support
5 1619 2766 00 Bolt, M8 x 20 Support to frame
7 2 1623 1774 00 Bracket
4 0147 1326 03 Bolt, M8 x 30 Brackets to support, over cooler
4 0301 2335 00 Washer Brackets to support, over cooler
2 0147 1362 03 Bolt, M10 x 25 Block to hose assembly
1 0663 2107 77 O-ring Block to hose assembly
8 1 1623 1248 00 Hose assembly
2 0147 1362 03 Bolt, M10 x 25 Hose assembly to valve
2 0301 2344 00 Washer Hose assembly to valve
1 0663 2109 68 O-ring Hose assembly to valve
1 0661 1000 25 Seal washer
1 0686 3716 01 Plug
9 1 1623 1213 00 Valve
3 0147 1322 03 Bolt, M8 x 16 Valve to frame
2 0147 1364 03 Bolt, M10 x 35 Valve to hose assembly
2 0301 2344 00 Washer Valve to hose assembly
2 0266 2111 00 Nut, M10 Valve to hose assembly
1 0663 2109 68 O-ring Valve to hose assembly
10 1 1623 1285 00 Hose assembly
1 0634 1000 28 Victaulic, DN 40 Hose assembly to pipe
11 1 0162 31288 00 Pipe
1 0634 1000 28 Victaulic, DN 40 Pipe to cooler
2 0634 1001 51 Coupling, DN32 Valve to pipe + pipe to cooler
12 1 1623 1317 00 Pipe
2 0147 1362 03 Bolt, M10 x 25 Hose assembly to block
2 0301 2344 00 Washer Hose assembly to block
1 0663 2107 77 O-ring Hose assembly to block
13 1 1623 1247 00 Hose assembly
2 0147 1364 03 Bolt, M10 x 35 Hose assembly to valve
2 0301 2344 00 Washer Hose assembly to valve
2 0266 2111 00 Nut, M10 Hose assembly to valve
1 0663 2109 68 O-ring Hose assembly to valve
14 1 0162 31213 00 Valve
3 0147 1322 03 Bolt, M8 x 16 Valve to frame
15 1 0162 32825 00 Pipe
2 0634 1001 51 Coupling, DN32 Valve to pipe & pipe to hose assembly
2 0147 1362 03 Bolt, M10 x 25 Valve to hose assembly
2 0301 2344 00 Washer Valve to hose assembly
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1 0663 2109 68 O-ring Valve to hose assembly
16 1 1623 1255 00 Hose assembly
1 0663 2109 68 O-ring Hose assembly to vessel
2 0147 1365 03 Bolt, M10 x 40 Hose assembly to vessel
2 0301 2344 00 Washer Hose assembly to vessel
1 2250 2528 00 Plug screw, 1 1/4" In hose assembly
1 0661 1000 31 Seal washer In hose assembly
1 0574 8235 11 Hose assembly Drain cooler
1 1614 9252 00 Plug End of hose assembly
1 1079 5840 15 Nipple Between cooler & hose assembly
1 0661 1000 27 Seal washer Between cooler & hose assembly
17 2 1089 0574 70 Temperarure sensor
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3 Elektronikon regulator
3.1 Elektronikon® regulator
Control panel
Introduction
In general, the Elektronikon regulator has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (made inactive)
Automatic control of compressor operation

The regulator maintains the net pressure between programmable limits by automatically loading and unloading
the compressor. A number of programmable settings, e.g. the unloading and loading pressures, the minimum
stop time and the maximum number of motor starts are taken into account.
The regulator stops the compressor whenever possible to reduce the power consumption and restarts it
automatically when the net pressure decreases. In case the expected unloading period is too short, the
compressor is kept running to prevent too short standstill periods.
A number of time-based automatic start/stop commands may be programmed. Take into

account that a start command will be executed (if programmed and activated), even after
manually stopping the compressor.
Protecting the compressor

Shut-down
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Several sensors are provided on the compressor. If one of these measurements exceeds the programmed shut-
down level, the compressor will be stopped. This will be indicated on display (1) and general alarm LED (2)
will blink.
Remedy the trouble and reset the message. See also the Status data menu.
Before remedying, consult the Safety precautions.
Shut-down warning
A shut-down warning level is a programmable level below the shut-down level.
If one of the measurements exceeds the programmed shut-down warning level, a message will appear on
display (1) and general alarm LED (2) will light up, to warn the operator that the shut-down warning level is
exceeded.
The message disappears as soon as the warning condition disappears.
Service warning
A number of service operations are grouped (called Level A, B, C, ...). Each level has a programmed time
interval. If a time interval is exceeded, a message will appear on display (1) to warn the operator to carry out
the service actions belonging to that level.
Automatic restart after voltage failure

The regulator has a built-in function to automatically restart the compressor if the voltage is restored after
voltage failure. For compressors leaving the factory, this function is made inactive. If desired, the function
can be activated. Consult the Atlas Copco Customer Centre.
If activated and provided the regulator was in the automatic operation mode, the
compressor will automatically restart if the supply voltage to the module is restored within
a programmed time period.
The power recovery time (the period within which the voltage must be restored to have an
automatic restart) can be set between 1 and 3600 seconds or to “Infinite”. If the power
recovery time is set to “Infinite”, the compressor will always restart after a voltage failure,
no matter how long it takes to restore the voltage. A restart delay can also be programmed,
allowing e.g. two compressors to be restarted one after the other.
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3.2 Control panel
Elektronikon regulator
Control panel
Parts and functions
Reference Designation Function

1 Start button Button to start the compressor. LED (8) lights up
indicating that the Elektronikon regulator is operative.
2 Display Shows messages about the compressor operating
condition, a service need or a fault.
3 Scroll keys Keys to scroll upwards or downwards through the
display.
4 Tabulator key Key to select the parameter indicated by the horizontal
arrow. Only the parameters followed by an arrow
pointing to the right can be modified.
5 Function keys Keys to control and program the compressor.
6 Voltage on LED Indicates that the voltage is switched on.
7 General alarm LED Is lit if a shut-down warning condition exists or
maintenance is required.
7 General alarm LED Flashes if a shut-down condition exists, if an important
sensor is out of order or after an emergency stop.
8 Automatic operation LED Indicates that the regulator is automatically controlling
the compressor.
9 Stop button Button to stop the compressor. LED (8) goes out.
S2 Emergency stop button Push button to stop the compressor immediately in the
event of an emergency. After remedying the trouble,
unlock the button by pulling it out.
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3.3 Function keys
Control panel
Function keys
The keys (1) are used:
• To manually load/unload the compressor (not for VSD compressors)
• To call up or to program settings
• To reset a motor overload, shut-down or service message, or an emergency stop
• To access all data collected by the regulator
The functions of the keys vary depending on the displayed menu. The actual function is indicated just above
the relevant key. The most common functions are listed below:
Designation Function
“Add” To add compressor start/stop commands (day/hour)
“Back” To return to a previously shown option or menu
“Cancel” To cancel a programmed setting when programming parameters
“Delete” To delete compressor start/stop commands
“Help” To find the Atlas Copco internet address
“Limits” To show limits for a programmable setting
“Load” To load the compressor manually
“Mainscreen” To return from a menu to the main screen
“Menu” Starting from the main screen, to have access to the submenus
“Menu” Starting from a submenu, to return to a previous menu
“Modify” To modify programmable settings
“Program” To program modified settings
“Reset” To reset a timer or message
“Return” To return to a previously shown option or menu
“Unload” To unload the compressor manually
“Extra” To find the module configuration of the regulator
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3.4 Scroll keys
Control panel
The keys (1) allow the operator to scroll through the display.
As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll key
with the same symbol can be used to see the next item.
As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key with
the same symbol can be used to see the previous item.
When the scroll key is kept pressed, the scrolling is continued.
3.5 Emergency stop button
Control panel
In case of emergency, press button (S2) to stop the compressor immediately.

At the occurrence of an emergency stop, the compressor element is stopped immediately and the solenoid
valve will be deactivated by Elektronikon ® regulator. No unload status is reached. The check valve prevents
oil flow back from reversed rotation of the compressor element.
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Before starting any maintenance or repairs, wait until the compressor has
stopped and open the isolating switch (customer's installation) to switch off the
voltage to the compressor.
Close the air outlet valve and open the manual condensate drain valves to
depressurize the air system.
Apply all relevant Safety precautions.
3.6 Control programs
Function
In order to facilitate programming and controlling, menu-driven control programs have been implemented in
the regulator.
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Menu flow for GA compressors
Table A
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"Oil Bypass Position" "Motor Starts" "Dp Oil Separator"

"Energy Recovery Valve" (only for "Module Hours" "Dp Air Filter"
units with optional energy recovery
system)
"Running Hours" "Load Relay"
"Loaded Hours" "Compressor Outlet"
Table B
"Oil Injection Element" "Energy Rec. Water Out" (only for "Remote Load/Unload"
units with optional energy recovery
system)
"Compressor Outlet" "Motor Winding 1U1" (optional) "Remote Pressure Sensing"
"Element Outlet" "Motor Winding 1V1" (optional) "Overload Motor"
"Cooling Medium" "Motor Winding 1W1" (optional) "Overload Fanmotor" (only for air-
cooled units)
"Ambient Air” "Motor Bearing D-end" (optional) "Starter Feedback Contact"
"Dryer PDP" (only for Full-Feature "Motor Bearing ND-end" (optional) "PB1 open / PB2 closed"
units)
"Refrigerant" (only for Full-Feature "Motor D-end" (optional) "Condensate Drain AC"
units)
"Oil Injection" "Motor ND-end" (optional) "Overload Dryer" (only for Full-
Feature units)
"Oil Separator" "Element 1 ND-end" (optional) "High Pressure Dryer" (only for
Full-Feature units)
"Condensing Pressure" (only for air "Gearbox" (optional) "Overload Dryer Fan" (only for air-
cooled units) cooled units)
"Dp DD Filter" (only for units with "Emergency Stop" Condensate Drain Dryer" (only for
optional DD filter) Full-Feature units)
"Energy Rec. Water In" (only for units "Remote Start/Stop" "Phase Sequence" (optional)
with optional energy recovery
system)
Table C
"Language In Use" "Vibration Unit" "Password"

