Aib Ga 37-45 VSD 9095 0504 83

Oil-injected rotary screw compressors

Oil-injected rotary screw compressors
GA 37 VSD, GA 45 VSD
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.
2015 - 01

www.atlascopco.com

Instruction book

1.1 SAFETY ICONS ....................................................................................................................... 6
1.2 SAFETY PRECAUTIONS, GENERAL ...................................................................................... 6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION ................................................................ 7
1.4 SAFETY PRECAUTIONS DURING OPERATION .................................................................... 9
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ......................................... 10

2.1 INTRODUCTION .................................................................................................................... 13
2.2 AIR FLOW .............................................................................................................................. 17
2.3 OIL SYSTEM .......................................................................................................................... 19
2.4 COOLING SYSTEM ............................................................................................................... 20
2.5 CONDENSATE SYSTEM ....................................................................................................... 22
2.6 REGULATING SYSTEM......................................................................................................... 23
2.7 ELECTRICAL SYSTEM .......................................................................................................... 23
2.8 AIR DRYER ............................................................................................................................ 24
2.9 SMARTBOX AND SMARTLINK.............................................................................................. 25
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3.1 ELEKTRONIKON® GRAPHIC CONTROLLER ....................................................................... 28
3.2 CONTROL PANEL ................................................................................................................. 30
3.3 ICONS USED ......................................................................................................................... 31
3.4 MAIN SCREEN....................................................................................................................... 35
3.5 CALLING UP MENUS ............................................................................................................ 39
3.6 INPUTS MENU ....................................................................................................................... 40
3.7 OUTPUTS MENU ................................................................................................................... 43
3.8 COUNTERS ........................................................................................................................... 45
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Instruction book

4.1 ENERGY RECOVERY UNIT .................................................................................................. 82
4.2 ENERGY RECOVERY SYSTEMS.......................................................................................... 83
4.3 OPERATION .......................................................................................................................... 84
4.4 MAINTENANCE ..................................................................................................................... 88
4.5 ENERGY RECOVERY DATA ................................................................................................. 88
* + ,
5.1 DIMENSION DRAWINGS ....................................................................................................... 90
5.2 INSTALLATION PROPOSAL.................................................................................................. 92
5.3 ELECTRICAL CONNECTIONS .............................................................................................. 95
5.4 COOLING WATER REQUIREMENTS .................................................................................... 97
5.5 PICTOGRAPHS ....................................................................................................................102
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6.1 BEFORE INITIAL START-UP ................................................................................................103
6.2 BEFORE STARTING .............................................................................................................106
6.3 STARTING ............................................................................................................................107
6.4 DURING OPERATION ..........................................................................................................108
6.5 CHECKING THE DISPLAY....................................................................................................110
6.6 STOPPING ............................................................................................................................111
6.7 TAKING OUT OF OPERATION .............................................................................................112

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7.1 PREVENTIVE MAINTENANCE SCHEDULE .........................................................................113
7.2 OIL SPECIFICATIONS ..........................................................................................................116
7.4 AIR FILTER ...........................................................................................................................117
7.5 OIL AND OIL FILTER CHANGE ............................................................................................118
7.6 COOLERS .............................................................................................................................120
7.7 SAFETY VALVES..................................................................................................................121
7.8 DRYER MAINTENANCE INSTRUCTIONS............................................................................121
7.9 SERVICE KITS ......................................................................................................................122
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Instruction book

7.10 DRAINING CONDENSATE FROM THE OIL TANK ...............................................................122
7.11 STORAGE AFTER INSTALLATION ......................................................................................123
7.12 DISPOSAL OF USED MATERIAL .........................................................................................123
# $
0 1 2 & %
+ 3 " +
9.1 READINGS ON DISPLAY .....................................................................................................129
9.2 ELECTRIC CABLE SIZE AND MAIN FUSES ........................................................................129
9.3 PROTECTION SETTINGS ....................................................................................................133
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4 5 6 7 8 9 8 : ; < 9
Danger for life
Warning
Important note
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9 8 7 6 8 A : ; < 9 B
To be read attentively and acted accordingly before installing, operating, repairing or

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decommissioning the unit

These recommendations apply to machinery processing or consuming air or insert gas.
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Processing of any other gas requires additional safety precautions typical to the application,
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which are not included herein.

In addition to normal safety rules, which should be observed with stationary air compressor and
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equipment, the following safety directions and precautions are of special importance.
Any modification on the compressor shall only be performed in agreement with Atlas copco and
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under stricter of the two shall apply

The operator must employ safe working practices and observe all related work safety
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requirements and regulations.

If any of the following statements does not comply with the applicable legislation, the stricter of
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the two shall apply.

Installation, operation, maintenance and repair work must only be performed by authorized,
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trained, specialized personnel.

The compressor is not considered capable of producing air of breathing quality. For air of
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breathing quality, the compressed air must be adequately purified according to the applicable
legislation and standards.
Before any maintenance, repair work, adjustment or any other non-routine checks:
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• Stop the compressor.

• Press the emergency stop button.
• Switch off the voltage.
• Depressurize the compressor.
• Lock Out – Tag Out (LOTO):
- Open the power isolating switch and lock it with a personal lock.
- Tag the power isolating switch with the name of the service technician.
• On units are powered by a frequency converter, wait 10 minutes before starting any
electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
The units are powered by a frequency converter, wait 10 minutes before starting any electrical
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repair.
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Instruction book

In a domestic environment, this product may cause radio interference in which
case supplementary mitigation measures are required.
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
Never play with compressed air. Do not apply the air to your skin or direct an air stream at
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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.
The owner is responsible for maintaining the unit in safe operating condition. Parts and
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accessories shall be replaced if unsuitable for safe operation.

It is not allowed to walk or stand on the roof of the compressor canopy.
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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.
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N 8 A : ; < 9 B O A ; 9 P < 6 8 : ; < 9
Apart from general engineering practice in conformity with the local safety regulations, the
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following directives are specially stressed:

In proposals/quotes to the customer it should be mentioned mandatory to ask for lockable
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isolators at customer installation, the same has to be added in AIB for commissioning/servicing
of the machine. Need of lockable isolators to be clearly communicated to customers.
A compressor shall be lifted only with adequate equipment in conformity with local safety rules.
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Please consult Atlas Copco to check if a dedicated lifting devise is designed for this purpose.
Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or
stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within
safe limits.
The units is designed for indoor use . If the unit is installed outdoors, special precautions must
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be taken; consult your supplier.

In case the devise is a compressor, place the machine where the ambient air is as cool and
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clean as possible if necessary, install a suction duct. Never obstruct the air inlet. Care must b
taken to minimize the entry of moisture at the inlet air
Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the
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pipes.
Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
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damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
In case the devise is a compressor, the aspirated air must be free of flammable fumes, vapours
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and particles, e.g. paint solvents, that can lead to internal fire or explosion.
In case the dives is a compressor, arrange the air intake so that loose clothing worn by people
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cannot be drawn in.

Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to
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expand under heat and that it is not in contact with or close to flammable materials.
No external force may be exerted on the air outlet valve; the connected pipe must be free of
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strain.
If remote control is installed, the machine must bear a clear sign stating: DANGER: This
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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
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Instruction book
electrical isolating switch is open, locked and labeled with a temporary warning before any
maintenance or repair. As a further safeguard, 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 start equipment.
Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
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available and that the exhausted air does not recirculate to the compressor air inlet or cooling
air inlet.
The electrical connections must correspond to the applicable codes. The machines must be
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earthed and protected against short circuits by fuses in all phases. A lockable power isolating
switch must be installed near the compressor.
On machines with automatic start/stop system or if the automatic restart function after voltage
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failure is activated, a sign stating "This machine may start without warning" must be affixed near
the instrument panel.
In multiple compressor systems, manual valves must be installed to isolate each compressor.
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Non-return valves (check valves) must not be relied upon for isolating pressure systems.
Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
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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.
Piping or other parts with a temperature in excess of 70°C (158°F) and which may be
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accidentally touched by personnel in normal operation must be guarded or insulated. Other high
temperature piping must be clearly marked.
For water-cooled machines, the cooling water system installed outside the machine has to be
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protected by a safety device with set pressure according to the maximum cooling water inlet
pressure.
If the ground is not level or can be subject to variable inclination, consult the manufacturer.
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If the device is a dryer and no free extinguishing system is present in the air close to the dryer,
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safety valves must be installed of the dryer.

Never Drill holes in an electrical cabinet. Small metallic burrs can cause short-circuits in
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electrical components
Make sure to avoid condensation on electrical components (e.g. cubicle, Elektronikon and
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frequency converter)
To preserve the protection of the electric cabinet and to protect its components from dust from
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the environment and the entry of moisture in the electrical cabinet. It is absolutely necessary to
use a proper cable gland when connecting the power supply cable to the compressor.
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< A 7 O 8 7 B < B A 7 : ; 9 R ; 8 9 O R 8 : 8 7 ; : ; B W
Avoid contact with sharp edges hot surfaces to prevent damage to cable insulation.
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Before initial start-up and after service interventions, make sure the following final inspection
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checks are made:

a. Inspect all electrical connections to verify there are no loose connections and all are
tightened correctly
b. Check for strain relief on the (main) power cables.
c. Verify that the power requirement for the unit has been provided for by referencing to the unit
power label on the inside of the electrical cabinet door of the unit
d. The branch circuit protection and supply cable size for the compressor must be sized to
meet the power requirement per local electrical codes
e. Verify that the unit is correctly grounded using the proper size of wire connected to a tested
earth ground
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X U ; B < A 7 O 8 7 B < B A 7 : ; 9 R ; 8 9 O R 8 : 8 7 ; : ; B W
Before initial start-up and after service inventions , make sure the following final mechanical
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inspection check are made:

a. Inspect all connections to make sure they are tight, sealed and secured.
b. Visually inspect metal or nylon tubing located in the compressor. Tubes can come loose or
get damaged in shipping. Verify the flexibility of the nylon tubes while inspecting for damage.
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Instruction book
c. Verify that all tubes are secure in their fittings to insure that none might leak or come loose
when the compressor is in operation.
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< S 6 B B < ; B ; 9 < 6 8 : ; < 9 8 9 O B A 7 : ; 9 O 8 S 8 P : < : U < S 6 B B < < R ; W
After inspection, the power can be put to the installed compressor. With the proper power
applied, the rotation of the compressor and the cooling fan can be verified.
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.
precautions, or non observance of the normal caution and care required for
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N 8 A : ; < 9 B O A ; 9 P < 6 8 : ; < 9
Air hoses shall be of correct size and suitable for the working pressure. Never use frayed
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damaged or deteriorated houses. Use only the correct type and size of hose end fittings and
connections. When blowing through a hose or airline, ensure that the open end is held securely.
A free end will whip and may cause injury. Make sure that a hose is fully depressurized before
disconnecting it.
Never play with compressed air. Do not apply it to your skin or direct an air stream at people.
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Never use it to clean dirt from clothes. When using it to clean equipment, do so with extreme
caution and use eye protection.
The compressor is not considered as capable of producing air for breathing quality. For
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breathing air quality, the compressed air must be adequately purified according to local
legislation and standards.
Never operate the unit at pressures below or in excess of its limit ratings as indicated on the
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Principal Data sheet.

Never touch any piping or components of the compressor during operation.
Persons switching on remotely controlled machines shall take adequate precautions to ensure
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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.
Never operate the machine when there is a possibility of taking in flammable or toxic fumes,
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vapors or particles.
Keep all bodywork doors shut during operation. The doors may be opened for short periods
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only, e.g. to carry out routine checks. Wear ear protectors when opening a door.
On compressor without bodywork, wear ear protection in the vicinity of the machines.
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People staying in environments or rooms where the sound pressure level reaches or exceeds
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80 dB(A) shall wear ear protectors.

Periodically check that:
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Instruction book
• 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
If warm cooling air from compressors is used in air heating systems, e.g. to warm up a
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workroom, take precautions against air pollution and possible contamination of the breathing
air.
On water-cooled compressors using open circuit cooling towers, protective measures must be
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taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
Do not remove any of, or tamper with, the sound-damping material.
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Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
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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.
Yearly inspect air receiver. Minimum wall thickness as specified in the instruction book must be
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respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during

installation and Safety precautions during maintenance.
gas. Processing of any other gas requires additional safety precautions
typical to the application which are not included herein.
precautions, or non-observance of the normal caution and care required for
? > @ ? > @ > ? ? > ?
N 8 A : ; < 9 B O A ; 9 P S 8 ; 9 : 9 8 9 < 6 8 ;
Maintenance and repair work shall only be carried out under supervision of someone qualified for the
job
To maintain warranty and to insure the compressor operates correctly and safety, genuine parts must
be used. Use of non-genuine parts, failure to correctly install equipment or perform recommended
scheduled maintenance will void warranty and result in damage to or failure of the equipment. This
could also result in fire and fatalities.
Always use the correct safety equipment such as safety glasses, gloves, safety shoes, etc.
Before performing any maintenance, stop the compressor, close the shut-off valve at the unit
discharge, remove all electrical power from the equipment, verify the receiver tank on the unit is at zero
pressure and let the machine cool down. Take positive precaution to ensure that the unit cannot be
started inadvertently by following a lock-out tag-out procedure. In addition, a warning sign bearing a
legend such as shall be attached to the starting equipment
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Instruction book
Before removing any pressurized component, effectively isolate the unit from all sources of
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pressure and relieve the entire system of pressure and electrical power. Take positive
precaution to ensure that the unit cannot be started inadvertently. In addition, a warning sign
bearing a legend such as shall be attached to the starting
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< ; 9 6 < P B B ` O < 9 < : B : 8 : a
equipment
Persons switching on remotely controlled machines shall take adequate precautions to ensure
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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.
Protect hands to avoid injury from hot machine parts, e.g during draining of oil
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Before removing any pressurized component, effectively isolate the machine from all sources of
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pressure and relieve the entire system of pressure.

Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
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precautions against toxic vapours of cleaning liquids.

Never use caustic solvents, which can damage materials of the air net, e.g polycarbonate
bowls.
Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering
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the parts and exposed openings with a clean cloth, paper or tape. Make sure that no tools,
loose parts or range are left on or the unit.
Never weld or perform any operation involving heat near the oil system. Oil tanks must be
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completely purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on,
or in any way modify, pressure vessels.
Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapour when air is admitted.
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6 B B A B B 7 : W
Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
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entering them, e.g. when steam-cleaning. Or due to condensation of humid ambient air.
If the branch circuit is provided using a fused disconnect to supply power to the compressor,
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and then verify that all the fuses are of the same type and properly sized. If a circuit breaker is
used to supply power, verify that it is properly sized.
Visually inspect and verify that the connections at the branch circuit protection device are tight
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and the wire insulation Is not degraded.

Visually inspect the wire from the branch circuit protection devise to the compressor starter to
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verify that it is sized correctly and in good order.

Verify that the power wire and ground connections at the compressor starter are tight and in
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good order.
Verify that the wire connections from the compressor starter to the compressor motor are tight
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and in good order

Replace filters in the electrical cabinet when they are saturated with dust.
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Check if the sealing of the electrical cabinet is in perfect condition. If not replace it.
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Inspect all tubing in the compressor for possible leaks or normal aging and replace with genuine
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parts if needed
Verify if all tube fitting are tight and tubes are securely held in the fittings.
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Also check all nylon for chaffing, cracks and flexibility and replace with genuine parts to insure
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safe operation.
Drain any condensate that may have collected in the receiver tank.
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Take oil samples for evaluation and be sure to mark with customer name, compressor model,
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compressor serial number and running hours of the compressor. Respect oil service intervals.
Oxidized oil will result in higher compressor temperatures that could result in fire.
Replace oil with genuine compressor oil of the same type when needed.
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Instruction book
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< A 7 O B A 7 : ; 9 R ; W
Replace all consumables at recommended service intervals or sooner if operating conditions

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several / warrant or replace every 12 months.

Make sure that all sound –damping material, e.g. on the bodywork and in the air inlet and outlet
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systems of the compressor, is in good condition. If damaged, replace it by genuine material to

prevent the sound pressure level from increasing.
Every time the separator element is renewed, examine the discharge pipe and the inside of the
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oil separator vessel for carbon deposits; if excessive, the deposits should be removed.
Before clearing the machine for use after maintenance or overhaul, check that operating
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pressures, temperatures and time settings are correct and that the control and shut-down
devices function correctly. If removed, check that the coupling guard of the compressor drive
shaft has been reinstalled.
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a. Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if
required, use breathing protection.
b. Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the
latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away;
then seek medical first aid.
c. Always wear safety glasses.
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B A 7 : ; 9 R ;
All regulating and safety devices shall be maintained with due care to ensure that they function
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properly. They may not be put out of action.

Customer to check all the safety / protection devices once in a month, Check function of
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following components and maintain the record of the same.

• Overload relay - set at min setting and check trip+ manual trip
• Safety valve - raise the pressure and check the opening at set press - even Elektronikon
have SV test function.
• Temp switch - open the contacts (make NO) and check trip.
• PSR - reverse any 2 phase and check the trip.
Also consult following safety precautions: Safety precautions during

installation and Safety precautions during operation.
gas. Processing of any other gas requires additional safety precautions
typical to the application which are not included herein.
ϭϮ 1904 0504 83

Instruction book
GA 37 VSD up to GA 45 VSD are single-stage, oil-injected screw compressors driven by an electric

motor.
The compressors are enclosed in a sound-insulated bodywork and are available in air-cooled and
water cooled version.
The compressors are controlled by the Atlas Copco Elektronikon® Graphic regulator.
The electronic control module is fitted to the door at the right side. An electric cabinet comprising
fuses, transformers, relays, etc. is located behind this panel.
Atlas Copco's integrated VSD (Variable Speed Drive) technology mirrors air usage, automatically
adjusting the motor speed depending on the compressed air demand.
= ? _ @ >
Y k < 6 7 8
l m n o p q r s t u v w x y z { | } ~ p n v w z { | n m ~ s
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Instruction book
s m q r s t u v w x y z { | } ~ p n v w z { | n m ~ s
> > ? > @ > >

R 9 b 8 S
AF Air filter
AR Air receiver
AV Air outlet valve
Ca Air cooler
Co Oil cooler
CV/Vs Check valve/oil stop valve
Da Automatic condensate outlet
E Compressor element
ER Elektronikon® Graphic controller
FN Cooling fan
M1 Drive motor
S3 Emergency stop button
VP Vent plug
1 Electric cabinet
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Instruction book
= ? _ @ > > ? >

Y k < 6 7 8 A 7 7 j 8 : A
The Workplace Full Feature compressors are provided with an air dryer which is integrated in the
sound insulated bodywork. The dryer removes condensate from the compressed air by cooling the air
to near freezing point.
l m n o p q r s t u v w x y z { | } ~ p n v w z { | n m ~ s l } l s p } m s
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Instruction book
s m q r s t u v w x y z { | } ~ p n v w z { | n m ~ s l } l s p } m s
> > ? > @ > >

R 9 b 8 S
AV Air outlet valve

Ca Air cooler
Co Oil cooler
CV/Vs Check valve/oil stop valve
Da Automatic condensate outlet
Dm Manual condensate outlet
E Compressor element
ER Elektronikon®/Elektronikon® Graphic controller
FN Cooling fan
M1 Drive motor
UA Unloader
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Instruction book
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7 < O ; 8 P 8 S B
v w x y z { | o v w z { | n m ~ s
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Instruction book
GA 37 VSD and GA 45 VSD Workplace Full-Feature

> > ? > @ > > @ ?
R 9 B [ B ; 6 : ; < 9
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air
E Condensate
F Dried compressed air (Full-Feature)
The cooling fan (FN) is not provided on water-cooled compressors.

>
b < : i
> @ ?
[ B ; 6 : ; < 9
Air drawn in through filter (AF) and check valve (CV) is compressed in compressor element (E).
A mixture of compressed air and oil flows into the air receiver/oil separator (AR). The air is discharged
through
the outlet valve via minimum pressure valve (Vp), air cooler (Ca) and condensate trap (MT).
Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum
pressure and
includes a check valve which prevents blow-back of compressed air from the net.
Full-Feature compressors are provided with a dryer (DR).
ϭϴ 1904 0504 83

Instruction book
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7 < O ; 8 P 8 S

r p s

A Intake air
B Air/oil mixture
C Oil
To the air outlet valve in case of a Workplace version.
1
To the dryer in case of a Workplace Full-Feature version.
The cooling fan (FN) is not provided on water-cooled compressors.

>
b < : i
> @ ?
[ B ; 6 : ; < 9
In air receiver (AR) most of the oil is removed from the air/oil mixture by centrifugal action. The
remaining oil is removed by oil separator (OS). The oil collects in the lower part of air receiver/oil
separator (AR) which serves as oil tank.
The oil system is provided with a thermostatic bypass valve (BV). When the oil temperature is below
40 ˚C (104 ˚F), the bypass valve shuts off the oil supply from oil cooler (Co). Air pressure forces the oil
from air receiver (AR) through oil filter (OF) and oil stop valve (Vs) to compressor element (E). Oil
cooler (Co) is bypassed. When the oil temperature has increased to 40 ˚C (104 ˚F), bypass valve (BV)
starts opening the supply from oil cooler (Co). At approx. 55 ˚C (131 ˚F), all the oil flows through the oil
cooler.
1904 0504 83 ϭϵ

Instruction book
? @ > @ ? > ?
Y ; j < < 7 O < S 6 B B > ? > @ > > @ ?

R 9 B [ B ; 6 : ; < 9
A Intake air
B Air/oil mixture
C Oil
E Condensate
> @ ?
[ B ; 6 : ; < 9
The cooling system on air-cooled compressors comprises air cooler (Ca) and oil cooler (Co).
The cooling air flow is generated by fan (FN). This cooling fan is switched on and off depending on the
operating conditions according a specific algorithm
ϮϬ 1904 0504 83

Instruction book

> ? @ > @ ? > ?

k 8 : j < < 7 O < S 6 B B > ? > @ > > @ ?

R 9 B [ B ; 6 : ; < 9
A Intake air
B Air/oil mixture
C Oil
F Water flow
> @ ?
[ B ; 6 : ; < 9
The cooling system on water-cooled compressors comprises air cooler (Cwa) and oil cooler (Cwo).
They are connected to a cooling water circuit. The water flows through the inlet pipe, the coolers and
the outlet pipe.
p s m n n s r m n n s m o n r n n s m
1904 0504 83 Ϯϭ

Instruction book
? @ > @
[ 8 ; 9 < 9 9 : ; < 9 B
The compressors have an centrifugal water separator WSD25 (1). The condensate formed in the air
cooler accumulates in the collector. When the condensate reaches a certain level, it is discharged
through the automatic drain outlet (Da). Also, the condensate water can be discharged manually through
the manual drain outlet (Dm).
On Full-Feature compressors, an additional centrifugal water drain WSD25 (2) is provided. The
condensate trap of the heat exchanger is drained by WSD25 and discharged through automatic drain
outlet (Da1). Also, the condensate water can be discharged manually through the manual drain outlet
(Dm1).

n o s o p s m r o u p ~ r s ~ s
> > ? > @ > >

R 9 [ B ; P 9 8 : ; < 9
Da Automatic drain connection

Dm Manual drain connection
Da1 Automatic drain connection of the dryer (only on Full-Feature units)
Dm1 Manual drain connection of the dryer (only on Full-Feature units)
ϮϮ 1904 0504 83

Instruction book

[
>
B
@ ?
; 6 : ; < 9
If the consumption is less than the air output of the compressor, the net pressure increases. When the
net pressure is higher than the set-point (desired net pressure), the regulator will decrease the motor
speed. If the net pressure keeps on rising when the motor runs at minimum speed, the regulator stops
the motor. If the motor is stopped automatically and the net pressure approaches the set-point, the
regulator will restart the motor

4 7
> @
:
?
;
@
8 7
@
< S 6 < 9
>
9 : B
The electrical system comprises the frequency convertor and following components:
s p m r r o s p n m v w x y z { | o v w z { |
> > ? > @ > >

R 9 [ B ; P 9 8 : ; < 9
Q15
T1 Transformer
Q15 Circuit breaker
Q1 Circuit breaker
K15 Contactor
Z1 EMC filter (option)
U1 Frequency converter
PE Earthing terminal
> @ ? @ ?
4 7 : ; 8 7 O ; 8 P 8 S
The complete electrical diagram can be found in the electric cubicle.
1904 0504 83 Ϯϯ

Instruction book
] ?
7 < O ; 8 P 8 S
w r m m s m
¡
AI Air inlet
AO Air outlet
1 Air/air heat exchanger
2 Air/refrigerant heat exchanger/evaporator
3 Condensate separator
4 Automatic drain / condensate outlet
5 Refrigerant compressor
6 Refrigerant condenser
7 Liquid refrigerant dryer/filter
8 Capillary
9 Bypass valve
10 Condenser cooling fan
11 Pressure switch, fan control
12 Liquid separator
¢ ? > > ? @ ? @
< S 6 B B O 8 ; ; A ; :
Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the
incoming air starts to condense. The air then flows through heat exchanger/evaporator (2), where the
refrigerant evaporates, causing the air to be cooled further to close to the evaporating temperature of
the refrigerant. More water in the air condenses. The cold air then flows through separator (3) where all
the condensate is separated from the air. The condensate is automatically drained through outlet (4).
The cold, dried air flows through heat exchanger (1) where it is warmed up by the incoming air.
Ϯϰ 1904 0504 83

Instruction book
> ? > ? @ ? @
R ; P 8 9 : ; A ; :
Refrigeration dryers of ID type contain high efficient refrigerant R410A of the HFC
group
Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where
most of the refrigerant condenses.
The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to capillary tube (8). The
refrigerant leaves the capillary tube at about evaporating pressure.
The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further
evaporation at about constant pressure. The heated refrigerant leaves the evaporator and is sucked in
by the compressor
(5) through a liquid separator (12).
By-pass valve (9) regulates the refrigerant flow. Fan (10) is switched on or off by switch (11) depending
on the pressure degree of the condensate.
/ £ ¤ 3 ¥ - ¦
= > > ?
9 8 7
The machine comes with a BOX mounted in the electrical cabinet.