"Time" "Level Unit“ "M.C.C.
"Date" "Flow Unit" "Digital PresBand Selec.“
"Date Format" "Volume Unit" "Prestart Dryer" (only for Full-
Feature units)
"Pressure Unit" "Start Mode" "SAVER Cycle"
"Temperature Unit" "Automatic Restart" "Energy Recovery Valve" (only for
units with optional energy
recovery system)
Program Function
Main screen Shows in brief the operational status of the compressor. Is the gateway to all
functions.
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Program Function
“Status Data” Calls up the status of the compressor protection functions (shut-down, shut-down
warning and service warning). Resets a shut-down, motor overload and service
condition.
“Measured Data” Calls up the data currently measured and the status of a number of inputs.
“Counters” Calls up:
• running hours
• regulator (module) hours
• number of motor starts
“Test” Display test.
“Modify Parameters” Modifying the settings for:
• Parameters (e.g. loading and unloading pressures)
• Protections (e.g. temperature shut-down level)
• Service plans (timers for service plans)
• Clock functions (automatic compressor start/stop/pressure band commands)
• Configuration (time, date, display language,...)
“Service” Calls up service plans and resets the timers after carrying out the service actions in
a service plan.
“Saved Data" Calls up the saved data: last shut-down, last emergency stop data.
“Unload”/”Load” Loads and unloads the compressor manually.
3.7 Calling up menus
Description
Control panel
When the voltage is switched on, the Main screen is shown automatically.
After pressing the “Menu” (F1) key, the option “Status Data” will be followed by a horizontal arrow:
• Either press the tabulator key (2) to select this menu,
• or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow and then press
the tabulator key (2) to select this menu.
46 APF176951
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The arrow down key (1) can be used for a quick look at the actual compressor status.
3.8 Main screen menu
Function
Control panel
The Main screen menu shows the status of the compressor operation and is the gateway to all functions
implemented in the regulator.
Procedure
The Main screen is shown automatically when the voltage is switched on.
If the function or arrow keys (1, 2 and 3) are not used for some minutes, the regulator will automatically return
to the Main screen.
Whenever displayed on a submenu screen, press the “Mainscreen” (F1) key to return to the Main screen.
The display indicates:
• The name of the sensor and its actual reading
• Messages regarding the compressor operating condition
• Just above the function keys (3), the actual functions of these keys
3.9 Status data menu
Warning
Before starting any maintenance or repairs, press the stop button (4), wait until the
compressor has stopped, press the red emergency stop button and open the isolating
switch (customer's installation) to switch off the voltage to the compressor.
Close the air outlet valve and depressurize the air system.
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Function
Control panel
The Status data submenu gives information regarding the status of the compressor protection functions (shut-
down, shut-down warning and service warning) and allows resetting of a shut-down, motor overload and
service condition.
Procedure
Starting from the Main screen (see Main screen menu):
• Press the key “Menu” (F1): the option “Status Data” will be followed by a horizontal arrow.
• Press the tabulator key (2).
No message exists
• General alarm LED (1) is out and the message on the display will indicate that all conditions are normal:
“All Conditions Are OK”

.
.
“Menu” “Help”
F1 F2 F3
A shut-down message exists

• In case the compressor is shut down, LED (1) will blink.
• In case of a shut-down due to too high a temperature at the outlet of the compressor element:
“Element Outlet” 114˚C

.
“Shutdown” “Maximum” 110˚C
“Menu”*** “Help” ***”Reset”
F1 F2 F3
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• The indicators (***) are blinking. The screen shows the actual reading and the shut-down setting.
• It remains possible to scroll through other menus, e.g. to check the values of other parameters.
When returning to the “Status Data” menu, the option “Shutdowns” will blink. This option can be selected
by pressing the tabulator key (2) to return to the above shut-down screen.
Shut-down reset
• Switch off the voltage and remedy the trouble. After remedying and when the shut-down condition has
disappeared, switch on the voltage and press the key “Reset” (F3).
• Press the keys “Menu” and “Mainscreen” to return to the Main screen and restart the compressor by means
of start button (3).
A shut-down warning message exists

A shut-down warning level is a programmable level below the shut-down level.
• If a shut-down warning exists, LED (1) is alight. The Main screen will change into a screen similar to the
one below:
“Compressor Outlet” 7.0 bar

.
*** “Shutdown Warning” ***
“Menu”*** ***”Unload”
F1 F2 F3
• The message “Shutdown Warning” appears.

• Press the key “Menu” (F1) and the tabulator key (2) to select the “Status data” menu; the option
“Protection” is blinking.
• Scroll to this option and select it by pressing the tabulator key (2). A screen similar to the one below
appears:
“Element 1 Outlet” 103˚C

.
“Shutd. Warn.” “Maximum” 100˚C
“Menu”*** ***
F1 F2 F3
• The screen indicates that the temperature at the outlet of compressor element 1 exceeds the programmed
shut-down warning level.
• If necessary, stop the compressor by means of stop button (4) and wait until it has stopped.
• Switch off the voltage, inspect and remedy.
• The warning message will disappear automatically as soon as the warning condition disappears.
A service warning exists

• LED (1) is alight. The Main screen will change into a screen similar to the one below:
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Instruction book
“Compressor Outlet” 7.0 bar

.
“*Service Required*”
“Menu”*** ***”Unload”
F1 F2 F3
• The indicators (***) are blinking and the service warning message appears.
• Press the key Menu (F1) and the tabulator key (2) to select the “Status data” menu: the option “Service”
is blinking.
• Scroll to this option and select it by pressing the tabulator key (2); two options may blink:
• “Inputs”: if the programmed service level of a component is exceeded (e.g. the maximum pressure
drop of the air filter).
• “Plan”: if a service plan interval is exceeded.
• Stop the compressor and switch off the voltage.
• In case the service message was referring to “Inputs” (air filter): replace the filter, switch on the voltage,
scroll in the “Status Data” menu to “Inputs” and press the “Reset” key to reset the service message.
• In case the service message was referring to “Plan”: carry out the service actions related to the indicated
plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See Service menu.
3.10 Measured data menu
Control panel
Function
To call up information regarding the actually measured data and the status of some inputs such as the motor
overload protection. Consult the menu flow in section Control programs.
Procedure
• Press the key “Menu” (F1).
• Press the arrow down key (1) until “Measured Data” is followed by a horizontal arrow.
• Activate the menu by pressing the tabulator key (2).
• By pressing the scroll keys (1), a number of actually measured data can be found.
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• If one of the sensors is linked to a shut-down, service or warning function, both the actually measured
value as well as the corresponding shut-down, warning or service level can be called up by pressing key
(2).
3.11 Counters menu
Control panel
Function
To call up:
• The running hours
• The loaded hours
• The number of motor starts
• The number of hours the regulator (module) has been under tension
• The number of load cycles
Procedure
• Press the arrow down key (1) until “Counters” is followed by a horizontal arrow.
• Press the tabulator key (2) to activate the menu.
• By pressing the arrow key (1), the above-mentioned data can be found.
Example of a Counters screen
.
“Running Hours” 2455 “hrs”
“Loaded Hours” 1973 “hrs”
“Motor Starts” 945
“Menu”
F1 F2 F3
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3.12 Test menu
Control panel
Function
To carry out a display test, i.e. to check whether the display and LEDs are still intact.
Procedure
• Starting from the Main screen (see Main screen menu), press the “Menu” (F1) key.
• Press arrow down key (1) until “Test” is followed by a horizontal arrow.
• Activate the menu by pressing the key (2).
To perform a display test:
• If necessary, scroll through the menu until “Display Test” is followed by a horizontal arrow.
• Press the key (2).
• During testing, the regulator will generate a series of patterns on the display which enable the operator to
check that each pixel still functions normally; the LEDs are lit at the same time.
• Press the “Menu” key (F1) to return to the submenu.
3.13 Modify parameters menu
Function
To modify a number of programmable settings:
• Fan motor settings (see section Modifying fan motor settings).
• Parameters (see section Modifying parameters).
• Protections (see section Modifying protections).
• Service plan settings (see section Modifying service plan settings).
• Clock function settings (see section Modifying clock function settings).
• Configuration settings (see section Modifying configuration settings).
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3.14 Fan motor settings
Control panel
Function
To modify the fan motor operation mode. Consult the menu flow in section Control programs.
Procedure
Starting from the Main screen (see section Main screen menu):
• Press the arrow down key (1) until “Modify Parameters” is followed by a horizontal arrow.
• The first item “Fan Motor” will be followed by a horizontal arrow.
• Press the arrow down key (1) until the option “Fan Operation Mode” is followed by the end marker; the
following screen appears:
“Minimum Speed” 0 “rpm”

“Maximum RPM Reduction” 100 “pct”
“Fan Operation Mode” “Normal”
“Menu” “Modify”
F1 F2 F3
• The screen shows that the current fan operation mode is “Normal”. To modify this setting, press the
“Modify” key (F2); the operation mode will flash.
• Use the scroll keys to change the operation mode.
• Press the “Program” key (F1) to program the new mode or the “Cancel” key (F3) to cancel the modification
operation.
It is possible to program two operation modes:
• “Normal”: In this mode, the fan algorithm will optimize the fan speed to get a lower power consumption
for the compressor. This operation mode is recommended to be used with Pack compressors.
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• “Lowest Dewpoint”: In this mode, the fan algorithm will try to cool down the air to the lowest temperature
possible in order to get the lowest LAT (Lowest Air Temperature) possible in any ambient condition. This
operation mode is recommended to be used with a Full-Feature compressor or with a compressor with a
stand-alone dryer combination.
3.15 Modifying parameters
Control panel
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
• The first item “Parameters” will be followed by a horizontal arrow.
• Press the tabulator key (2): the first items and their settings will appear.
• Press the arrow down key (1) until the parameter to be modified is followed by a horizontal arrow.
Modifying the loading pressure setpoint

If desired, the operator can program two pressure bands (Loading pressure/Unloading pressure and
Loading pressure 2/Unloading pressure 2).
• Consult the section Procedure to select “Loading Pressure”.
• The screen shows the current setting. To modify this setting, press the key “Modify” (F2); the setting will
blink.
• The key “Limits” (F2) can be used to find out the limitations for the parameter.
• Use the scroll keys (1) to change the setting.
• Press the key ”Program” (F1) to program the new value or the key “Cancel” (F3) to cancel the modification
operation.
• The procedure to modify other parameters pressure is similar.
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The regulator will not accept new values beyond the limitations. Press the key “Limits” to check
the limitations for the parameter. Consult Programmable settings for the most important
settings.
3.16 Modifying protection settings
Control panel
Function
To modify protection settings:
• “Shutdown”, e.g. for the compressor element outlet temperature
• “Shutdown warning”, e.g. for the compressor element outlet temperature
• “Service warning”, e.g. for the maximum pressure drop over the air filter
To check various compressor conditions, e.g. the status of the emergency stop button. Some parameters cannot
be modified.
Procedure
• Press the “Menu” (F1) key.
• Press the arrow down key (1) until “Modify parameters” is followed by a horizontal arrow.
• Press the arrow down key (1) until “Protections” is followed by a horizontal arrow.
• Press the tabulator key (2): the first items will appear.
• Press the arrow down key (1) until the item to be modified is followed by a horizontal arrow and press
the tabulator key (2).
Modifying settings for the compressor element temperature

• Consult the section Procedure above to select the parameter “Element outlet”.
• The screen (see example below) shows the current temperature on the first line and the shut-down setting
on the third line. To modify the setting, press the “Modify” (F2) key; the setting will flash.
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• The “Limits” (F2) key can be used to find out the limits for the parameter.
• Use the scroll keys (1) to change the setting.
• Press ”Program” (F1) to program the new value or “Cancel” (F3) to cancel the modification operation.
• The screen (see example below) shows a horizontal arrow indicating that the shut-down warning value
can be modified (the procedure is similar to the description above).
• The procedure to modify other items is similar. For some settings, a delay can be programmed.
Example of the screen for GA compressors
“Element Outlet” 94˚C
“Shutdown” “Maximum” 110˚C

“Menu” “Modify”
F1 F2 F3
The regulator will not accept new values beyond the limits. Press the key “Limits” to check
the limits for the parameter. Consult Programmable settings for the most important settings.
3.17 Modifying service plans
Function
To modify the hour intervals for the service levels.
Service plans
The service actions to be carried out are grouped in plans called Service level A, B, C or D. When reaching
an interval, a message will appear on the screen indicating which Service plans are to be carried out.
Always consult your Atlas Copco Customer Centre in case any timer should be changed. The
intervals must not exceed the programmed nominal values.
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3.18 Programming clock function
Control panel
Function
To program:
• Time-based start/stop commands for the compressor
• Time-based change-over commands for the net pressure band
Programming start, stop and pressure band commands

In this example, the compressor will be programmed as follows:
• On Monday at 06:15 starting in pressure band 1
• On Friday at 18:00 changing over to pressure band 2
• On Saturday at 18:00 stopping
• Activate the menu by pressing tabulator key (2).
• Use the arrow down key (1) to scroll until the option “Clock Function” is followed by a horizontal arrow.
• Activate the menu by pressing tabulator key (2); following screen appears:
“Clock Function”
“Not Activated”
.
“Menu” “Modify” “Delete”
F1 F2 F3
• Press the tabulator key (2), following screen appears:
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“Monday”
“Tuesday”
“Wednesday”
“Menu” “Delete”
F1 F2 F3
• Use the scroll keys (1) until the day on which a command must be programmed is followed by a horizontal
arrow. Press the tabulator key (2); following screen appears:
--:-- ----------------------
--:-- ----------------------
--:-- ----------------------
F1 F2 F3
• Press the key “Modify” (F2). The first two dashes will flash. Use the scroll keys (1) to enter “06”. Press
the tabulator key (2) to jump to the following two dashes. Use the scroll keys to enter “15”. Press the
tabulator key to jump to the row of dashes. Use the scroll keys to enter the command “Start Compressor”.
• Press the key “Program” to program the command : “06:15 Start Compressor”.
• Press the arrow down key (1): the horizontal arrow indicates that the second line is accessible. Press the
key “Modify” and modify this line in a similar way to the following command: ”06:15 Pressure Band 1”.
• Press the key “Menu” (F1) and scroll to “Friday”:
“Thursday”
“Friday”
“Saturday”
F1 F2 F3
• Programming the command to change over at 18 o’clock to “Pressure Band2” is carried out in a similar
way as described above.
• Press the key “Menu” (F1) and scroll to “Saturday”. Programming the command “18:00 Compressor Stop”
is carried out in a similar way as described above.
Activating/deactivating the timer

• The timer can only be activated if at least one start/stop command is programmed.
• Starting from the Main screen, press the key “Menu” (F1).
• Use arrow down key (1) until the option “Modify Parameters” is followed by a horizontal arrow.
• Use the arrow down key until the option “Clock Function” is followed by a horizontal arrow, press the
tabulator key (2), following screen appears:
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“Not Activated”
.
F1 F2 F3
• Press the key “Modify”, “Not Activated” starts blinking.

• Press the arrow down key (1) “Not Activated” changes to “Activated”.
• Press the key “Program”.
It is necessary to program the start/stop commands in successive order timewise. Program

the commands from Monday till Sunday, e.g.:
• 07.30 Start Compressor
• 07.30 Pressure Band 1
• 08.30 Pressure Band 2
• 18.00 Stop Compressor
Make sure that the timer function is activated (“Activated”). If not, the programmed start/stop
commands will not be executed.
The timer can be deactivated again. In this case, the programmed start/stop commands will
not be executed (but remain in the memory of the regulator).
Modifying a command
Suppose the command to stop the compressor on Saturday 18:00 is to be modified, i.e. stopping at 17 o'clock
instead of 18 o'clock.
• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key (1) until the option
“Modify Parameters” is followed by a horizontal arrow.
Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
“Monday”
“Tuesday”
“Wednesday”
F1 F2 F3
• Scroll through the display until “Saturday” is followed by a horizontal arrow. Press the tabulator key (2).
If necessary, scroll through the commands until the command to be modified is followed by a horizontal
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arrow. Press the key “Modify”, the first two digits of the command start blinking. Modify as required
using the scroll keys, i.e. in the example above change “18” into “17” using the arrow up key (1).
• If necessary, press the tabulator key (2) to go to the next field to be modified, the minutes indication and
the start/stop/pressure band indication.
• Press the key “Program” to program the new command or the key “Cancel” to quit without reprogramming.
Adding a command at the end of an existing list

• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the option
Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
Suppose the command to stop the compressor at 18:00 must be added to the list of Monday
“Monday”
“Tuesday”
“Wednesday”
F1 F2 F3
• Scroll through the display until “Monday” is followed by a horizontal arrow. Press the tabulator key (2).
Scroll through the compressor start/stop/pressure band commands until the first empty command line is
indicated by the horizontal arrow.
• Press the key “Modify”; the first two digits start blinking. Enter “18:00 Compressor Stop” using the scroll
keys (1) to modify a field and the tabulator key (2) to jump from one field to another.
• Press the key “Program” to program the new command or the key “Cancel” to quit without reprogramming.
Adding a command between two existing commands

Suppose the command “17:00 Pressure Band 2” must be added to the following list:
• 06:00 Start Compressor
• 06:00 Pressure Band 1
• 18:00 Stop Compressor
The regulator does not allow to enter a new command which is situated before the last command in the list
timewise.
Scroll through the display until the command before which the new command must be entered is followed
by a horizontal arrow (in the example above: “18:00 Stop Compressor”) and press the key “Modify”.
Change this command to the new command (in the example above “17:00 Pressure Band 2”)
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Press the arrow down key and add the last command of the list (in the example above “18:00 Stop Compressor”
and press the key “Program”.
Deleting a command
• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the option
• Use the scroll keys (1) to scroll until the option “Clock Function” is followed by a horizontal arrow. Press
the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
Deleting all commands

• Press the key “Delete” in the screen above. A question to confirm the deleting operation will appear.
Deleting all commands of a specific day
• Scroll through the display until the desired day is followed by a horizontal arrow. Press the key “Delete”,
a question to confirm the deleting operation will appear.
Deleting a specific command
• Scroll through the display until the command to be deleted is followed by a horizontal arrow. Press the
key “Delete”, a question to confirm the deleting operation will appear.
3.19 Modifying configuration settings
Control panel
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Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
• Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to the right.
• Press the arrow down key (1) to scroll until “Configuration” is followed by a horizontal arrow.
• Activate the menu by pressing tabulator key (2): the first item will appear. Scroll through the display until
the option to be modified is followed by a horizontal arrow. Select the option by pressing the tabulator
key (2).
• In case of the option “Time”, the second line on the screen indicates the actual setting, e.g. “14:30”. To
modify this setting, press the key “Modify” (F2); the first field “14” will blink.
• Use the scroll keys (1) to change the setting, then press the tabulator key (2) to go to the next field “30”.
The setting of this field can now be modified using the scroll keys (1).
• Press the key ”Program” (F1) to program the new value or the key “Cancel” (F3) to cancel the modification
operation (the original value will be retained).
• The procedure to modify other parameters is similar.
Programming compressor control modes

The compressor can be controlled locally, remotely or via a local area network (LAN).
Procedure
• Activate the menu “Configuration” as described above.
• Scroll through the display until the option “C.C.M.” is indicated and press the “Modify” key. Following
screen appears:
.
“C.C.M.” “Local Control”
.
“Program” “Cancel”
F1 F2 F3
• “Local Control” is blinking, use the scroll keys (1) to select the desired control mode.
• Press the key “Program” to program the new control mode or “Cancel” to quit without reprogramming.
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3.20 Service menu
Control panel
Function
• To reset the service plans which are carried out.
• To check when the next service plans are to be carried out.
• To find out which service plans were carried out previously.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level stands for a number
of service actions to be carried out at the time intervals programmed in the Elektronikon regulator.
When a service plan interval is reached, a message will appear on the screen, see section Status data. After
carrying out the service actions related to the indicated levels, the timers are to be reset.
Example
Service plans Intervals

Service plan A Every 4000 running hours
Service plan B Every 8000 running hours
Service plan C Every 16000 running hours
Service actions according to Intervals