Y X
§ ¨
The BOX allows read-out of a number of parameters of the machine on a user login-
Y X
§ ¨
protected web site called LINK. The connected antenna is mounted on the outside of the
Y X
§ ¨
machine.
1904 0504 83 Ϯϱ

Instruction book
> ? > @
8 R : \ 6 8 A : ; < 9 B
It is important to follow all regulations regarding the use of radio equipment, in particular regarding
the possibility of radio frequency (RF) interference. Please follow the safety advice given below
carefully.
• Respect restrictions on the use of radio equipment in fuel depots, chemical plants or other
explosive environments.
Avoid BOX operation close to inadequately protected personal medical devices
Y X
• § ¨
such as hearing aids and pacemakers. Consult the manufacturers of the medical device to
determine if it is adequately protected.
Avoid BOX operation close to other electronic equipment which may also cause
Y X
• § ¨
interference if the equipment is inadequately protected. Observe any warning signs and
manufacturer recommendations.
Respect a distance from the human body of at least 20 cm (8 inch) during BOX
Y X
• § ¨
operation.
Do not operate the BOX in areas where cellular modems are not advised without
Y X
• § ¨
proper device certifications. These areas include environments where cellular radio can
interfere, such as explosive atmospheres, medical equipment, or any other equipment
which may be susceptible to any form of radio interference. The modem can transmit
signals that could interfere with this equipment.
Y X Z b ©
e
§ ¨
The machine is LINK-ready.

Y X
§ ¨
Ϯϲ 1904 0504 83

Instruction book
LINK is Atlas Copco’s web-based platform to monitor compressed air installations. It is

Y X
§ ¨
available in 3 product levels:
LINK Service
Y X
• § ¨
LINK Service rules out all uncertainties. Scheduling maintenance visits becomes as
Y X
§ ¨
simple and easy as it should be; the service log book is always just one click away and the
online link with Atlas Copco allows to request and quickly receive quotes for spare parts or
additional services.
This product level is free of charge and available for 3 years following the machine
purchase.
LINK Uptime
Y X
• § ¨
LINK Uptime keeps your compressors up and running. By e-mail and/or text, you
Y X
§ ¨
receive all relevant machine indications (warnings and shutdowns) in advance. Based on
this information, you can then take all necessary actions and measures to avoid the risk of
a breakdown.
This product level is available as a free of charge 3-month trial.
LINK Energy
Y X
• § ¨
LINK Energy safeguards the performance of your equipment. It enables you to

Y X
§ ¨
continuously monitor and analyze the energy efficiency of the compressor room. You
decide which performance indicators, benchmarks and reports are created. You can make
accurate and immediate improvements when needed. The results can be used for energy
monitoring according to ISO50001.
This product level is available as a free of charge 3-month trial.
Once a LINK level is chosen, gaining access is the next step. To gain access at least one
Y X
§ ¨
machine LINK-ready component (compressor, dryer, ...) is required. Follow the next steps:
Y X
§ ¨
Gather the information about the LINK-ready machine(s) (e.g. picture of the data
Y X
• § ¨
plate; invoice,…)
Go to the LINK web site http://www.atlascopco.com/smartlink
Y X
• § ¨
• Click on the left button in the screen below.

Use the data of the LINK–ready machine to register as a user.
Y X
• § ¨
• You will receive an e-mail with login credentials.

Go to the LINK web site http://www.atlascopco.com/smartlink, log in with the user
Y X
• § ¨
credentials.
Enjoy LINK!
Y X
• § ¨
In case more LINK-ready machines are available, you can add these via .
Y X
§ ¨ ª « ¬ ® ¯ ° ± ²
1904 0504 83 Ϯϳ

Instruction book
> ?
X S ; 9 < 7 > ? d > > _ ? _ ? > ? ] @

Z 9 P 9 8 7 : U 4 7 : < 9 ; < 9 P A 7 8 : < U 8 B R < 7 7 < ; 9 P R A 9 : ; < 9 B i
Controlling the compressor

µ
Protecting the compressor

µ
Monitoring components subject to service

µ
Automatic restart after voltage failure (made inactive)

@ @ ? > @ ? > ? > ?
Y A : < S 8 : ; < 9 : < 7 < R : U < S 6 B B < < 6 8 : ; < 9
The controller maintains the net pressure between programmable limits by automatically loading and
unloading the compressor (on compressors running at a fixed speed) or by adapting the motor speed
(compressors with frequency converter). A number of programmable settings, e.g. the unloading and
loading pressures (for fixed speed compressors), the setpoint (for compressors with frequency
converter), the minimum stop time and the maximum number of motor starts and several other
parameters are hereby taken into account.
The controller 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.
Ϯϴ 1904 0504 83

Instruction book

? > @ > @ ? > ?
N < : : ; 9 P : U < S 6 B B <
]
U A : j O < 9
Several sensors are provided on the compressor. If one of these measurements exceeds the
programmed shutdown 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 Inputs menu.
Before remedying, consult the Safety precautions.
] ] ?
U A : j O < 9 8 9 ; 9 P
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.
?
k 8 9 ; 9 P
A warning message will appear if, on full-Feature compressors, the Dewpoint temperature is too high
inrelation to the ambient temperature
> ? c @ > ] ?
; 8 9 ; 9 P
A number of service operations are grouped (called Service Plans). Each Service Plan 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 Service Plan.
@ ? > ? > ? c > ? >

Y A : < S 8 : ; B : 8 : 8 R : < 7 : 8 P R 8 ; 7 A
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.
1904 0504 83 Ϯϵ

Instruction book
> _ ? _ ? > ?
4 7 : < 9 ; < 9 P A 7 8 : <

n o p m n ~ o s
> _ ? _ ? > ?
4 7 : < 9 ; < 9 P A 7 8 : <
> > ? > @ > > @

R 9 [ B ; P 9 8 : ; < 9 A 9 : ; < 9
Shows the compressor operating condition and a number of icons

1 Display
to navigate through the menu.
2 Pictograph Automatic operation
3 Pictograph General alarm
General
4 Flashes if a shut-down warning condition exists.
alarm LED
5 Pictograph Service
6 Service LED Lights up if service is needed
Automatic
Indicates that the regulator is automatically controlling the
7 operation
compressor.
LED
Voltage on
8 Indicates that the voltage is switched on.
LED
9 Pictograph Voltage on
Key to select the parameter indicated by the horizontal arrow.
10 Enter key Only the parameters followed by an arrow pointing to the right can
be modified.
11 Escape key To go to previous screen or to end the current action
12 Scroll keys Keys to scroll through the menu.
13 Stop button Button to stop the compressor. LED (7) goes out.
Button to start the compressor. LED (7) lights up indicating that
14 Start button
the Elektronikon regulator is operative.
ϯϬ 1904 0504 83

Instruction book
@
: 8 : A B ; < 9 B
>
b 8 S
@ > @ ?
Z < 9 [ B ; 6 : ; < 9
Stopped / Running When the compressor is stopped, the icon stands

still. When the compressor is running, the icon is
rotating.
Compressor status Motor stopped
Running unloaded
Running loaded
Machine control mode Local start / stop
Remote start / stop
Network control
Automatic restart after voltage Automatic restart after voltage failure is active
failure
Week timer Week timer is active
Active protection functions Emergency stop
Shutdown
Warning

1904 0504 83 ϯϭ

Instruction book

Service Service required
Main screen display Value lines display icon
Chart display icon
General icons No communication / network problem
Not valid
@
Z 9 6 A : ; < 9 B
@ > @ ?
Z < 9 [ B ; 6 : ; < 9
Pressure
temperature
Digital input
Special protection
> @
\ B : S ; < 9 B
@ > @ ?
Z < 9 [ B ; 6 : ; < 9
Compressor element (LP, HP, ...)
Dryer
Fan

ϯϮ 1904 0504 83

Instruction book

@ > @ ?
Z < 9 [ B ; 6 : ; < 9
Frequency converter
Drain
Filter
Motor
Failure expansion module
Network problem
General alarm
> @
9 A ; < 9 B
@ > @ ?
Z < 9 [ B ; 6 : ; < 9
Inputs
Outputs
Alarms (Warnings, shutdowns)
Counters
Test
Settings
Service

1904 0504 83 ϯϯ

Instruction book

@ > @ ?
Z < 9 [ B ; 6 : ; < 9
Saved data
Access key / User password
Network
Setpoint
Info
c ? ? ]
b 8 ; P 8 : ; < 9 8 @ ?
Z < 9 [ B ; 6 : ; < 9
Up
Down
ϯϰ 1904 0504 83

Instruction book
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
@
A 9 : ; < 9
The Main screen is the screen that is shown automatically when the voltage is switched on and one of
the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed.
Typically, 5 different main screen views can be chosen:
1. Two value lines

2. Four value lines
3. Chart (High resolution)
4. Chart (Medium resolution)
5. Chart (Low resolution)
] ? c > > @ ? > >
X < 8 9 O R < A 8 7 A 7 ; 9 B B 9 B
This type of Main screen shows the value of 2 or 4 parameters (see section Inputs menu).
¶ ~ r · r o m s s o ¸ ¹ q } s r o s º
1904 0504 83 ϯϱ

Instruction book
Text on figures
(1) Compressor Outlet

(2) Flow
(3) Load, shutdown, ... (text varies upon the compressors actual condition)
(4) Menu
(5) Unload, ES,...(text varies upon the compressors actual condition)
¶ ~ r · r o m s s o ¸ q } s r o s º
Text on figures
(1) Compressor Outlet

(2) Flow
(3) Off, Shutdown,... (text varies upon the compressors actual condition)
(4) Menu
(5) Running hours
(6) Element outlet
(7) Load, Unload, ... (text varies upon the compressors actual condition)
• shows information regarding the compressor operation (e.g. the outlet pressure
> @
: ; < 9 Y
or the temperature at the compressor outlet). On compressors with a frequency converter,

the load degree (flow) is given in % of the maximum flow.
• shows Status icons. Following icon types are shown in this field:
> @
: ; < 9 »
• Fixed icons
These icons are always shown in the main screen and cannot be selected by the cursor (e.g.
Compressor stopped or running, Compressor status (running, running unloaded or motor
stopped).
• Optional icons
These icons are only shown if their corresponding function is activated (e.g. week
timer, automatic restart after voltage failure , etc.)
• Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To call up more information about the icons shown, select the icon concerned using the
scroll keys and press the enter key.
• is called the Status bar
> @ ¢
: ; < 9
This bar shows the text that corresponds to the selected icon.
ϯϲ 1904 0504 83

Instruction book
• shows the Action buttons. These buttons are used:

> @
: ; < 9 [
• To call up or program settings

• To reset a motor overload, service message or emergency stop
• To have access to all data collected by the regulator
The function of the buttons depends on the displayed menu. The most common functions are:
> @
[ B ; P 9 8 : ; < 9 A 9 : ; < 9
Menu To go to the menu

Modify To modify programmable settings
Reset To reset a timer or message
To activate an action button, highlight the button by using the Scroll keys and press the Enter
key. To go back to the previous menu, press the Escape key.
¢ ? c > ]
U 8 : ; B
Instead of viewing values, it is also possible to view a graph of one of the input signals (see section
Inputs menu) in function of the time.
When Chart (High Resolution) is selected, the chart shows the variation of the selected input (in this
case the pressure) per minute. Also the instantaneous value is displayed. The screen shows the last 4
minutes.
The switch button (icon) for selecting other screens is changed into a small Chart and is highlighted
(active).
When the Chart (Medium Resolution) is selected, the chart shows the variation of the selected
input per hour. The screen shows the last 4 hours.
1904 0504 83 ϯϳ

Instruction book
When the Chart (Low Resolution) is selected, the chart shows the variation of the selected input per day.
The screen shows the evolution over the last 10 days.
> > @ @ ? > > c > ]
7 : ; < 9 < R 8 S 8 ; 9 B 9 ;
To change between the different screen layouts, select the far right icon in the control icons line (see
value lines display icon or chart display icon in section Icons used) and press the Enter key. A screen
similar to the one below opens:
Select the layout required and press the Enter key. See also section Inputs menu.
ϯϴ 1904 0504 83