Service plan A 4000 running hours
Service plan A and B 8000 running hours
Service plan A 12000 running hours
Service plan A, B and C 16000 running hours
... ...
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Procedure
• Press the arrow down key (1) until “Service” is followed by a horizontal arrow.
• A screen similar to the one below appears:
“Service Timer”
“Running Hours”
7971 “hrs”
“Menu” “Reset”
F1 F2 F3
• The screen shows that the total compressor running time is 7971 hours.
“Next Timer”
“Level” AB
8000 “hrs”
“Back” “Reset”
F1 F2 F3
• The screen shows that the next service plans to be carried out are plans A and B and that these plans are
to be carried out every 8000 running hours.
• Press the arrow down key (1) to find out which service plans were carried out previously, following screen
appears:
“Previous Timer”
“Level” A
4008 “hrs”
“Back”
F1 F2 F3
• The screen shows that plan A was carried out at 4008 running hours.
• Stop the compressor, switch off the voltage and carry out the service operations related to the indicated
service plans, see section Preventive maintenance schedule.
• Switch on the voltage and scroll to the “Next Timer” service screen.
• Press the “Reset” button (F3). Confirm the question for resetting.
The “Reset” button only appears when the “Next Timer” level is almost reached.
After pressing the arrow down key in the “Service Timer” screen, the “Life Time” hours are
shown, i.e. the number of hours elapsed since initial programming ex-factory. This timer is
not taken into account.
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3.21 Saved data menu
Control panel
Function
To call up some data saved by the regulator. These data are:
• Last shut-down data
• Last emergency stop data
Procedure
• Press the arrow down key (1) until “Saved Data” is followed by a horizontal arrow.
• The first option is shown “Last shutdown 1”.
• Press the tabulator key (2) to find out the date, time and other data reflecting the status of the compressor
at the last shut-down.
• If desired, scroll through the other items.
3.22 Programmable settings
Regulation settings
Parameters
Minimum Factory Maximum

setting setting setting
Motor running time in star sec 10 10 20
Load delay time (star-delta) sec 0 0 20
Number of motor starts (star-delta) starts/day 0 120 120
Minimum stop time sec 20 20 99
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Programmed stop time sec 30 30 30
Permissive start timer sec 0 30 255
Power recovery time (ARAVF) sec 15 15 3600
Start delay time (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60
Unloading pressure, 8.6 bar compressor bar(e) 3.5 8.6 9.105
Loading pressure, 8.6 bar compressor bar(e) 3.5 8.0 9.105
Protection settings

Compressor outlet pressure (shut-down bar 0 16.5 17.0
warning level)
Compressor outlet pressure (shut-down bar 0 17.0 17.0
level)
Oil injection pressure, element (start bar 2.0 2.5 13.2
protection)
dp oil separator (shut-down warning level) mbar -- 850 1000
dp oil separator (shut-down level) mbar -- 1000 1000
Delay at signal, dp oil separator sec 5 60 255
Compressor outlet temperature (without DD ˚C 0 66 120
filter) (shut-down warning level)
Compressor outlet temperature (without DD ˚C 0 80 120
filter) (shut-down level)
Compressor outlet temperature (delay at sec 5 5 5
signal)
Compressor element outlet temperature ˚C 80 114 114
(shut-down warning level)
Delay at shut-down signal sec 5 5 5
Oil separator temperature (shut-down) ˚C 0 120 120
Delay at start, motor overload sec 0 1 1
Delay at signal, motor overload sec 0 1 1
Delay at start, fan motor overload sec 0 1 3
Delay at signal, fan motor overload sec 0 1 3
Delay at start, starter feedback contact = sec 0 13 60
open
Delay at signal, starter feedback contact = sec 0 2 3
closed
Dp Air filter (shut-down) mbar - 85 - 85 0
High ambient protection, warning °C 0 50 55
High ambient protection, shut-down °C 0 50 55
Delay at signal sec 0 255 255
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Temperature winding 1U1, warning level °C 0 145 155
Temperature winding 1U1, shut-down level ° C 0 155 155
Temperature winding 1V1, warning level °C 0 145 155
Temperature winding 1V1, shut-down level ° C 0 155 155
Temperature winding 1W1, warning level °C 0 145 155
Temperature winding 1W1, shut-down level ° C 0 155 155
Temperature bearing D-end, warning level °C 0 105 115
Temperature bearing D-end, shut-down °C 0 115 115
level
Temperature bearing ND-end, warning level ° C 0 105 115
Temperature bearing ND-end, shut-down °C 0 115 115
level
Service settings
Service plans

Service plan A (operating hours) hr 4000
Service plan B (operating hours) hr 8000
Service plan C (operating hours) hr 16000
Service plan D (running hours) hr 24000
Service plan I (operating hours) hr 2000
Analog inputs

Service warning level for oil separators bar 0 0.8 0.8
Delay at signal, oil separator sec 0 60 255
Service warning level for air filters bar -0.1 -0.05 -0.05
Delay at signal, air filter sec 0 60 255
Delay at signal, DD filter sec 0 60 255
Terminology
Term Explanation
ARAVF Automatic restart after voltage failure. See Elektronikon regulator.
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Term Explanation
Required stop Once the compressor has automatically stopped, it will remain stopped for the minimum
period/Minimum stop time (approx. 20 seconds), whatever the net air pressure. In automatic operation, the
stop time compressor will not be stopped by the regulator until a standstill period of at least the sum
of the minimum stop time and required stop period is expected. However, if the decrease
in air net pressure should require a new start of the compressor, the regulator will start the
compressor after the minimum stop time.
Power recovery Is the period within which the voltage must be restored to have an automatic restart. Is
time accessible if the automatic restart is activated. See Elektronikon regulator. To activate the
automatic restart function, consult Atlas Copco.
Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is
Loading pressure programmed at 7.0 bar(e)/101 psig, the maximum limit for the loading pressure changes
to 6.9 bar(e)/100 psig. The recommended minimum pressure difference between loading
and unloading is 0.6 bar/9 psig.
Delay at shut- Is the time for which the signal must exist before the compressor is shut down. If it is
down signal required to program this setting to another value, consult Atlas Copco.
Permissive start The compressor will not start if this level is exceeded at the moment of starting. If the level
level remains too high for 30 seconds, the message “Start failure” will appear on the display.
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4 Installation
4.1 Dimension drawing
Compressor dimensions
Dimension drawing of air-cooled Pack compressors
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Text on drawing
(1) Compressed air outlet
(2) Cooling air outlet
(3) Compressor air inlet
(4) Cooling air inlet
(5) Right hand side view
(6) Left hand side view
(7) Electric cable entry
(8) Automatic drain, dryer
(9) Rear side view
(10) Manual drain
(11) Automatic drain
(12) Detail X
(15) Front view
(16) Top view
(17) Slotted holes for horizontally pulling unit out of container
(18) Manual drain, aftercooler
(19) Automatic drain, aftercooler
(20) z: height of compressor
(21) Type
(25) Compressed air outlet, Pack compressor
(34) Motor and canopy ventilation
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4.2 Installation proposal
Compressor room example
Compressor room example of air-cooled GA Pack compressor
Text on drawing
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(1) Minimum free area to be reserved for compressor installation
(2) Ventilation proposals
(3) Cooling systems
(4) Compressor air outlet, if dryer is by-passed
(5) Compressor air outlet, Full-Feature compressors
(6) Motor ventilation, air outlet
(7) Motor ventilation, air inlet
(9) Cooling air outlet
(10) Dryer cooling air outlet
(11) Dryer and motor cooling air inlet
(13) Only C can be ducted
(14) Only C and G can be ducted
(15) Cubicle ventilation inlet
(16) Cubicle ventilation outlet
(17) C & F (if ducted) should be ducted separately
(18) Cooling air inlet
(19) Only C, F and G can be ducted
(20) Motor ventilation, air inlet and dryer cooling air inlet
(21) Only C, E and D can be ducted
(22) C & E (if ducted) should be ducted separately
(23) Only F, E and B can be ducted
(24) F & E (if ducted) should be ducted separately
Description
Holes in the cubicle which are not used should be plugged.

All electric screens in the control cubicle and drive cubicle have to be installed before start-
up and remain installed during operation.
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Phase Description
1 Install the compressor on a level floor suitable for taking its weight. For ventilation
alternative 1 (indicated as Alt. 1), the minimum distance between the top of the bodywork
and the ceiling is 1200 mm (47.2 in).
2 Remove the plastic plug (if provided) from the compressor air outlet pipe and fit the air
outlet valve (to be provided by the customer) to the pipe. Close the valve and connect it
to the net.
3 The pressure drop over the air outlet pipe can be calculated as follows:
For SI Units:
dp = (L x 450 x Qc1.85) / (d5 x p)
d = Inner diameter of the outlet pipe in mm
dp = Pressure drop (recommended maximum = 0.1 bar)
L = Length of outlet pipe in m
p = Absolute pressure at the compressor outlet in bar(a)
Qc = Free air delivery of the compressor in l/s
It is recommended that the connection of the compressor air outlet pipe is made on top of
the main air net pipe in order to minimize carry-over of possible condensate residue.
As a rule of thumb, the following formula can be used to calculate the recommended
volume of the air net:
V = (30 x C x p x Q) / Dp
C = Correction factor
Dp = Pressure difference between unloading and loading pressures in bar (recommended
minimum = 0.6)
p = Compressor inlet pressure in bar absolute
Q = Free air delivery of compressor in l/s
V = Recommended air net volume in l
Correction factors
Air consumption divided by compressor free air delivery Correction factor C

0.9 0.10
0.8 0.15
0.7 0.20
0.5 0.25
0.3 0.20
0.2 0.15
0.1 0.10
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Phase Description
4 The inlet grids and ventilation fan should be installed in such a way that any recirculation
of cooling air to the compressor is avoided. The maximum air velocity through the grids is
5 m/s (16.5 ft/s).
The required ventilation to limit the compressor room temperature can be calculated as
follows:
For SI Units:
On air-cooled compressors: Qv = 0.92 N/dT
Qv = Required ventilation capacity in m3/s
N = Shaft input of compressor in kW (for Pack compressors)
dT = Temperature increase in compressor room
If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is
30 Pa (0.12 in wc). The maximum pressure drop depends on the ambient temperature.
The fan capacity should match the compressor fan capacity at a pressure head equal to
the pressure drop caused by the cooling air outlet ducts. Consult Atlas Copco.
5 Remove the plastic plugs (if provided) from the condensate outlets and fit the manual
condensate drain valve. Lay out the drain piping towards the condensate collector. The
drain pipes must not dip into the water of the drain collector. It is recommended to provide
a funnel to allow visual inspection of the condensate flow.
6 Location of the Elektronikon regulator.
7 See Electric cable size for the recommended size of the supply cables.
Check that the electrical connections correspond to the local codes. The installation must
be earthed and protected against short circuits by fuses in all phases. An isolating switch
must be installed near the compressor.
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4.3 Electric cable size
Electrical connections
Electrical connections
Cable connection
Connect the electrical cables as shown below.
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Water-cooled compressors
Connect the electrical cables as shown below.
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Cable glands
Always use the correct cable glands:
Cable section Cable diameter Cable gland size Ordering number

50 8.0 16 0698 5140 71
70 9.4 16 0698 5140 71
95 11.0 20 0698 5140 72
120 12.4 25 0698 5140 73
150 13.8 25 0698 5140 73
Cable size
All cables should be mounted on a horizontal ventilated tray.