Instruction book
¢ ? >
< 9 : < 7 6 8 9 7

n o p m n ~ o s
(1) Scroll keys

(2) Enter key
(3) Escape key
> @ ?
[ B ; 6 : ; < 9
When the voltage is switched on, the main screen is shown automatically.
To go to the Menu screen, select <Menu> (3), using the Scroll keys
µ
Press the Enter key to select the menu. Following screen appears:
1904 0504 83 ϯϵ

Instruction book
• The screen shows a number of icons. Each icon indicates a menu item. By default, the
Pressure Settings (Regulation) icon is selected. The status bar shows the name of the menu
that corresponds with the selected icon.
• Use the Scroll keys to select an icon.
µ
Press the Escape key to return to the Main screen.
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
> @ d
9 A ; < 9 ; 9 6 A : B
@
A 9 : ; < 9
• To display the actual value of the measured data (analog inputs) and the status of the digital inputs (e.g.
emergency stop contact, motor overload relay, etc.).
• To select the digital input to be shown on the chart in the main screen.
ϰϬ 1904 0504 83

Instruction book

? @ > ? >
N < O A
Starting from the Main screen (see Main screen):

µ
Move the cursor to the action button Menu and press the enter key , following screen appears:
Text on figure
(1) Menu
(2) Regulation
µ
Using the scroll keys, move the cursor to the inputs icon (see above, section Menu icon)
µ
Press the enter key, a screen similar to the one below appears:
(1) Inputs
(2) Compressor outlet
(3) Element outlet
(4) Ambient air
(5) Emergency stop
• The screen shows a list of all inputs with their corresponding icons and readings.
• If an input is in warning or shutdown, the original icon is replaced by the warning or
shutdown icon respectively (i.c. the Stop icon and the Warning icon in the screen shown
above).
A small chart icon, shown below an item in the list means this input signal is shown on the chart at the
main screen. Any analog input can be selected.
> > @ > ? @ ?
7 : ; 9 P 8 9 < : U ; 9 6 A : B ; P 9 8 7 8 B S 8 ; 9 U 8 : B ; P 9 8 7
With the Modify button active (light grey background in above screen), press the Enter button on the
controller. A screen similar to the one below appears:
.
1904 0504 83 ϰϭ

Instruction book
The first item in the list is highlighted. In this example, the Net Pressure is selected (chart
icon). To change, press the Enter button again: a pop-up window opens:
Press Enter again to remove this input from the chart. Another confirmation pop-up opens:
Select Yes to remove or No to quit the current action.

In a similar way, another input signal can be highlighted and selected as Main Chart signal:
(1): Set as main chart signal
ϰϮ 1904 0504 83

Instruction book
¢ ? >
< 9 : < 7 6 8 9 7
> @ d
9 A ; < 9 < A : 6 A : B
@
A 9 : ; < 9
To call up information regarding the actually measured data and the status of some inputs such as the
motor overload protection.
? @ > ? >
N < O A

µ
Move the cursor to the action button Menu and press the enter key (2), following screen appears:
1904 0504 83 ϰϯ

Instruction book
Text on figure
(1) Menu
(2) Regulation
Move the cursor to the outputs icon (see above, section Menu icon, using the scroll keys (1)
µ
Press the enter key (2), a screen similar to the one below appears:
(1) Outputs
(2) Fan motor contact
(3) Blow-off contact
(4) General shutdown
(5) Automatic operation
The screen shows a list of all outputs with their corresponding icons and readings.
µ
If an input is in warning or shutdown, the original icon is replaced by the warning or

shutdown icon respectively.
ϰϰ 1904 0504 83

Instruction book
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
> @ d @ > ?
9 A ; < 9 < A 9 : B
@
A 9 : ; < 9
To call up:
µ
The running hours

µ
The loaded hours

µ
The number of motor starts

µ
The number of hours that the regulator has been under tension
µ
The number of load cycles
1904 0504 83 ϰϱ

Instruction book
? @ > ? >
N < O A

µ
Move the cursor to the action button Menu and press the enter key (2), following screen appears:
Text on figure
(1) Menu
(2) Regulation
µ
Using the scroll keys , move the cursor to the counters icon (see above, section Menu icon)
Press the enter key, following screen appears:
Text on figure
(1) Counters
(2) Running hours
(3) Motor starts
(4) Load relay
VSD 1-20 % rpm in % (the percentage of the time during which the motor
(5) speed
was between 1 and 20 %) (compressors with frequency converter)
µ
The screen shows a list of all counters with their actual readings.
ϰϲ 1904 0504 83

Instruction book
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
@
A 9 : ; < 9
To select the control mode, i.e. whether the compressor is in local control, remote control or controlled
via a local area network (LAN).
? @ > ? >
N < O A
Starting from the main screen, make sure the button Menu (1) is selected:
1904 0504 83 ϰϳ

Instruction book
Next, use the scroll buttons to go to the regulation icon (2) and press the enter button:
There are 3 possibilities:

• Local control
• Remote control
• LAN (network) control
After selecting the required regulation mode, press the enter button on the controller to confirm your
selection. The new setting is now visible on the main screen. See section Icons used for the meaning of
the icons.
¢ ? >
< 9 : < 7 6 8 9 7
ϰϴ 1904 0504 83

Instruction book
(1) Scroll keys

(2) Enter key
(3) Escape key
> @ d > ? c @ >

9 A ; < 9 ;
¨ §
@
A 9 : ; < 9
• 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 in the past.
• To modify the programmed service intervals.
? @ > ? >
N < O A
Starting from the Main screen,

• Move the cursor to the action button Menu and press the Enter key. Following screen appears:
• Using the Scroll keys, move the cursor to the Service icon (see above, section Menu icon).
• Press the Enter key. Following screen appears:
1904 0504 83 ϰϵ

Instruction book
Text on image
(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History
• Scroll through the items to select the desired item and press the Enter key to see the
details as explained below.
¼ c > ? c > ]
;
Text on image
(1) Overview
(2) Running Hours
(3) Real Time hours
(4) Reset
Example for service level (A):

The figures at the left are the programmed service intervals. For Service interval A, the programmed
number of running hours is 4000 hours (upper row) and the programmed number of real time hours is
8760 hours, which corresponds to one year (second row). This means that the controller will launch a
service warning when either 4000 running hours or 8760 real hours are reached, whichever comes
first. Note that the real time hours counter keeps counting, also when the controller is not powered.
The figures within the bars are the number of hours to go till the next service intervention. In the
example above, the compressor was just started up, which means it still has 4000 running hours or
8280 hours to go before the next Service intervention.
> ? c @ >
; 6 7 8 9 B
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®
controller.
When a service plan interval is reached, a message will appear on the screen.
After carrying out the service actions related to the indicated levels, the timers must be reset.
ϱϬ 1904 0504 83

Instruction book
From the Service menu above, select Service plan (3) and press Enter. Following screen appears:
Text on image
(1) Service plan

(2) Level
(3) Running hours
(4) Real time hours
(5) Modify
> ? c @ >
< O ; R \ ; 9 P 8 B ; 6 7 8 9
Dependant on the operating conditions, it can be necessary to modify the service intervals. To do so,
use the Scroll keys to select the value to be modified. A screen similar to the one below appears:
Press the Enter key. Following screen appears:
Modify the value as required using the Ĺ or Ļ scroll key and press the Enter key to confirm.
Running hours can be modified in steps of 100 hours, real time hours can be modified in
>
b < : i
steps of 1 hour.
1904 0504 83 ϱϭ

Instruction book
> > ? c @ >

b 5 : ;
Text on image
(1) Next service

(2) Level
(3) Running hours
(4) Actual
In the example above, the A Service level is programmed at 4000 running hours, of which 0 hours have
passed.
?
½ ; B : < \
The History screen shows a list of all service actions done in the past, sorted by date. The date at the
top is the most recent service action. To see the details of a completed service action (e.g. Service
level, Running hours or Real time hours), use the Scroll keys to select the desired action and press
the Enter key.
¢ ? >
< 9 : < 7 6 8 9 7
ϱϮ 1904 0504 83

Instruction book
(1) Scroll keys

(2) Enter key
(3) Escape key
> @ d >
9 A ; < 9 : 6 < ; 9 :
¨ §
@
A 9 : ; < 9
, it is possible to program two

¼ @ ? > ? ] ? > V > @ @ c > ? > ? ? c > ?
9 < S 6 B B ? >
N < O A

• Highlight the action key Menu using the Scroll keys and press the Enter key. Following screen
appears:
Text on image
(1) Menu
(2) Regulation
• Activate the menu by pressing the enter key. A screen similar to the one below appears:
1904 0504 83 ϱϯ

Instruction book
Text on image
(1) Regulation
(2) Setpoint 1
(3) Indirect stop level 1
(4) Direct stop level 1
(5) Setpoint 2
(6) Modify
• The screen shows the actual settings.

To modify the settings, move the cursor to the action button Modify and press the Enter
key. Following screen appears:
• The first line of the screen is highlighted. Use the Scroll keys (1) to highlight the setting to
be modified and press the Enter key (2). Following screen appears:
The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the Ĺ
or Ļ key of the Scroll keys to modify the settings as required and press the Enter key to accept.
If necessary, change the other settings as required in the same way as described above.
Indirect stop: occurs when the pressure rises to the pre-set Indirect stop setpoint (= setpoint plus
Indirect stop level). The motor will decelerate to minimum speed and the compressor will switch to
unloaded condition.
Direct stop: occurs when the compressor runs at a speed between minimum and maximum and the net
pressure rises above the direct stop setpoint (= setpoint plus Direct stop level).
Both settings (Indirect stop level and Direct stop level) are programmable, see section Programmable
settings.
ϱϰ 1904 0504 83

Instruction book
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
> @ d c > ?
9 A ; < 9 4 9 : ½ ; B : < \
@
A 9 : ; < 9
To call up the last shut-down and last emergency stop data.
? @ > ? >
N < O A

1904 0504 83 ϱϱ

Instruction book
• Using the Scroll keys, move the cursor to the Event History icon (see above, section Menu
icon)
• The list of last shut-down and emergency stop cases is shown.
~ s n q s o p ¾ r p n m m s s o
• Scroll through the items to select the desired shut-down or emergency stop event.
• Press the Enter key to find the date, time and other data reflecting the status of the
compressor when that shut-down or emergency stop occurred.
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
ϱϲ 1904 0504 83

Instruction book
> @ d >
9 A ; < 9 : : ; 9 P B
¨ §
@
A 9 : ; < 9
To display and modify a number of settings.
? @ > ? >
N < O A

• Next, move the cursor to the Settings icon (see above, section menu icon).using the Scroll keys.
This screen shows again a number of icons. By default, the User Password icon is selected. The status
bar shows the description that corresponds with the selected icon. Each icon covers one or more items ,
such as
• Access level
• Elements
• Dryer
• Fan
• Converter(s)
• Filter(s)
• Motor/Starter
• General
• Automatic restart after voltage failure (ARAF)
• Network
• Regulation
• Remote
For adapting certain parameters, a password may be necessary.
Example: Selecting the General Settings icon gives the possibility to change e.g. the
language, the date, the date format, etc.:
1904 0504 83 ϱϳ

Instruction book
Text on image
(1) General
(2) Language used
(3) Time
(4) Date
(5) Date format
(6) Modify
• To modify, select the Modify button using the Scroll keys and press the Enter key.
• A screen similar to the one above is shown, the first item (Language) is highlighted. Use the
Ļ key of the Scroll keys to select the setting to be modified and press the Enter key.
• A pop-up screen appears. Use the Ĺ or Ļ key to select the required value and press the Enter
key to confirm.
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
ϱϴ 1904 0504 83

Instruction book
> @ d
9 A ; < 9 Z 9 R <
@
A 9 : ; < 9
To show the Atlas Copco internet address.
? @ > ? >
N < O A

• Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon).
• Press the Enter key. The Atlas Copco internet address appears on the screen.
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
1904 0504 83 ϱϵ

Instruction book
> @ d > > _ > ?