See table if cables need to be spaced!
Connect cables in the cubicle with the correct cable lugs. Spacing of 10 mm between naked
cable parts should be obtained.
Supply Cables :
• CSA/UL type: 110 ˚C insulation cable
CSA/UL 60 Hz Pack air-cooled compressors
Compressor type Voltage Cable size, air-cooled Remark

compressors
GA 160 / GA 160+ 460V 4X (3X AWG2/0 + AWG8) Grouping cables bunched
4.4 Quality of safety components

When installing a remote emergency button or a motor contactor, the following B10d values are advised:
• Emergency stop button: 500 000
• Main contactor: 1 333 333
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4.5 Installation instructions for dryer by-pass
Description
It is not required to connect a bypass, a blind flange is foreseen ex factory. If by-passing of the dryer is required,
connect the compressor to the air net as shown below. The compressed air outlet temperature sensor (G3/8”)
and the pressure transducer (1/4” -18 NPT) must be relocated to the delivery pipe upstream of the shut-off
valve. The new location is indicated by “x”. The temperature sensor and pressure transducer must be positioned
perpendicular to the air flow at all time (as shown).
V1 Shut-off valve, air net
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V2 By-pass valve, compressor

V3 By-pass valve, dryer
X New location for temperature sensor and pressure transducer
1 Pipe towards air net
2 Nipple
4.6 Pictographs
Control panel Elektronikon MkIV controller
Pictographs on control panel
Reference Description
1 Start
2 Keys to scroll through display
3 Key to go to next field on display
4 Voltage on
5 Alarm
6 Automatic operation
7 Stop
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Control panel of Elektronikon GraphicPlus controller
Pictographs on control panel
Reference Name
1 Alarm
2 Service
4 Voltage on
5 Enter
6 Escape
7 Scroll keys
8 Stop
9 Start
Other locations
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13 Automatic condensate drain
14 Automatic condensate drain for optional oil/water separator (type OSD)
15 Manual condensate drain
16 Stop the compressor before maintenance or repair
17 Warning: under tension
18 Read Instruction book before starting the compressor
19 Switch off the voltage and depressurize the compressor before maintenance or repair
20 Before connecting the compressor electrically, consult the Instruction book for the motor
rotation direction
21 Torques for steel (Fe) or brass (CuZn) bolts
22 Consult the Instruction book before greasing
23 Switch off the voltage before removing the protecting cover inside the electric cabinet
24 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)
25 Consult the Instruction book before maintenance or repair
26 Cooling water inlet
27 Cooling water outlet
28 Oil outlet
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5 Operating instructions
5.1 Initial start-up
Warning
The operator must apply all relevant Safety precautions.
Switch off the voltage before making any adjustment.
Outdoor/altitude operation
If the compressor is installed outdoors or if the air inlet temperature can be below freezing point, precautions
must be taken. In this case, and also if operating at high altitude, consult Atlas Copco.
Moving/lifting
The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude
from the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Make
sure that the beams cannot slide and that they protrude from the frame equally. The chains must be held parallel
to the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment must be
placed in such a way that the compressor is lifted perpendicularly. Lift gently and avoid twisting.
General preparations for GA compressors
Plug to fill the compressor element at initial start-up
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Step Action
1 Install the compressor, see the sections Dimension drawing, Installation proposal and
Electric cable size.
2 Stick labels near the control panel to warn the operator that:
• the compressor may start automatically after a voltage failure
• the compressor is automatically started and stopped
• the compressor may be remotely controlled
3 A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to
protect the compressor against corrosion. Remove the plates.
4 If the compressor has not run for the past 6 months, it is required to improve the lubrication
of the compressor element before starting. Fill up the compressor element as described
in section Oil change (paragraph: Filling the compressor element with oil).
5 Check that the compressor is filled with oil; the pointer of the oil level indicator should be
in the green range (see the section Oil change).
Protection during transport
Transport fixtures of GA compressors
Step Action
1 The gear casing supports, motor support and air receiver supports are secured to the
frame, immobilizing the vibration dampers during transport.
2 Remove the bolts (1) from the gear casing supports and the motor support.
3 Remove the brackets fitted next to the air receiver supports.
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Electric cabinet
Environmental condition for the electrical equipment: 3K3 according to IEC 60721-3-3
Step Action
1 Check that the electrical connections correspond to the local codes. The installation must
be earthed and protected by fuses in all phases. An isolating switch must be fitted.
2 Check the wires on transformers for correct connection.
3 Check the setting of the circuit breakers (see the section Settings of circuit breakers).
Start up
Step Action
1 Close the drain valves (see the section Cooling and condensate system).
2 Switch on the voltage.
3 Start the compressor and stop it immediately. Check the rotation direction of the drive
motor while the motor is coasting to a stop. To determine the rotation direction of the motor,
look at the fan through the grating at the non-drive end of the motor. The correct rotation
direction is indicated by an arrow on the gear casing and on the fan cowl.
On air-cooled compressors, check the rotation direction of the fan motor, the fan is visible
through the grating in the air inlet panel (see section Dimension drawing). The correct
rotation direction is indicated by arrows on the fan inlet plate.
4 If the rotation direction is wrong, press the emergency stop button, switch off the voltage
and reverse two incoming electric lines.
If the rotation direction of the fan motor is wrong, consult your Atlas Copco customer centre.
5 Run the compressor for a few minutes and check that it is operating normally.
5.2 Before starting
Warning
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Control panel
Step Action
1 Switch on the voltage. Voltage on LED (6) lights up.
2 Close the condensate drain valves (see the section Cooling and condensate system).
3 Open the air outlet valve.
4 Check the oil level indicator (see the section Oil change). The pointer should be in the
green range or orange range.
5.3 Starting
Warning
Control panel
Elektronikon MkIV controller
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1 Start
2 Display
3 Keys to scroll through display
4 Key to go to next field on display
5 Function keys
6 Voltage on
7 Alarm
9 Stop
Elektronikon GraphicPlus controller
Reference Name
1 Alarm
2 Service
4 Voltage on
5 Enter
6 Escape
7 Scroll keys
8 Stop
9 Start
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Procedure
Step Action
1 Press the start button. The compressor starts running in unloaded condition. The automatic
operation LED lights up.
2 Approx. 10 seconds later (programmable), the compressor starts running loaded. On the
Elektronikon controller, the message on the display changes from “Automatically
unloaded” to “Automatically loaded”. On the Elektronikon GraphicPlus controller, the status
icon on the display changes from the running unloaded icon to the running loaded icon.
5.4 During operation
Warning
The operator should immediately stop the machine in case of oil leaks internally in the
machine as well as externally and consult a competent technician to resolve the cause.
The machine should not be restarted before the problem has been remedied.
The load cycle of the compressor must be limited to maximum two cycles per minute.
Compressors with MkIV regulator
Control panel of MkIV regulator
1. When the automatic operation LED (8) is lit, the starting and stopping of the motor is controlled
automatically.
2. Check the readings on display (2).
3. To unload the compressor manually, press the “Unload” key (5). To put the compressor back into automatic
operation, press the “Load” key (5).
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Compressors with Elektronikon GraphicPlus controller
1. Check the readings on display (1).

2. When reaching the preset unloading pressure, shown on display (1), the compressor will start running
unloaded. From now on, the electronic control module will calculate the optimum moment to stop and
restart the compressor motor automatically, depending on the maximum permissible number of motor
starts and on the air consumption.
3. To unload the compressor manually, select Unload on the display using the cursor keys and press the Enter
key. To put the compressor back into automatic operation, select Load on the display using the cursor
keys and press the Enter key.
If the compressor is stopped, it may start automatically.
5.5 Checking the display
Warning
Before carrying out any maintenance, repair work or adjustment, stop the compressor,
press the emergency stop button and switch off the voltage. Close the air outlet valve and
open the manual condensate drain valve.
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Elektronikon MkIV
Step Action
1 Regularly check the display for readings and messages. Normally, the main display is
shown, indicating the compressor outlet pressure, the status of the compressor and the
functions of the keys below the display.
2 Always check the display and remedy the problem if alarm LED (7) is lit or flashing.
3 The display will show a service message if a service plan interval has been exceeded or
if a service level for a monitored component has been exceeded. Carry out the service
actions of the indicated service plans or replace the component and reset the relevant
timer.
4 Regularly check the actual compressor status by pressing the arrow down key from the
main screen.
Example of the main menu
“Status data”
“Measured Data”
“Counters”
“Mainscreen”
F1 F2 F3
Example of the main display

Main display of GA compressors
“Compressor outlet” 7.5 bar
“Automatically loaded”
“Menu” “Unload”
F1 F2 F3
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Elektronikon GraphicPlus
1. Regularly check the display for readings and messages. Normally, the main display is shown.
2. Always check the display and remedy the trouble if alarm LED (4) is alight or blinks.
The display will show a service message if a service plan interval has been exceeded or if a service level
for a monitored component has been exceeded. Carry out the service actions of the indicated plans or
replace the component and reset the relevant timer.
Regularly check the Inputs and Outputs menus for a quick look at the compressor status.
5.6 Manual loading/unloading
On compressors equipped with an Elektronikon MkIV controller
Control panel of Elektronikon MkIV regulator
Example of the main display

Main display of GA compressors
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“Compressor outlet” 7.5 bar (109 psi)