9 A ; < 9 k : ; S
@
A 9 : ; < 9
• To program time-based start/stop commands for the compressor

• To program time-based change-over commands for the net pressure band
• Four different week schemes can be programmed.
• A week cycle can be programmed, a week cycle is a sequence of 10 weeks. For each week
in the cycle, one of the four programmed week schemes can be chosen.
? ? > ? _
Z S 6 < : 8 9 : S 8 i
In the Elektronikon you can select different timers on one day.(up to 8 actions). It
is however not possible to program 2 actions at the same time. The solution:
leave at least 1 minute in between 2 actions.
Example: Start Compressor: 5.00 AM, Pressure Setpoint 2: 5.01 AM (or later).
? @ > ? >
N < O A
Starting from the Main screen (see Main screen),

• Move the cursor to the action button Menu and press the Enter key. Use the Scroll buttons
to select the Timer icon.
Text on figure
(1) Menu
(2) Week Timer
• Press the Enter key on the controller. Following screen appears:
ϲϬ 1904 0504 83

Instruction book
(1) Week Timer

(2) Week Action Schemes
(3) Week Cycle
(4) Status
(5) Week Timer Inactive
(6) Remaining Running Time
The first item in this list is highlighted in red. Select the item requested and press the Enter key on the
controller to modify.
? ? ] > > _ @ > >
N < P 8 S S ; 9 P B U S B
• Select Week action schemes and press Enter. A new window opens. The first item in the list
is highlighted in red. Press the Enter key on the controller to modify Week Action Scheme 1.

(2) Week Action Scheme 1
• A weekly list is shown. Monday is automatically selected and highlighted in red. Press the
Enter key on the controller to set an action for this day.

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
1904 0504 83 ϲϭ

Instruction book
(6) Friday
(7) Saturday
(8) Sunday
• A new window opens. The Modify action button is selected. Press the enter button on the
controller to create an action.
(1) Monday
(2) Modify
• A new pop-up window opens. Select an action from this list by using the Scroll keys on the
controller. When ready press the Enter key to confirm.
(1) Monday
(2) Actions
(3) Remove
(4) Start
(5) Stop
(6) Pressure Setpoint 1
(7) Modify
• A new window opens. The action is now visible in the first day of the week.
ϲϮ 1904 0504 83

Instruction book
(1) Monday
(2) Start
(3) Save
(4) Modify
• To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A pop-up window opens. Use the Ĺ or Ļ key of Scroll keys to modify the values of the hours.
Use the ĸ or ĺ Scroll keys to go to the minutes.
(1) Monday
(2) Time
(3) Save
(4) Modify
1904 0504 83 ϲϯ

Instruction book
• Press the Escape key on the controller. The action button Modify is selected. Use the Scroll
keys to select the action Save.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A new pop-up window opens. Use the Scroll keys on the controller to select the correct
actions. Press the Enter key to confirm.
(1) Monday
(3) Are you sure?
(4) No
(5) Yes
(6) Save
(7) Modify
Press the Escape key to leave this window.

• The action is shown below the day the action is planned.
ϲϰ 1904 0504 83

Instruction book

(2) Monday - Start
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
Press the Escape key on the controller to leave this screen.
? ? > ] > > _ @ @ >

N < P 8 S S ; 9 P : U \ 7
A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed
week schemes can be chosen.
• Select Week Cycle from the main Week Timer menu list.
(1) Week Timer

(3) Week Cycle
(4) Status
• A list of 10 weeks is shown.
(1) Week Cycle

(2) Week 1
1904 0504 83 ϲϱ

Instruction book
(3) Week 2
(4) Week 3
(5) Week 4
(6) Modify
Press twice the Enter key on the controller to modify the first week.
• A new window opens. Select the action, example: Week Action Scheme 1
(1) Week Cycle

(2) Week 1
(6) Modify
• Check the status of the Week Timer

Use the Escape key on the controller to go back to the main Week Timer menu. Select the
status of the Week Timer.
(1) Week Timer

(3) Week Cycle
(4) Status
• A new window opens. Select Week 1 to set the Week Timer active.
ϲϲ 1904 0504 83

Instruction book
(1) Week Timer

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

(3) Week Cycle
(4) Status
• Press the Escape key on the controller to go to the main Week Timer menu. Select
Remaining Running Time from the list and press the Enter key on the controller to Modify.
1904 0504 83 ϲϳ

Instruction book
(1) Week Timer

(3) Week Cycle
(4) Status
• This timer is used when the week timer is set and for certain reasons the compressor must
continue working, for example, 1 hour, it can be set in this screen. This timer is prior to the
Week Timer action.
(1) Week Timer

(2) Week action schemes
¢ ? >
< 9 : < 7 6 8 9 7
> @ d >
9 A ; < 9 X B :
ϲϴ 1904 0504 83

Instruction book
or
@
A 9 : ; < 9
• To carry out a display test, i.e. to check whether the display and LEDs are still intact.
? @ > ? >
N < O A

• Move the cursor to the action button Menu and press the enter key (2), following screen appears:
• Using the scroll keys (1), move the cursor to the test icon (see above, section Menu icon)
• Press the enter key (2), following screen appears:
• The safety valve test can only be performed by authorized personnel and is protected by a
security code.
• Select the item display test and press the enter key. A screen is shown to inspect the display,
at the same time all LED's are lit.
1904 0504 83 ϲϵ

Instruction book
¢ ? >
< 9 : < 7 6 8 9 7
(1) Scroll keys

(2) Enter key
(3) Escape key
> @ d ] ?
9 A ; < 9 N 8 B B < O
@
A 9 : ; < 9
If the password option is activated, it is impossible for not authorized persons to modify any setting.
? @ > ? >
N < O A
Starting from the Main screen (see Main screen),

• Move the cursor to <Menu> and press the Enter key (2). Following screen appears:
• Using the Scroll keys, select the <Settings> icon (see section Modifying general settings)
ϳϬ 1904 0504 83

Instruction book
• Move the cursor to the Password icon (see above, section Menu icon)
• Select <Modify> using the Scroll keys and press the Enter key. Next, modify the password as required.
All Elektronikon controllers have a built-in web server that allows direct connection to the company
network or to a dedicated PC via a local area network (LAN). This allows to consult certain data and
settings via a PC instead of via the display of the controller.
= > ? >
: : ; 9 P B : 8 : O
Make sure you are logged in as administrator.

• Use the internal network card from your computer or a USB to LAN adapter (see picture below).
¿ { À p n Á w Â ~ p s m
• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).
1904 0504 83 ϳϭ

Instruction book
¢ ? > > ] ? _ @ ?
< 9 R ; P A 8 : ; < 9 < R : U 9 : < 8 O
• Go to My Network places (1).
• Click on View Network connections (1).
• Select the Local Area connection (1), which is connected to the controller.
• Click with the right button and select properties (1).
ϳϮ 1904 0504 83

Instruction book
• Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck
other properties if they are checked. After selecting TCP/IP, click on the Properties button (2)
to change the settings.
• Use the following settings:

• IP Address 192.168.100.200
• Subnetmask 255.255.255.0
Click OK and close network connections.
¢ ? > ] > > ? c > ?
< 9 R ; P A 8 : ; < 9 < R : U T B
¢ ? > > ] > > ? @ >

< 9 R ; P A : U T ; 9 : R 8
The internal web server is designed and tested for Microsoft® Internet Explorer 6,
7 and 8. Other web browsers like Opera and Firefox do not support this internal
web server. When using Opera or Firefox, a redirect page opens. Click on the
hyperlink to connect to the download server from Microsoft® to download the
latest version of Internet Explorer, and install this software
• When using Internet Explorer:

Open Internet Explorer and click on Tools - Internet options (2).
1904 0504 83 ϳϯ

Instruction book
• Click on the Connections tab (1) and then click on the LAN settings button (2).
• In the Proxy server Group box, click on the Advanced button (1).
ϳϰ 1904 0504 83

Instruction book

• In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses
can be given but they must be separated with semicolons (;).
Example: Suppose that you already added two IP addresses (192.168.100.1 and
192.168.100.2). Now you add 192.168.100.100 and separate the 3 IP addresses by putting
semicolons between them (1) (see picture). Click OK (2) to close the window.
> ] > @ ? > ?

Ã ; ; 9 P : U < 9 : < 7 7 O 8 : 8
1904 0504 83 ϳϱ

Instruction book
All screen shots are indicative. The number of displayed fields depends on the
selected options.
• Open your browser and type the IP address of the controller you want to view in your
browser (in this example http://192.168.100.100). The interface opens:
c
b 8 ; P 8 : ; < 9 8 9 O < 6 : ; < 9 B
• The banner shows the compressor type and the language selector. In this example, three
languages are available on the controller.
• On the left side of the interface you can find the navigation menu (see picture
below). If a license for ESi is foreseen, the menu contains 3 buttons.
• Compressor (or machine): shows all compressor settings.
• Es: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure units.
ϳϲ 1904 0504 83

Instruction book

¢ ? > ? >
< S 6 B B < B : : ; 9 P B
All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest
and it will be displayed. Only the machine status is fixed and cannot be removed from the main screen.
Y 9 8 7 ?
< A 9 : B
Lists all current counter values from controller and compressor.
Z 9 R < B : 8 : A B
Machine status is always shown on the web interface.
[ ; P ; : 8 7 ; 9 6 A : B
Lists all Digital inputs and their status.
1904 0504 83 ϳϳ

Instruction book
[ ; P ; : 8 7 < A : 6 A : B
Lists all Digital outputs and their status.
> @ ? > @
6 ; 8 7 6 < : : ; < 9 B
Lists all special protections of the compressor.
> ? c @ >
; 6 7 8 9
Displays all levels of the service plan and their status. This screen shot underneath only shows the
running hours. It is also possible to show the current status of the service interval.
@ ? > > @ ? > ?

4 B 9 < 9 : < 7 7
If an ESi license is provided, the ES button is displayed in the navigation menu. At the left all
compressors in the ES are shown. At the right the ES status is shown.
ϳϴ 1904 0504 83

Instruction book
w ~ n r s { r m s s o
¢ ? > ? Ä ?
< S 6 B B < S < : <
Å ¡ Æ ¡ Ç È Å É ¡ Æ ¡
Ê Ê Ê
Set-point 1 and 2, Workplace compressors bar(e) 4 7 13

Set-point 1 and 2, Workplace compressors psig 58 100 188
Set-point 1 and 2, Workplace Full-Feature bar(e) 4 6.8 12.8
compressors
Set-point 1 and 2, Workplace Full-Feature psig 58 99 186
compressors
Indirect stop level bar 0.1 0.3 1
Indirect stop level psi 1.45 4.35 14.5
Direct stop level bar 0.3 1 1.5
Direct stop level psi 4.35 14.5 21.8
Proportional band % 6 10 15
Integration time sec 5 6 10
? > > ?
N 8 8 S : B
Å ¡ Æ ¡ Ç È Å É ¡ Æ ¡
Ê Ê Ê
Minimum stop time sec 5 5 30

Power recovery time sec 10 10 3600
Restart delay sec 0 0 1200
Communication time-out sec 10 30 60
Fan motor starts per day (air-cooled 1 240 240
compressors)
1904 0504 83 ϳϵ

Instruction book
? > @
N < : : ; < 9 B
Å ¡ Æ ¡ Ç È Å É ¡ Æ ¡
Ê Ê Ê
Compressor element outlet temperature ˚C 50 110 119

(shut-down warning level)
Compressor element outlet temperature ˚F 122 230 246
(shut-down warning level)
Compressor element outlet temperature ˚C 111 120 120
(shut-down level)
Compressor element outlet temperature ˚F 232 248 248
(shut-down level)
> @ @ ? > @ ? > ? > @ ? > ?

6 ; R ; 6 < : : ; < 9 B R < A 7 7 j 8 : A < S 6 B B @ @ ? > @ ? ] > ? @ > @ ? > ?