.
“Automatically loaded”
“Menu” “Unload”
F1 F2 F3
Automatic operation
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and
restarts the compressor automatically. LED (8) is then lit.
Manually unloading
Press “Unload” key (F3), LED (8) goes out. The message “Manually Unloaded” appears on the display. The
compressor remains running unloaded unless it is loaded again manually.
Manually loading
Press “Load” key (F3), LED (8) lights up. The command “Load” does not force the compressor into loaded
condition, but it will switch the compressor to automatic operation again; the compressor will be loaded if
the air net pressure drops below the programmed level.
On compressors equipped with an Elektronikon GraphicPlus controller
General
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and
restarts the compressor automatically. LED (7) is then alight.
If required, the compressor can be unloaded manually. In this case, the compressor is switched out of automatic
operation i.e. the compressor remains running unloaded unless it is loaded again manually.
Manual unloading
Starting from the main screen, move the cursor so that Unload is highlighted in grey. When the Enter key is
pressed, the compressor starts running unloaded and LED (7) fades. The message Manual Unload appears
on the display.
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Manual loading
Starting from the main screen, move the cursor so that Load is highlighted in grey. When the Enter key is
pressed, LED (7) lights up and the compressor starts running loaded in case the air net pressure drops below
the programmed level. The message Load appears on the display.
If the Load or Unload buttons are not displayed on the bottom line of the screen, make
sure to return to the Main screen first.
5.7 Stopping
Important
After pressing stop button (9), the compressor will run unloaded for 30 seconds. The
compressor stops after this period. A start command during this period is ignored.
After stopping, the compressor is prevented from restarting within a programmable time
(20 seconds). A start command given during this minimum stop time will be memorized;
the automatic operation LED lights up. The compressor will start when the minimum stop
time has elapsed.
On compressors equipped with an Elektronikon MkIV controller
Control panel of Elektronikon MkIV regulator
Reference Name
1 Press stop button (9). LED (8) goes out. The message “Programmed stop” appears. The
compressor runs unloaded for 30 seconds and then stops.
2 To stop the compressor in the event of an emergency, press button (S2). Alarm LED (7)
blinks. After remedying the fault, unlock the button by pulling it out
3 Close the air outlet valve.
4 Open the condensate drain valves.
5 Switch off the voltage.
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On compressors equipped with an Elektronikon GraphicPlus controller
Procedure
Frequently stopping the compressor using the emergency stop button may damage the
compressor. Only use the emergency stop button in case of emergency.
Step Action
1 Press stop button (13). The compressor will run unloaded for 30 seconds and then stop.
2 To stop the compressor in case of emergency, press the emergency stop button. Alarm
LED (4) starts flashing. After remedying the trouble, unlock the emergency stop button by
pulling it back.
3 Close the air outlet valve.
4 Open the condensate drain valves.
5 Switch off the voltage.
5.8 Taking out of operation
Disconnecting the compressor

At the end of the service life of the compressor, proceed as follows:
Step Action
1 Stop the compressor and close the air outlet valve.
2 Switch off the voltage and disconnect the compressor from the mains.
3 Depressurize the compressor by opening the drain valve and loosening the oil filler plug
one turn.
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Step Action
4 Shut off and depressurize the part of the air net which is connected to the outlet valve.
Disconnect the compressor air outlet pipe from the air net.
5 Drain the oil and condensate circuits.
6 Disconnect the compressor condensate piping from the condensate drain net.
8 Also read section Disposal of used material.
5.9 Use of air receiver
Instructions
Step Action
1 This equipment can contain pressurised air and oil; be aware of its potential danger if used
improperly.
2 This equipment must only be used as compressed air/oil separator and must be operated
within the specified limits.
3 No alterations must be made to this equipment by welding, drilling, grinding or other
methods of mechanical working without written permission of the manufacturer. If there is
damage to a part under pressure from any cause, the complete part must be replaced.
4 For the oil separator vessel: original bolts have to be used after opening for inside
inspection. The bolts must be removed and fitted with the correct tool. The bolts must be
tightened with a torque of 355 Nm (+/- 85 Nm). Damaged bolts must not be re-used. O-
rings must be replaced.
5 The safety valve is designed in such a way that the pressure will not permanently exceed
the maximum allowable operating pressure of the vessel, except for short pressure surges
up to 1.1 times the design pressure.
6 Only use oil specified by the manufacturer.
7 Make sure the vessel is fully depressurised before opening the drain plug or fill plug.
8 This vessel and other parts under pressure have been designed and built to guarantee an
operational lifetime in excess of 20 years and an infinite number of pressure load cycles.
A visual inspection (for damage, non-authorised alterations,...) of the vessel (at the outside
and inside) is recommended every 5 years. Make sure the vessel is fully depressurised
and isolated before carrying out an internal inspection.
9 At every inspection, also check the oil drain flexible. Replace if there is any wear or
damage.
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6 Maintenance
6.1 Preventive maintenance schedule
Warning
Before carrying out any maintenance, repair work or adjustment, proceed as follows:
• Stop the compressor.
• Press emergency stop button (S2).
• Close the air outlet valve and open the manual condensate drain valves.
• Switch off the voltage.
• Open and lock the isolating switch.
Warranty - Product Liability

Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered
by Warranty or Product Liability.
General
When servicing, replace all removed gaskets, O-rings and washers.
Preventive maintenance schedule
Period Running hours Operation

Daily 8 Check readings on display.
Daily 8 Check that condensate is discharged during loading.
Daily 8 Check oil level. Before starting, the level should be in the middle of the
sight-glass.
Weekly -- Check the cleanliness of the cubicle filters. Replace or clean if dusty.
Weekly -- Drain condensate from air receiver, if installed
3-Monthly -- Clean compressor.
3-Monthly -- Check for possible leaks.
3-Monthly 500 Check the coolers; clean them if necessary. See the section Coolers.
3-Monthly -- Remove air filter elements and inspect.
Yearly -- Have safety valve tested.
Yearly -- Have all flexibles inspected.
Yearly 4000 If Roto-Inject Fluid is used, change oil.
Yearly 8000 Replace oil filters.
Yearly 8000 Replace air filter element.
Yearly -- Regrease motor, for the interval and quantity, see section Motors.
2-Yearly 8000 Have oil separator element replaced.
When displayed -- Carry out service action according to the displayed service plans.
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When operating in a dusty atmosphere, inspect the air filters more frequently.
Use always Atlas Copco filters.
The separator element must also be replaced when the pressure difference over the element
exceeds 0.8 bar (12 psi). Check the pressure drop when the compressor is running loaded
and preferably with a stable working pressure.
Damaged flexibles must be replaced immediately.
Service agreements
Atlas Copco Customer Centres have a range of service agreements to suit your needs:
• An Inspection Plan
• A Preventive Maintenance Plan
• A Total Responsibility Plan
Contact your Customer Centre to set up a tailor-made service agreement. It will ensure optimum operational
efficiency, minimize downtime and reduce the total life cycle costs.
Service plan
A number of service operations are grouped (called Level A, Level B, Level C...). Each level stands for a
number of service actions to be carried out at the time intervals programmed in the Elektronikon regulator.
When a level is reached, a message will appear on the screen. After carrying out all service actions, the interval
timers must be reset using the “Reset” key in the “Service” menu. Consult your Atlas Copco Service Centre.
6.2 Motors
Warning
Stop the compressor and switch off the voltage. The operator must apply all relevant Safety
precautions.
Never mix greases of different brands or types.
Fan motors
The bearings of the fan motors are greased for life. The bearings of the fan motor must be replaced after 24000
operating hours.
WEG drive motor
Compressor type Power Interval Amount Interval Amount

D end D end ND end ND end
GA 160 75 psi, 100 psi, 125 psi, 150 psi, 200 200 HP 6000 h 45 gr (1.59 6000 h 35 gr (1.23
psi oz) oz)
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6.3 Oil specifications
Atlas Copco Roto-Inject Fluid

Roto-Inject Fluid is a high-quality lubricant for single-stage, oil-injected rotary screw compressors. See the
section Service kits.
Important
Never mix oils of different brands or types.
6.4 Oil change
Warning
Control panel
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Procedure
1. Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage.
Wait a few minutes and depressurize by unscrewing the vent plug on top of the air receiver to permit any
pressure in the system to escape. Wait until all the pressure in the system is released.
2. Drain the oil by removing the drain plug of the flexible fixed to the bottom of the air receiver.
Draining the oil cooler on air-cooled compressors:
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1. Take off the side panels of the compressor and remove the stays.
2. Open the cooler compartment and disconnect the cooler inlet pipe (1).
3. Disconnect the cooler outlet pipe (4) and roll out the oil cooler (2).
4. Remove the three bolts at the left side of the cooler.
5. Lift the oil cooler and fix the safety support. Remove the vent plug at the left side of the cooler. The oil
is drained via the cooler drain plug at the inlet connection.
6. After draining, remove the safety support and bring the oil cooler back to its original position. Fix the
cooler.
7. Drain the compressor element as described below.
8. Reconnect the cooler inlet (1) and oulet pipe (4).
9. Reinstall the stays and side panels of the compressor.
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Draining the compressor element, oil filter housing and oil stop valve
1. Remove the drain plug (3) to drain the oil stop valve.
2. Remove the drain plug of the flexible to drain the oil from the gearbox.
3. Reinstall the drain plugs after draining.
4. Disconnect the flexible from the bypass valve (5) to drain the oil from the oil filter housing.
5. Reinstall the flexibles to the bypass valve after draining.
Oil filter change
1. Use an oil pan to avoid oil spillage. Unscrew the oil filters (6).
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2. Clean the filter seats on the manifold.

3. Oil the gaskets of the new filters and screw the filters into place until the gaskets contact their seats. Then
tighten by hand.
Filling the compressor element with oil
On following compressors, remove the plug (7) from the unloader, pour 10 l (2.64 US gal, 2.20 Imp gal, 0.35
cu.ft) of oil into the unloader. Reinstall the plug (7) after filling.
• GA 160 125 psi
On GA VSD compressors, disconnect the air inlet hose from the compressor element and pour 10 l (2.64 US
gal, 2.20 Imp gal, 0.35 cu.ft) of oil into the compressor element. Reinstall the inlet hose after filling.
Filling the air receiver with oil
1. Reinstall and tighten the oil drain plug of the air receiver.
2. Remove filler plug (FC).
3. Fill the air receiver with oil until the level reaches the filler opening.
4. Refit and tighten filler plug (FC) and tighten the vent plug on top of the air receiver.
5. Run the compressor loaded for a few minutes.
6. Stop the compressor and wait a few minutes.
7. Depressurize the system by unscrewing the vent plug on top of the air receiver.
8. Remove the filler plug and fill the air receiver with oil until the level reaches the filler opening.
9. Tighten filler plug (FC).
10. Tighten the vent plug on top of the air receiver.
Resetting the Elektronikon regulator
After carrying out all service actions in the relevant “Service Plan”, reset the service warning as follows:
1. Press the “Menu” key (3).
2. Press key (1) until “Service” is followed by an arrow pointing to the right. Activate the menu by pressing
key (2).
3. Press key (1) until the related “Service Plan” is followed by an arrow pointing to the right and activate by
pressing key (2).
4. Press the “Reset” key (3); the timer is reset to 0.
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6.5 Storage after installation
Procedure
Run the compressor, e.g. twice a week, until warm. Load and unload the compressor a few times to operate
the components of the unloading/loading system.
If the compressor is going to be stored without running from time to time, protective
measures must be taken. Consult the Atlas Copco Customer Centre.
6.6 Service kits
General
Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco
parts while keeping the maintenance budget low. All service kits are indicated in the relevant Parts Lists.
Atlas Copco Roto-Inject Fluid

Roto-Inject Fluid can be ordered in the following quantities:
• 20-litre can: 2901 0522 00
• 209-litre drum: 2901 0045 01
See the section Oil specifications.
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7 DD filter
7.1 Maintenance
When maintaining the filter, keep in mind the following:

• On filters with manual drain valve, open the latter at regular intervals to evacuate collected dust or liquid
• Change the filter element yearly or when the pressure drop reaches approx. 0.35 bar
• In case an automatic drain valve is installed, manual draining can be carried out by turning the connection
nipple of the automatic drain valve counterclockwise.
•
When the filter has to process air with a temperature higher than the specified maximum
temperature, the filter's lifetime will be reduced considerably!
7.2 Filter element change
Procedure
When maintaining the filter, keep in mind the following:

1. Isolate the filter from the air net.
2. Depressurize the filter by turning the connection nipple of the automatic drain valve counterclockwise or
by opening the manual drain valve.
3. Unscrew the bowl. A whistling noise will warn you if the bowl is not fully depressurized. If this occurs,
the bowl should be screwed back and the venting should be repeated.
4. Discard the old filter element.
5. Remove the O-ring from the bowl and clean the bowl with isopropanol. Cleaning cloths of Kimtech are
recommended. Position a new O-ring on the bowl.
6. Open the sealed bag at the topcap side of the filter cartridge.
7. Take the cartridge and lower the plastic until the middle of the cartridge.
8. Position the cartridge under the filter head and push it in place. Only touch the plactic bag. Avoid contact
of the filter cartridge with the hands.
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9. Remove the plastic bag and reposition the bowl.
A small amount of paint compatible lubricant ( e.g . FOODLUBE EXTREME) may be applied
to screw threads and O-rings to facilitate the assembly.
7.3 Service intervals
7.4 Filter disposal
Used filters must be disposed of in an environmentally friendly and safe manner, and in line with the local
recommendations and environmental legislation.
7.5 Reference conditions
Air inlet pressure 7 bar(e)

Air inlet temperature 20˚C
Ambient temperature 20˚C
7.6 Principal data
Maximum compressed air inlet pressure 16 bar(e)

Minimum compressed air inlet pressure 1 bar(e)
Minimum compressed air inlet temperature 1˚C
Maximum compressed air inlet temperature 65˚C
Maximum compressed air inlet pressure 16 bar(e)
Minimum ambient temperature 1˚C
Maximum ambient temperature 65˚C
Maximum recommended pressure drop 0.35 bar(e)
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8 Integrated dryer
8.1 Condensate drain system
Description
The condensate enters the Electronic Water Drain (EWD) via inlet (1) and accumulates in the water separator
of the heat exchanger and in collector (2). A capacitive sensor (3) continuously measures the liquid level. As
soon as the collector is filled up to a certain level, a drain delay timer is started. As soon as the delay time has
expired, pilot valve (4) is activated and diaphragm (5) opens outlet (6), discharging the condensate.
When the collector has been emptied, the outlet closes quickly without wasting compressed air.
When the controller registers a malfunction, the red alarm LED starts flashing, a warning appears on the
display of the regulator and the electronic drain valve will automatically change to the alarm mode, opening
and closing the valve according to a sequence as shown below. This condition continues until the fault is
remedied. If the fault is not remedied automatically, maintenance is required.
Electronic water drain
Drain frequency during alarm condition
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Testing the Electronic water drain
Control panel, EWD
Briefly press the TEST button and check that the valve opens for condensate discharge.
Checking the alarm signal
• Press and hold the test button for at least 1 minute.
• Check that the alarm LED flashes.
• Check that a warning is generated on the display of the regulator.
• Release the test button.
8.2 Maintenance instructions
Important
Cooling dryers of the ID type contain refrigerant HFC.
Safety precautions
When handling refrigerant R404a, all applicable safety precautions must be observed. The following
points are stressed:
• Contact of refrigerant with the skin will cause freezing. Special gloves must be worn and, if there is contact
with the skin, the skin should be rinsed with water. On no account may clothing be removed.
• Fluid refrigerant will also cause freezing of the eyes; therefore, safety glasses must be worn.
• Refrigerant R404a is poisonous. Do not inhale refrigerant vapours. Check that the working area is
adequately ventilated.
Local legislation
Local legislation may impose that:
• Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function
must be carried out by an authorised control body.
• The installation should be checked once a year by an authorised control body.
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Warranty and product liability

Use only Atlas Copco authorised genuine parts. Any damage or malfunction caused by the use of unauthorised
parts is not covered by Warranty or Product Liability.
General
The following remarks should be kept in mind:
• Keep the dryer clean.
• On air-cooled dryers, brush or blow off the finned surface of the condenser regularly.
• Regularly test the EWD.
8.3 Problem solving
Faults and remedies
Condition Fault Remedy

- Pressure dew-point too high Ambient temperature too high Check and correct; if necessary, draw
cooling air via a duct from a cooler
place or relocate dryer
Shortage of refrigerant Have circuit checked for leaks and
recharged
Refrigerant compressor does See below
not run
Evaporator pressure too high See below
Condenser pressure too high See below
Automatic drain system Have the system cleaned
clogged
- Condenser pressure too high Cooling water system clogged Have cooling water system cleaned
or too low
Cooling water temperature too Check and correct as necessary
high
- Compressor stops or does not Electric power supply to Check and correct as necessary
start compressor is interrupted
Motor overload protection of Have motor checked
refrigerant compressor motor
has tripped
High-pressure switch tripped See above
- Condensate drain remains Automatic drain system Have system inspected
inoperative clogged
- Condensate trap continuously Automatic drain system out of Have system checked
discharges air and water order
- Evaporator pressure is too high Hot-gas by-pass valve Have hot-gas by-pass valve adjusted
or too low at unload incorrectly set or out of order
Condenser pressure too high See above
or too low
Shortage of refrigerant Have circuit checked for leaks and
recharged
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9 Adjustments and servicing procedures
9.1 Air filters
Warning
Stop the compressor, close the air outlet valve, press the emergency stop button and
switch off the voltage. The operator must apply all relevant Safety precautions.
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Position of air filter
Procedure
Step Action
1 Remove panel (4) from the compressor.
2 Remove the filter element.
3 Fit the new filter element.
4 Reinstall panel (4)
5 Reset the message and service timer:
• Press the “Menu” key (3).
• Press key (1) until “Service” is followed by an arrow pointing to the right. Activate the
menu by pressing key (2).
• Press key (1) until “Air filters” is followed by an arrow pointing to the right. Activate the
menu by pressing key (2).
• Press “Reset” key (3); the timer is reset to 0.
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9.2 Coolers
Checking the coolers for cleanliness on air-cooled compressors
Activate the "Cleanlinesstest" option in the Elektronikon regulator as follows:

• Starting from the main screen, press the "Menu" key.
• Press the arrow down key (1) until "Test" is followed by a horizontal arrow.
• Press the arrow down key (1) until the option "Cleanliness" is followed by a horizontal arrow.
Measure the pressure drop by the water column in mmWG. The condition of the cooler cleanliness can be
analyzed by comparing this value with the value in the table below depending on the compressor model.
Substract 3 mm WG from the values in the table when ducting is installed.
The values are given at maximum fan speed as activated by the cleanliness test. Mild clogging means that
25% of the section is blocked. Heavy clogging means that 50% of the section is blocked. The values should
only be used as guideline. Depending on the local (ambient) conditions the limits can be different. Readings
on the compressor should be observed on a regular basis to avoid high temperatures. Regular cleaning is
anyhow advised since clean coolers will reduce fan speed and thus power consumption.
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Clean Mild clogging Heavy

clogging
Maximum fan No action Cleaning Cleaning
speed (rpm) advised necessary
GA 160 Pack and Full- 1500 85 102 124
Feature
Cleaning the coolers
Stop the compressor, press the emergency stop button and switch off the voltage. The
operator must apply all relevant Safety precautions.
Procedure
Coolers of air-cooled compressors
Keep the cooler block clean to maintain the cooling efficiency.

On air-cooled compressors proceed as follows:
Step Action
1 Take off the side panels of the compressor and remove the stays.
2 Open the two inside doors.
3 Remove any dirt form the coolers with a fibre brush, brush in the direction of the fins. Also
remove any dirt from the fans.
4 Clean the coolers with an air jet in the reverse direction to normal flow. Use low pressure
air; if necessary, the pressure may be increased up to 6 bar (e) (87 psig)
5 If it is necessary to clean the coolers with a cleaning agent, consult Atlas Copco.
6 Close the inside doors.
7 Reinstall the stays and side panels of the compressor.
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9.3 Safety valve
Warning
Stop the compressor and switch off the voltage. The operator must apply all relevant Safety
precautions.
Never run the compressor without safety valves.