6 ; R ; 6 < : : ; < 9 B R < 8 : < < 7 O < S 6 B B < B
Å ¡ Æ ¡ Ç È Å É ¡ Æ ¡
Ê Ê Ê
Cooling water inlet temperature (warning ˚C 0 50 99

level)
Cooling water inlet temperature (warning ˚F 32 122 210
level)
Cooling water outlet temperature (warning ˚C 0 60 99
level)
Cooling water outlet temperature (warning ˚F 32 140 210
level)
> ? c @ >
; 6 7 8 9
The built-in service timers will give a Service warning message after their respective preprogrammed
time interval has elapsed.
For specific data, see section Preventive Maintenance.
Consult Atlas Copco if a timer setting needs to be changed. The intervals must not exceed the nominal
intervals and must coincide logically. See section Modifying general settings.
> ?
X S ; 9 < 7 ?
X S 4 5 6 7 8 9 8 : ; < 9
ARAVF Automatic Restart After Voltage Failure. See section Elektronikon regulator.
Is the period within which the voltage must be restored to have an automatic
Power recovery restart. Is accessible if the automatic restart is activated.
time To activate the automatic restart function, consult Atlas Copco.
ϴϬ 1904 0504 83

Instruction book
4 5 6 7 8 9 8 : ; < 9
Ë ¡
This parameter allows to programme that not all compressors are restarted at
Restart delay the same time after a power failure (ARAVF active).
The recommended minimum setting is 70 ˚C (158 ˚F). For testing the
Compressor temperature sensor
element outlet the setting can be decreased to 50 ˚C (122 ˚F). Reset the value after testing.
The regulator does not accept inconsistent settings, e.g. if the warning level is
programmed
at 95 ˚C (203 ˚F), the minimum limit for the shut-down level changes to 96 ˚C
(204 ˚F). The
recommended difference between the warning level and shut-down level is 10
˚C (18 ˚F).
Is the time period during which the warning signal must exist before the warning
Delay at signal message appears.
Is the time period after starting which must expire before generating a warning.
Delay at start The setting should be less than the setting for the delay at signal.
Once the compressor has automatically stopped, it will remain stopped for the
Minimum stop minimum stop time, whatever happens with the net air pressure.
time
Proportional The settings for the Proportional band and integration time are determined by
band and experiment.
integration time Altering these settings may damage the compressor. Consult Atlas Copco.
1904 0504 83 ϴϭ

Instruction book
> @ ?
[ B ; 6 : ; < 9
A large part of the energy required for any compression process is transformed into heat. For GA
oil- injected screw compressors, the major part of the compression heat is dissipated through the oil
system. The Atlas Copco energy recovery (ER) systems are designed to recover most of the above-
mentioned heat by transforming it into warm or hot water without any adverse influence on the
compressor performance. The water can be used for diverse applications.
¢ >
< S 6 < 9 9 : B
The energy recovery system is completely integrated and mainly comprises:

Stainless steel oil/water heat exchanger
Ì
Selector handle (V1) to enable/disable Energy Recovery

Ì
Thermostatic by-pass valve for energy recovery heat exchanger(s) (BV2)

Ì
Two temperature sensors for water inlet and outlet control (3 and 4)
Ì
The necessary bolts, flexibles, etc.

Ì
> ? ? > @ c > ?

4 9 P \ < \ A 9 ; : Í 4 j A 9 ; : Î
· r o n ~ n o s o p n p ³ s } o r p
ϴϮ 1904 0504 83

Instruction book
> > ? > @ > >

R 9 [ B ; P 9 8 : ; < 9
1 Water inlet pipe

2 Water outlet pipe
3 Temperature sensor, water inlet pipe
4 Temperature sensor, water outlet pipe
5 Oil drain plug
6 Oil line from compressor oil separator vessel to ER unit
7 Oil line from ER unit to oil filter housing
BV2 Location of heat exchanger by-pass valve (BV2)
HE Heat exchanger
V1 Selector valve
AR Oil separator vessel
OF Oil filter housing
BV1 Location of oil cooler bypass valve (BV1)
>
; 7 O ; 9 B : 8 7 7 8 : ; < 9
The main components are assembled ex-factory as a compact unit which fits inside the bodywork
of the compressor. Consult Atlas Copco for installing and connecting the energy recovery unit.

= >
9
> ?
8 7

The energy recovery systems can be applied as low temperature rise/high water flow systems or
as high temperature rise/low water flow systems.
] > > ? ? > ? > Ä ] > ? ] >
< : S 6 8 : A ; B U ; P U 8 : R 7 < B \ B : S B
e
For this type of application, the temperature difference between the water in the energy recovery
system and the compressor oil is low. As a consequence, a high water flow is needed for maximum
energy recovery.
Example: The heated water is used to keep another medium at a moderately high temperature,
in a closed circuit, e.g. central heating.
> > ? ? > ? > Ä ] > ? ] >
½ ; P U : S 6 8 : A ; B U ; P U 8 : R 7 < B \ B : S B
For this type of application, a high water temperature rise in the energy recovery system is
obtained, which consequently brings on a low flow rate.
Example: An open circuit where cold water from a main supply is heated by the energy recovery
system for use in a factory, e.g. pre-heating of boiler feed water.
> @ c > ? ] > ? ]
< \ 8 : R 7 <
For the references, see section Energy recovery data.

The recovery water enters the unit at inlet connection (1). In heat exchanger (HE) the compression
heat is transferred from the compressor oil to the water. The water leaves heat exchanger (HE) via
outlet connection (2).
1904 0504 83 ϴϯ

Instruction book
> ? ? > V ? > > ? @ > ] > ? @ ? @

k 8 : A ; S 9 : B R < 7 < B O 8 : ; A ; : B
The use of a closed water circuit minimises make-up water requirements. Therefore, the use of soft
or even demineralised water is economically feasible and eliminates the problem of scale deposits.
Although the heat exchanger is made of stainless steel, the water circuit connected to the compressor
may require corrosion inhibitors. Consult section Cooling water requirements to minimise problems due
to bad water quality. If in any doubt, consult Atlas Copco.
Add an anti-freeze product such as ethylene-glycol to the water in proportion to the expected
temperature to avoid freezing.
> ? ? > V ? > > ? > ] > ? @ ? @
k 8 : A ; S 9 : B R < < 6 9 8 : ; A ; : B
For open, non-recirculation water circuits, the major problems usually encountered are related to deposit
control, corrosion control and microbiological growth control. To minimize these problems, the water
should meet a number of requirements. See section Cooling water requirements. If in any doubt,
consult Atlas Copco.
= > > ?
9 8 7
The compressor oil flow is controlled by two thermostatic valves (BV1 and BV2), ensuring reliable
compressor operation and optimum energy recovery.
> > > @ ?
[ : 8 ; 7 O O B ; 6 : ; < 9
Bypass valve (BV1) is integrated in the oil filter housing of the compressor and controls the oil flow
through the main oil cooler (Co) of the compressor. Bypass valve (BV2) controls the oil flow through the
oil/water heat exchanger (HE) of the ER unit. Both valves consist of an insert (thermostat) mounted in a
housing.
ϴϰ 1904 0504 83

Instruction book
l n t r m n n ~ m s n m t r p ³ s o s m m s n q s m p s
> > ? > @ > > > > ? > @ > >
R 9 [ B ; P 9 8 : ; < 9 R 9 [ B ; P 9 8 : ; < 9
Thermostatic bypass valve of

BV2 ER unit OF Oil filter
Oil/water heat exchanger (ER
HE unit) AR Oil separator vessel
Thermostatic bypass valve in
E Compressor element BV1 oil filter housing
Co Oil cooler (compressor) Ca Aftercooler (compressor)
1 Water inlet 2 Water outlet
BV2 starts closing the bypass line over the heat exchanger (HE) at the lower limit of its temperature
range. At the upper limit of its temperature range, the bypass line is completely closed and all the oil
flows through the ER heat exchanger.
On compressors versions with a maximum pressure lower than 13 bar (175 psi), BV2 starts opening at
40 ˚C (104 ˚F) and is completely open at 55 ˚C (131 ˚F).
On compressors with a maximal pressure of 13 bar (175 psi), BV2 starts opening at 60 ˚C (140 ˚F)
and is completely open at 75 ˚C (167 ˚F).
The housing of BV2 is provided with a special wheel (V1), allowing to control the energy recovery
system.
As can be seen on the ER label, the ER unit is integrated in the oil circuit and will recover energy
when the wheel is completely turned in clockwise.
When the wheel is turned out anticlockwise, the heat exchanger (HE) is bypassed and no energy
will be recovered.
1904 0504 83 ϴϱ

Instruction book
| s p r n q q s ³ n } r o n À z ¹ t r p ³ ³ o s z Ï ¸ p ~ r s ~ s º
s
Attention: It is only allowed to turn the handle completely in or out. No in-

between position is allowed.
The oil cooler bypass valve (BV1) starts closing the bypass line and opening the oil supply line from the
main oil cooler (Co) at the lower limit of its temperature range. At the upper limit of its temperature
range, the bypass line is completely closed and all the oil flows through the main oil cooler.
BV1 must have a higher opening temperature (set point) than BV2 in order to prevent the heat from
being dissipated in the compressor oil cooler (Co) before the warm oil is fed to the oil/water heat
exchanger when using the compression heat as source for energy recovery.
Thermostat BV1 starts to open at 60 ˚C (140 ˚F) and is completely open at 75 ˚C (167 ˚F).
> ? ? > @ c > ? > > > > ? ]
4 9 P \ < \ B \ B : S ; 9 A B Í B O 8 ; 9 P Î
The wheel (V1) of BV2 (bypass valve of the HE) is totally .

? > @ @ _ ] >
: A 9 O ; 9 7 < ; B
Compressor start-up
ϴϲ 1904 0504 83

Instruction book
When the compressor is started up from cold, the oil temperature will be low. Bypass valve (BV2) shuts
off the oil supply from the heat exchanger (HE) and bypass valve (BV1) shuts off the oil supply from the oil
cooler (Co) to prevent the compressor oil from being cooled. The oil flows from the oil separator vessel
(AR) through the oil filter(s) (OF) back to compressor element (E).
All energy input is used to rapidly warm up the compressor oil. No energy is recovered.
Ì
Maximum energy recovery

As soon the oil temperature reaches the set point (opening temperature) of bypass valve (BV2), the
valve starts closing off the bypass over the heat exchanger (HE) oil line, while gradually allowing the oil to
flow through the heat exchanger (HE). As the oil temperature rises to approx. 15 °C above the set
point, all the oil passes through the heat exchanger. The exchange of heat between the compressor
oil and the heat recovery water is maximum. The oil from the heat exchanger outlet flows via oil filter
(OF), oil stop valve(Vs - if present), compressor element (E) and separator (AR) back to the inlet of
heat exchanger (HE). Bypass valve (BV1) bypasses the oil cooler (Co) as long as the oil temperature
remains below its set point.
Operation principle at different loads:
Ì
Low consumption of recovered energy In this case, the temperature of the oil leaving heat
exchanger (HE) would become too high for the oil to be injected into compressor element (E).
Oil cooler bypass valve (BV1) will open the supply line to the compressor oil cooler to allow the
hot oil to be cooled in cooler (Co).The amount of energy supplied to the water is adapted to the
need of energy.
Ì
Recovery water flow too high/temperature too low In this case, bypass valve (BV2) will open
the bypass line of the oil separator vessel, allowing colder oil from heat exchanger (HE) to be
mixed with hot oil from separator (AR). Energy is transferred from the compressor oil to the
water, but at a relatively low temperature level.
> ? ? > @ c > ? > >
4 9 P \ < \ B \ B : S 9 < : ; 9 A B
The handle (V1) is completely turned out anti-clockwise.

The oil circuit is the same as without installation of the energy recovery system.
No energy is recovered.
This situation should be considered as exceptional, e.g. in case of maintenance of the energy recovery
system or when no energy is required for a long period.
On fixed speed compressors, run the unit unloaded for a few minutes before isolating the energy
recovery system from the compressor.
> ? > ?
: < 6 6 ; 9 P : U A 9 ; : R < 8 7 < 9 P 6 ; < O
In case of an open water system and/or if freezing temperatures can be expected, isolate the
compressor water system and blow it through with compressed air.
1904 0504 83 ϴϳ

Instruction book
¢ ? > ?
< S 6 B B < < ; 7
For references used consult section Energy recovery unit.

¼ @ >
; 7 U 8 9 P i
Check if handle (V1) is totally turned in clockwise (energy recovery in use).

C D
Run the unit until warm. Stop the unit, switch off the isolating switch and close the air outlet valve
E D
of the compressor.
Depressurize the compressor and drain the oil by opening the drain valve on the oil separator
F D
vessel. See Oil and oil filter change.

Resume oil change as described in section Oil and Filter Change in this book.
G D
> ? @ c c >
X U S < B : 8 : ; T \ 6 8 B B 8 7 B
The inserts (thermostats) must be replaced by new ones when abnormal function is noticed. Examples:
regulating temperature is not within the normal range, ER heat exchanger remains cold.
> > @ > ?
½ 8 : 5 U 8 9 P Í ½ 4 Î
If the temperature rise over the energy recovery system declines over a period of time with the same
basic working conditions, the heat exchanger should be inspected. To clean the oil side, soak the heat
exchanger in a degreasing solution. To remove scale formation in the water compartment, a proper
descaling process should be applied. Consult Atlas Copco.
> > ? > @ > @

R 9 < 9 O ; : ; < 9 B
See section Reference conditions and limitations.

> @ c > ] ? _ ? > ? >
4 R R : ; < ; 9 P 6 B B A
Consult section Compressor data for the normal working pressure..