No adjustments are allowed.
Testing
The valve can be tested on a separate compressed air line.
Consult the Atlas Copco Customer Centre if the valve does not open at the correct pressure (see the section
Settings of safety valve).
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10 Problem solving
10.1 Problem solving
Warning
Before carrying out any maintenance, repair work or adjustment, stop the compressor,
press the emergency stop button and switch off the voltage. Close the air outlet valve and
open the manual condensate drain valves.
Open and lock the isolating switch.
Control panel
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Faults and remedies
A service message appears on the display

Stop the compressor and carry out the indicated service actions.
Reset the message, see Section Service menu.
A shut-down warning message appears on the display

The alarm LED will light up indicating that the temperature at the outlet of the compressor elements is too
high. The message disappears as soon as the cause of the problem is remedied.
Unit is shut down

The alarm LED will flash indicating either that the outlet temperature is too high or that the motor overload
relay has tripped. Remedy the problem.
On compressors equipped with the MkIV regulator, it may be necessary to reset the display after
remedying the fault: press the “Reset” key (2); the message “All protection functions are OK” will appear, after
which the compressor can be restarted.
On compressors equipped with an Elektronikon GraphicPlus controller, move the cursor to the Menu
action button and push the enter key (5). Using the Scroll keys (1), move the cursor to the protections icon.
Push the Enter key (5). Move the cursor to the blinking icon and press the Enter key (5). Move the cursor to
the reset button and press the enter key again.
Excessive oil consumption

Have the compressor inspected by the Atlas Copco Customer Centre.
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Condensate is not discharged from Discharge pipe of condensate trap Check and correct as necessary.
condensate traps during loading. clogged.
Float valve of condensate traps Remove float valve assembly,
malfunctioning. clean and check.
EWD (electronic water drain) Consult Atlas Copco.
malfunctioning.

Compressor air delivery or pressure Air consumption exceeds air Check equipment connected.
below normal. delivery of compressor.
Choked air filters. Replace filters.
Air leakage. Check and correct.

Compressor element outlet Oil level too low. Check and correct.
temperature or delivery air
temperature above normal.
Oil coolers clogged. Consult the section Coolers.
Air cooler clogged. Consult the section Coolers.
On air-cooled compressors, Check and correct as necessary.
insufficient cooling air or cooling
air temperature too high.
On water-cooled compressors, Increase flow.
cooling water flow too low.
On water-cooled compressors, Consult Atlas Copco Customer
restriction in cooling water system. Centre.
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11 Technical data
11.1 Readings on display
Important
The readings are valid when operating under reference conditions. See the section
Reference conditions.
Normally the main display is shown (see the section Function keys), indicating the
actual air outlet pressure and the actual compressor status. The arrow down key
allows the operator to call up other information such as actually measured
pressures and temperatures.
Important readings
Compressor outlet pressure bar(e) (psig) Depends on programmed

unloading and loading
pressures
Pressure drop over air filters bar Below 0.05
Pressure difference over oil separator bar Below 0.8
Oil injection pressure at the compressor elements bar(e) (psig) Depends on programmed
unloading and loading
pressures
Compressor outlet temperature, air-cooled Pack compressors ˚C Approx. 28
Cooling air inlet temperature of GA 110, GA 132 and GA 160 ˚C Below 46
Pack
11.2 Reference conditions
Reference conditions
Absolute inlet pressure bar(a) 1

Relative air humidity % 0
Air inlet temperature ˚C 20
Nominal working pressure See Compressor data
Cooling medium inlet temperature ˚C 20
APF176951 117
Instruction book
11.3 Limits
Limits
Maximum air inlet/ambient temperature, GA 110 Pack, GA 132 ˚C 46

Pack and GA 160 Pack
Minimum air inlet/ambient temperature ˚C 0
Maximum cooling air temperature, GA 110 Pack, GA 132 Pack ˚C 46
and GA 160 Pack
Minimum cooling air temperature ˚C 0
Maximum working pressure See section Compressor
data
11.4 Settings of safety valve
Compressor type Setting

For GA compressors with a maximum working pressure of 5.2, 6.9, 8.6, 10.4 or 13.8 15 bar (e)
bar
11.5 Settings for overload relay and fuses
Overload relay
60 Hz CSA/UL compressors
Compressor type Voltage F21

GA 160 / GA 160+ 460V 159.3 A
Maximum fuses
Explanation fuse types:
• Type2: gL/gG: IEC: 60947-4-1 according:
• IEC60269
• DIN43620
• VDE0636
• CSA: HRC form II/UL: Class K5 according:
• UL248-9
CSA/UL 60 Hz Pack air-cooled compressors
118 APF176951
Instruction book
Compressor type Voltage Temp Temp Temp Temp

reduction reduction not reduction reduction not
needed needed needed needed
CSA: HRC CSA: HRC Type2: gL/gG Type2: gL/gG
form II/ UL: form II/ UL:
Class K5 Class K5
11.6 Settings of circuit breakers
For cooler cooling fan
Pack compressors Approval Frequenc Supply Setting

y voltage Q25
(Hz) (V) (A)
GA 160 / GA 160+ CSA/UL 60Hz 460V 20.0
11.7 Compressor data
Data for GA 125 psi (8.6 bar) 60 Hz compressors
Units GA 160
Maximum working pressure, GA Pack bar(e) 9.1
Nominal working pressure bar(e) 8.6
Motor shaft speed r/min 1790
Power input, GA Pack kW 175.6
Oil capacity, GA l 89
Sound pressure level, GA dB(A) 71
APF176951 119
Instruction book
12 Pressure equipment directives
Category IV
Product
GA 160 125 psi 250 l
This machine is a pressure assembly of cat. IV according to 97/23/EC.

Parts of article 3.3 of 97/23/EC are subject to good engineering practice.
Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion of article
I, section 3.6.
The following pressure bearing parts are of category higher than I :
Oil separator vessel : Cat IV
Design pressure 15 bar(e), content see table above
Design standard : ASME section VIII div. 1.
Safety valve : Cat IV
Design code : AD-Merkblätter, A2
120 APF176951
Instruction book
13 Documentation
Declaration of conformity
Typical example of a Declaration of Conformity document
APF176951 121
What sets Atlas Copco apart as a company is our conviction that
we can only excel in what we do if we provide the best possible
know-how and technology to really help our customers produce,
grow and succeed.
There is a unique way of achieving that - we simply call it the Atlas
Copco way. It builds on interaction, on long-term relationships
and involvement in the customers’ process, needs and objectives.
It means having the flexibility to adapt to the diverse demands of
the people we cater for.
It’s the commitment to our customers’ business that drives our
effort towards increasing their productivity through better
solutions. It starts with fully supporting existing products and
continuously doing things better, but it goes much further, creating
advances in technology through innovation. Not for the sake of
technology, but for the sake of our customer’s bottom line and
peace-of-mind.
That is how Atlas Copco will strive to remain the first choice, to
succeed in attracting new business and to maintain our position
as the industry leader.

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GA 160

1.1 SAFETY ICONS...................................................................................................................................6

1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................6

1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................7

1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................8

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

2.2 AIR AND OIL SYSTEM.........................................................................................................................12

2.3 COOLING AND CONDENSATE SYSTEM....................................................................................................15

2.4 REGULATING SYSTEM........................................................................................................................16

2.5 ENERGY RECOVERY SYSTEM...............................................................................................................17

3.1 ELEKTRONIKON® REGULATOR.............................................................................................................38

3.2 CONTROL PANEL..............................................................................................................................40

3.3 FUNCTION KEYS...............................................................................................................................41

3.4 SCROLL KEYS..................................................................................................................................42

3.5 EMERGENCY STOP BUTTON................................................................................................................42

3.6 CONTROL PROGRAMS........................................................................................................................43

3.7 CALLING UP MENUS..........................................................................................................................46

3.8 MAIN SCREEN MENU.........................................................................................................................47

3.9 STATUS DATA MENU..........................................................................................................................47

3.10 MEASURED DATA MENU.....................................................................................................................50

3.11 COUNTERS MENU.............................................................................................................................51

3.12 TEST MENU.....................................................................................................................................52

3.13 MODIFY PARAMETERS MENU...............................................................................................................52

3.14 FAN MOTOR SETTINGS.......................................................................................................................53

3.15 MODIFYING PARAMETERS...................................................................................................................54

3.16 MODIFYING PROTECTION SETTINGS......................................................................................................55

3.17 MODIFYING SERVICE PLANS................................................................................................................56

3.18 PROGRAMMING CLOCK FUNCTION.........................................................................................................57

3.19 MODIFYING CONFIGURATION SETTINGS..................................................................................................61

3.20 SERVICE MENU................................................................................................................................63

3.21 SAVED DATA MENU...........................................................................................................................65

3.22 PROGRAMMABLE SETTINGS.................................................................................................................65

4.1 DIMENSION DRAWING........................................................................................................................69

4.2 INSTALLATION PROPOSAL...................................................................................................................71

4.3 ELECTRIC CABLE SIZE.......................................................................................................................75

4.4 QUALITY OF SAFETY COMPONENTS.......................................................................................................78

4.5 INSTALLATION INSTRUCTIONS FOR DRYER BY-PASS .................................................................................79

5.1 INITIAL START-UP..............................................................................................................................83

5.2 BEFORE STARTING............................................................................................................................85

5.4 DURING OPERATION..........................................................................................................................88

5.5 CHECKING THE DISPLAY.....................................................................................................................89

5.6 MANUAL LOADING/UNLOADING.............................................................................................................91

5.8 TAKING OUT OF OPERATION................................................................................................................94

5.9 USE OF AIR RECEIVER.......................................................................................................................95

6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................96

6.3 OIL SPECIFICATIONS..........................................................................................................................98

6.4 OIL CHANGE....................................................................................................................................98

6.5 STORAGE AFTER INSTALLATION.........................................................................................................103

6.6 SERVICE KITS................................................................................................................................103

7.2 FILTER ELEMENT CHANGE ................................................................................................................104

7.3 SERVICE INTERVALS........................................................................................................................105

7.4 FILTER DISPOSAL............................................................................................................................105

7.5 REFERENCE CONDITIONS.................................................................................................................105

7.6 PRINCIPAL DATA.............................................................................................................................105

8.1 CONDENSATE DRAIN SYSTEM............................................................................................................106

8.2 MAINTENANCE INSTRUCTIONS...........................................................................................................107

8.3 PROBLEM SOLVING.........................................................................................................................108

9 Adjustments and servicing procedures...................................................................109

9.1 AIR FILTERS..................................................................................................................................109