] > ? > ? > > > > @ > ?
8 5 ; S A S 8 7 7 < O 6 B B A < R : U U 8 : 5 U 8 9 P
Oil side 15 bar (217 psi)

Water side 10 bar (145 psi)
> >
8 O ; 9 P B : : ; 9 P B
I
> ? d > ] > > ? ? > @ > ? > > > _ ? _
9 8 O O ; : ; < 9 : < < : U O 8 : 8 : U R < 7 7 < ; 9 P : S 6 8 : A B 8 9 T 8 O < 9 : U 4 7 : < 9 ; < 9
O ; B 6 7 8 \ i
? ? @ >
< 8 ; j < < 7 O A 9 ; : B i
The water inlet temperature of the energy recovery system

µ
The water outlet temperature of the energy recovery system

? ] > ? @ >
< 8 : j < < 7 O A 9 ; : B i
The water inlet temperature of the energy recovery system

µ
The water outlet temperature of the energy recovery system

µ
The cooling water outlet temperature of the compressor
ϴϴ 1904 0504 83

Instruction book

< O ; R \ ; 9 P B
>
: : ; 9 P B
If the programmed warning settings for the water temperatures are exceeded, a warning indication is
shown on the Elektronikon:
Ë ¡ Æ Æ Å ¡ Æ ¡ ¡ Ð Å É ¡ Æ ¡
Ê Ê Ê
Water inlet temperature of energy recovery ˚C 0 50 99

Water inlet temperature of energy recovery ˚F 32 122 210
Energy recovery water outlet temperature ˚C 0 Depends on 99
application
Energy recovery water outlet temperature ˚F 32 Depends on 210
application
To modify a setting, consult the relevant section in the description of the Elektronikon controller.
> @ c > ? > > > ?

< 8 T 7 9 P \
The recoverable energy can be calculated from:

RECOVERED ENERGY (kW) = 4.2 x water flow (l/s) x water temperature rise
(°C) In the tables below, typical examples are given, except for the recovered
energy.
? ] > > ? ? > ? > Ä ] > ? ] >
[ 8 : 8 R < 7 < : S 6 8 : A ; B U ; P U 8 : R 7 < B \ B : S B
Ñ ¡ Ò Ó Ô Õ Ö Ò Ó Õ Ö
Recoverable energy kW 32.5 39.5

Recoverable energy hp 44.2 53.7
Water flow l/min 46.6 56.6
Water flow cfm 1.7 2.0
Temperature at inlet ˚C 50 50
Temperature at inlet ˚F 122 122
Temperature at outlet ˚C 60 60
Temperature at outlet ˚F 140 140
? > > ? ? > ? > Ä ] ] > ? ] >

[ 8 : 8 R < U ; P U : S 6 8 : A ; B 7 < 8 : R 7 < B \ B : S B
Ñ ¡ Ò Ó Ô Õ Ö Ò Ó Õ Ö
Recoverable energy kW 32.5 39.5

Recoverable energy hp 44.2 53.7
Water flow l/min 6.5 7.9
Water flow cfm 0.2 0.3
Temperature at inlet ˚C 20 20
Temperature at inlet ˚F 68 68
Temperature at outlet ˚C 92 92
Temperature at outlet ˚F 198 198
1904 0504 83 ϴϵ

ϵϬ
COOLING AIR COOLING AIR
212 OUTLET OF OUTLET OF
DRYER COMPRESSOR & VSD DRIVE
116 3 L 28 175 3
COMPRESSOR AIR
OUTLET G1 1/2'' F
28
3
A
1800
3
COOLING AIR
1285
INLET OF
|
746
COMPRESSOR
r
H
& AIR INTAKE

46(2x)
380
C
s
o

33,5(2x)
r
n
182
156
o
380 295,5

200(2x) 690(2x) 200(2x) 301,5(2x) 72 730
3(4x)
92(4x)
v
970 3
1765 3
w
AMBIENT
SENSOR
x
B MANUAL DRAIN OF
y
COOLING AIR COOLING AIR C(1:2) AFTER-COOLER G1/4'' F
INLET OF
z
INLET OF
DRYER CUBICLE AUTOMATIC DRAIN TUBE
{
275 220 *886 MANUAL DRAIN OF 8 OF AFTER-COOLER
|
DRYER G1/4'' F
}
AUTOMATIC DRAIN
~
TUBE 8 OF DRYER
50
p
n
v
297
VIEW A
50
w
100 ELECTRICAL CABLE 420 86,5

PASSAGE 65(2x)
245(2x)
811(2x)

523
116
z
W
{
88,5 131(2x) 283(2x)
|
150
25(2x)
131(2x)
610
6,5
70,5 370
79,5(3x)
660,5 295(2x) 295(2x)
715(2x)
50 80
VIEW B COMPRESSOR MOUNTING
433,5 890 3 HOLES 13(4x)
1665
20
1132,5
CENTER OF GRAVITY MASS
W ITH DRYER W ITHOUT DRYER
W ITH DRYER W ITHOUT DRYER
TYPE L H W L H W
GA37 VSD
GA45 VSD
Dimensions in mm: +/- 50 mm MASS in Kg(Oil included) : +/-50 Kg
3
COOLING AIR
Tolerances, if not indicated, according to:
INLET OF
930
VSD DRIVE ATLAS COPCO STANDARD CLASS

Name Class
DIMENS. DRWG. GA37-45 VSD Confidentiality
acc. to 1102 K
Material
Not Applicable Internal
Treatment
Not Applicable INV
Scale Family Drawing owner
1:10 A1 Compare
Drawn by INEamp Blank nr. Replaces PNE
00 00.00 Version Drwg Blank wt Fini wt. Sheet 1 / 1
9096999106 STATUS Kg 0 Kg Designation
Posi- Des checked. Prod checked. Approved. Date
Ed Modified from D ate In tr./Appd. Parent 3D model Ed . Version 3D Approved
tion 23-04-2014 9096999106
1904 0504 83

Instruction book

Instruction book
Centre of gravity
× Ø Ù Ú Û Ü Ý Þ Ü × Ø Ù Ú Û Ü Ý Þ Ü × Ø Ù Ú Û Ü Ý Þ Ü × Ø Ù Ú ß à Ù × Ø Ù Ú ß à Ù × Ø Ù Ú ß à Ù
Û Ü Ý Þ Ü Û Ü Ý Þ Ü Û Ü Ý Þ Ü
Ý â Þ ã ä å ã ä å
GA 37 VSD mm 955 440 800 915 435 765

GA 37 VSD in 376 173 315 360 171 301
GA 45 VSD mm 955 440 800 915 435 765
GA 45 VSD in 376 173 315 360 171 301
Dimensions +/- 50 mm (1.97 in) Weight
Ý â Þ æ ç Ø Ù ä Þ Ø è Ú Ù é à ç Ø Ù × Ø Ù Ú Û Ü Ý Þ Ü ä Þ Ø è Ú Ù é à ç Ø Ù × Ø Ù Ú ß à Ù Û Ü Ý Þ Ü
GA 37 VSD kg 1227 1142

GA 37 VSD lb 2705 2518
GA 45 VSD kg 1290 1200
GA 45 VSD lb 2844 2646
Weights (oil included) +/- 50 kg (110 lb)

Dimensions and weights in tables for air cooled units, 380V-460V.
1904 0504 83 ϵϭ

Instruction book
ê ë ì í î ï ð ð ë î î ë ë ì ï ñ ò ì í ó ï
ô õ ö ÷ ø ù ú ú õ ø ø õ õ ö ù û ü ö ÷ ý ù
(1) Air cooling

(2) Water cooling
(3) The direction of the cooling flows may never be inverted
ϵϮ 1904 0504 83

Instruction book
ï ð ÿ î í ë
þ
1 Install the compressor unit on a solid, level floor suitable for taking the weight.
2 Position of the compressed air outlet valve.
The pressure drop over the air delivery pipe can be calculated from:
ǻp = (L x 450 x Qc 1.85) / (d5 x P), with
d = inner diameter of the pipe in mm
ǻp = pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi))
3 L = length of the 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.
Ventilation: the inlet grids and ventilation fan should be installed in such a way that any
recirculation
of cooling air to the compressor or dryer is avoided. The maximum air velocity through
the grids is
5 m/s (16.5 ft/s).
The maximum allowed pressure drop in ventilation ducts before or after the compressor
is 30 Pa.
The maximum air temperature at the compressor intake is 46 ˚C (115 ˚F), the minimum
temperature
is 0 ˚C (32 ˚F).
• For air-cooled compressors and ventilation alternatives 1 and 3, the ventilation
capacity
required to limit the compressor room temperature can be calculated as follows:
• For compressors without dryer:
Qv = 1.06 N/ǻT
• For compressors with dryer:
Qv = (1.06 N + 1.2 D)/ǻT
with
4 Qv = required ventilation capacity in m3/s
N = nominal power of the compressor motor in kW
D = electric power of the dryer in kW
ǻT = temperature increase in the compressor room in °C
For ventilation alternatives 2 and 4: the fan capacity should match the compressor fan
capacity at a pressure head equal to the pressure drop over the air ducts.
• For water-cooled compressors, the ventilation capacity required to limit the
compressor
room temperature can be calculated from:
• For compressors without dryer:
Qv = 0.13 N/ǻT
• For compressors with dryer:
Qv = (0.13 N + 1.2 D)/ǻT
with
Qv = required ventilation capacity in m3/s
N = nominal power of the compressor motor in kW
D = electric power of the dryer in kW
ǻT = temperature increase in the compressor room in °C
The cooling air of the dryer can be ducted outside

1904 0504 83 ϵϯ

Instruction book

The drain pipes to the drain collector must not dip into the water of the drain
collector. Atlas Copco has oil/water separators (type OSD or OSCi) to separate the
oil from the condensate to ensure that the condensate meets the requirements of the
5
environmental codes.
Drain pipes of different compressors may not be interconnected before the
(atmospheric) collector as this can damage the electronic drains.
6 Control module with monitoring panel.
7 Power supply cable to be sized and installed by a qualified electrician.
To preserve the protection degree of the electric cubicle and to protect its components
from dust from the environment, it is mandatory to use a proper cable gland when
connecting the supply cable to the compressor.
8 Provision for energy recovery system.
Filter, type DD for general purposes. The filter traps solid particles down to 1 micron
with a max. carry-over of 0.5 mg/m3. A high-efficiency filter, type PD, maybe installed
downstream of a DD This filter traps solid particles down to 0.01 micron with a max. oil
9 carry-over of 0.01 mg/m3. If vapours and odours are undesirable, a QD type filter
should be installed downstream of the PD It is recommended to install by-pass pipes
over each filter together with ball valves, in order to the filters during service operations
without disturbing the compressed air delivery.
Install the air receiver (to be purchased separately) in a frost free room, on a solid,
level floor, suitable
for taking its weight.
For normal air consumption, the volume of the air net (receiver and piping) can be
calculated from:
V = (0.25 x Qc x P1 x T0)/(fmax x ǻP x T1), with
10 V = volume of the air net in l
Qc = free air delivery of the compressor in l/s
P1 = compressor air inlet pressure in bar(a)
fmax = maximum cycle frequency (recommended: 1 cycle/30s)
ǻP = difference between unloading pressure and loading pressure in bar
T1 = compressor air inlet temperature in K
T0 = air receiver temperature in K
11 By-pass system to by-pass the dryer during service operations (available as an option,
consult Atlas Copco).
12a Air-cooled compressors:
To prevent feedback of exhaust air into the cooling inlet, sufficient space should be
foreseen above
the unit to evacuate the exhaust air. Otherwise a duct for the exhaust air should be
installed. See alternatives 1 up to 4.
12b On water-cooled compressors:
Water flow and pressure to be adjusted depending upon local
conditions. For cooling water quality see section Cooling water
requirements.
A water shut-off valve and water drain valve should be installed by the customer in the
compressor water inlet pipe and outlet pipe. If water shut-off valves at the compressor
water inlet and outlet pipe are installed, a safety device with set pressure according to
the maximum cooling water inlet pressure (see section Reference conditions and
limitations) has to be installed between the compressor water outlet pipe and shut-off
valve. When operating the unit, the operator must ensure that the cooling water system
cannot be blocked. The above-mentioned applies also to the energy recovery cooling
water system. Remove the plastic plugs (if provided) from the compressor water pipes
and connect the pipes to the cooling water circuit.
ϵϰ 1904 0504 83

Instruction book
13 Cooling air grating, dryer

14 When a duct is foreseen on the air inlet, the ambient temperature sensor need to be
repositioned in such a way that the inlet temperature is monitored.
15 Safety valve
ò ï
The operator must apply all relevant safety precautions, including those
mentioned in this book
ë ë î ò ó ï ë í ï î ò ë
Fix speed compressors can be sold with option rain protection. With this option, this compressor can be
installed outside under a shelter, in frost free conditions. If frost might occur, the appropriate measures
should be taken to avoid damage to the machine and its ancillary equipment. In this case, and also if
operating above 1000 m (3300 ft), consult Atlas Copco.
ë ó
The compressor can be moved by a lift truck using the slots in the frame. Take care not to damage the
bodywork during lifting or transport. Before lifting, reinstall the transport securing bolts. 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.
In case of units equipped with the Lifting Device Option, it is not allowed to lift
the compressor if the canopy parts or lifting supports are not completely
installed. When the compressor is being lifted, it is also forbidden to come under
the load or to perform maintenance activities to it.
ì í ë î ò î ï ì ò î
To preserve the protection degree of the electric cubicle and to protect its
components from dust from the environment, it is mandatory to use a proper
cable gland when connecting the supply cable to the compressor.
1904 0504 83 ϵϱ

Instruction book
ý ù ø ü ý õ ù õ ú õ ø ÷ õ

ï ï î ï ÿ ï ï ð ò ë
þ
(1) Customer's installation

(2) Option dryer
(3) Star connection: All other voltages
Delta connection: 200-230V 50/60 Hz (see motor data plate for correct
(4)
connection)
(5) For Modbus communication
ë ï
The complete electrical diagram can be found in the electrical cubicle.

ð î ÿ ë ð
Provide an isolating switch.

! "
Check that the motor cables and wires inside the electric cabinet are clamped tight to their
# "
terminals.
Check the fuses. See section Electric cable size and fuses
$ "
Connect the power supply cables to terminals (1, 3 and 5) on contactor (K21).
% "
Connect the earth conductor to the earth bolt (PE).

"
&
ϵϲ 1904 0504 83

Instruction book

ê ë ì í î ï ð ð ë î ð ò ð ÿ ò ë
The Elektronikon® Graphic controller is provided with potential-free auxiliary NO contacts (NO =
normally open) (K05, K07 and K08) for remote indication of:
Manual or automatic operation (K07)
Warning condition (K08)
Shut-down condition (K05)
Maximum contact load: 10 A / 250 V AC.
Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas
Copco.
Maximum contact load: 10 A / 250 V AC.
Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas
Copco.
ê ë ì í î ï ð ð ë î ÿ ë î ë ó ì ë ï
On compressors equipped with an Elektronikon® graphic controller, see section Control mode selection.
ï ë ó ó ë ) ÿ ë î ë ó ì ë ï ð ÿ ò * ï ð ï ó ï ÿ ï +
' (
• The compressor will react to commands entered by means of the buttons on the
ë ÿ ò ó ÿ ë î ë ó +
control panel. Compressor start/stop commands via Clock function are active, if programmed.
• The compressor will react to commands from external switches. Emergency
ï ì ë ï ÿ ë î ë ó +

stop remains active. Compressor start/stop commands via Clock function are still possible.
Have the modifications checked by Atlas Copco.

Stop the compressor and switch off the voltage before connecting external
equipment. Only potential-free contacts are allowed
• The compressor is controlled via a local network. Consult Atlas Copco.

ÿ ë î ë ó +
, -
. ï ï î ò ó
Cooling water needs to fulfill certain requirements in order to avoid problems

of scaling, fouling, corrosion or bacterial growth.
In open circuit cooling towers, protective measures must be taken to avoid the
growth of harmful bacteria such as legionella pneumophila when there is a risk
of inhalation of the water droplets.
No general recommendation can encompass the effects of all combinations of the various compounds,
solids and gases typically found in cooling water in interaction with different materials. Therefore the
recommendations formulated in our Cooling Water Specifications are a general guide line for acceptable
coolant quality. However, where strict limits apply, a statement is made in the specification.
The water requirements refer to untreated water. When water is treated, some parameters will change.
Water treatments should be carried out by a specialized water treatment company, taking the
responsibility for the performance of the treated cooling water and the compatibility with the materials in
the cooling circuit. This includes not only the selection of the appropriate additives, but also the correct
application,
1904 0504 83 ϵϳ

Instruction book
monitoring of concentrations and properties, prevention of sludge formation and maintenance of the
system. This applies also to treatment with antifreeze products. They must be provided with suitable
stabilizers and inhibitors. Specifications are also depending on the type of cooling circuit (open, once
through / recirculating with tower / closed) and on the application (Standard – max 65 °C cooling water
temperature at the outlet) or Energy Recovery (water temperature up to 95 °C).
In case water is not in line with recommended values or if any doubt, consult the manufacturer.
ê ë ë ó ) ò ï î í ò î ò ì ï ï î ð
1.
í /
The effect of pH is already included in the Ryznar Stability Index (RSI - see item 4 below), but also
the pH itself is subject to limitations:
â å
Ý â Þ ß 0 1 ß ß 2 Ø ç è 3 Ý 3 Ù Þ 4 5 6 Ù Þ Ü Ø 6 2 3 7 Ù 6 ç Û 6 Ü Û 8 ç Þ Ü è Ý Ü Þ 1 ß 9 Þ Ü Ý
Single pass Containing copper : ; <

- =
; > : ; <
- =
; >
Stainless steel with carbon : ; <

- 9.3 : ; <
- 9.3
steel and / or cast iron
Stainless steel only :
- 9.3 :
- 9.3
Recirculating (with tower) Containing copper : ; <
- =
; >
not applicable
Stainless steel with carbon : ; <
- 9.3
- 9.3
Closed loop Containing copper ? ; @
- =
; > ? ; @
- =
; >
Stainless steel with carbon ? ; @

- 9.3 ? ; @
- 9.3
- 9.3 :
- 9.3
The values in are rejection limits.

* ë ó
When the system contains Zn or Al, the pH must be < 8.5.
2.
ë ò ó ð ð ë ó ï ð ë ó ð A B ò ÿ ë ÿ
' ' þ
The conductivity is expressed in ȝS/cm, the TDS in ppm.

Both parameters are related with each other. The conductivity is convenient for quick monitoring of general
water quality, but the TDS is required for calculating the RSI. If only one of both parameters is measured, an
estimation can be obtained by using a theoretical conversion factor (0.67):
TDS = conductivity x 0.67
3.
/ ò î ï ð ð
Different types of hardness are in relation with each other and together with the pH and the
alkalinity of the water they determine the equilibrium situation of the water, determined and
specified by the RSI. In addition, the calcium hardness must be limited to:
C C C E F G
6 D â â 4 6
Ý â Þ ß 0 1 ß ß 2 Ø ç è 3 Ý 3 Ù Þ 4 7 Ù 6 ç Û 6 Ü Û 8 ç Þ Ü è Ý Ü Þ 1 ß 9 Þ Ü Ý
Single pass < 500 <2

Recirculating (with tower) < 500 not applicable
Closed loop < 1000 < 50
ϵϴ 1904 0504 83

Instruction book
4.
ï H ò î ò * ó ï ñ A B
' (
The Ryznar Stability Index is a parameter for predicting whether water will tend to dissolve or
precipitate calcium carbonate. The adhesion of scaling depositions and their effect are different on
different materials, but the equilibrium of the water (scaling or corrosive) is only determined by its
actual pH value and by the saturation pH value (pHs). The saturation pH value is determined by the
relationship between the calcium hardness, the total alkalinity, the total solids concentration and the
temperature.
The Ryznar Stability Index is calculated as follows:
RSI = 2*pHs -
pH, in which
• pH = measured pH (at room temp) of the water sample
• pHs= pH at saturation
pHs is calculated from:
pHs = (9.3 + A + B) - (C +
D), in which
• A : depends on the total solids concentration
• B : depends on the water temperature at the outlet of the heat exchanger
• C : depends on the calcium hardness (CaCO3)
-
• D : depends on the HCO3 concentration or M-alkalinity
The values of A, B, C and D can be found in below table:
C C
á á
ß Ù 6 2 I Þ 4 â Þ Ü 6 Ù à Ü Þ J 6 Ú 6 Ü Û ç Þ 3 3 5 K I 2 L 6 2 Ø ç Ø Ù Ý M
C G O P P Q R S R T U V O P P Q R S R T U V
Û Ø 3 3 ß 2 9 Þ Û D N
3 ß 2 Ø Û 3
D 4 è W 2
< 30 0.1 0-1 2.3 9 - 11 0.6 10 - 11 1.0

30 - 320 0.2 2-6 2.2 12 - 14 0.7 12 - 14 1.1
> 320 0.3 7 - 11 2.1 15 - 17 0.8 15 - 17 1.2
12 - 16 2.0 18 - 22 0.9 18 - 22 1.3
17 - 22 1.9 23 - 28 1.0 23 - 28 1.4
23 - 27 1.8 29 - 35 1.1 29 - 35 1.5
28 - 32 1.7 36 - 44 1.2 36 - 44 1.6
33 - 38 1.6 45 - 56 1.3 45 - 56 1.7
39 - 43 1.5 57 - 70 1.4 57 - 70 1.8
44 - 49 1.4 71 - 89 1.5 71 - 89 1.9
50 - 55 1.3 90 - 112 1.6 90 - 112 2.0
56 - 61 1.2 113 - 141 1.7 113 - 141 2.1
62 - 67 1.1 142 - 177 1.8 142 - 177 2.2
68 - 73 1.0 178 - 223 1.9 178 - 223 2.3
74 - 79 0.9 224 - 281 2.0 224 - 281 2.4
80 - 85 0.8 282 - 355 2.1 282 - 355 2.5
86 - 91 0.7 356 - 446 2.2 356 - 446 2.6
92 - 95 0.6 447 - 563 2.3 447 - 563 2.7
564 - 707 2.4 564 - 707 2.8
708 - 892 2.5 708 - 892 2.9
893 - 1000 2.6 893 - 1000 3.0
1904 0504 83 ϵϵ

Instruction book
ï î í î ï ò ë ë ï ò ó ï ð ë * ò ï +
(
• RSI < 6: boiler scale formation

• 6 < RSI < 7: neutral water
• RSI > 7: corrosive water
As a general rule, the RSI index should be between 5.6 and 7.5. If that is not
the case, contact a specialist.
X Y Z [ \ \ ] ^ _ ` [ a b \ c d _ e f
Disinfecting with chlorine is not done in closed systems, neither in energy recovery systems.
A continuous level of 0.5 ppm should not be exceeded. For shock treatments, a maximum limit of 2 ppm
for maximum 30 minutes/day applies.
g
Y d ^ _ ` [ a h \ i c d _ j f
Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited,
depending from the RSI value.
RSI < 5.5 5.6 < RSI < 6.2 6.3 < RSI < 6.8 6.9 < RSI < 7.5 7.6 < RSI
Cl- (ppm) 200 350 500 350 200

ë î ï ï î î ï ÿ ë ï î ð ð ï ì ð l ï ó ì ð m n n í í ì o
k (
e j
v B
p Y q r _ s ^ t u \ i c
7 à 2 â Ú 6 Ù Þ D â â 4
Single pass < 1000 < 200

Closed loop < 400 < 200
o î ë ò ò ò ï ð ï
w
G G
M Ø 3 3 ß 2 9 Þ Û Ø Ü ß ç D â â 4 M Ø 3 3 ß 2 9 Þ Û 4 6 ç è 6 ç Þ 3 Þ D â â 4
Ý â Þ ß 0 1 ß ß 2 Ø ç è x y z { | z } | 8 ç Þ Ü è Ý Ü Þ 1 ß 9 Þ Ü Ý 7 Ù 6 ç Û 6 Ü Û 8 ç Þ Ü è Ý Ü Þ 1 ß 9 Þ Ü Ý
3 Ý 3 Ù Þ 4
Single pass <1 < 0.2 < 0.2 < 0.05

Recirculating (with < ~
not applicable <
; not applicable
tower)
Closed loop <1 < 0.2 < 0.2 < 0.05
The values in are rejection limits.

* ë ó
ϭϬϬ 1904 0504 83

Instruction book
9.
ê ë í í ï î
C G
ß â â Þ Ü D â â 4
Single pass <1 < 0.2

Recirculating (with tower) <1 not applicable
Closed loop <1 < 0.2
10.
ì ì ë ì
The limit of is a rejection limit.

n o í í ì
The limitation only applies for copper containing systems.
11.
ð í ï ï ð ë ó ð
Large particles (size > 10 µm) should not be present as they can be filtered
out. Small particles (< 0.5 µm) are not taken into account.
For particles between 0.5 µm and 10 µm, the following limits apply:
G
7 à 3 â Þ ç Û Þ Û 3 ß 2 Ø Û 3 D â â 4
Single pass < 10 <1

Closed loop < 10 <1
m o ó ë î î ï ò ð ï
< (rejection value)

m í í ì
m o ë ó ë
If biology is present, it must be aerobic. Anaerobic biology (in closed systems) must be avoided.
C G
J Ø ß 2 ß è Ý D æ W 4 2
5 3

Single pass < 10 / ~

< 10 / ~
5

Recirculating (with tower) < 10 / ~
not applicable
3 3

Closed loop < 10 / ~ < 10 / ~
The table shows the recommended values. The values in are rejection limits.
* ë ó
If additives are used in the cooling water, take into account that the cooling
capacity will change.
ǻm = ((Cpw - Cpa) * X) / (Cpw *(1-X) + X*Cpa) *
100 % with
ǻm: change of mass flow of the
coolant Cpw: specific heat
capacity of water
Cpa: specific heat capacity of the additives
X: the percentage of additives
1904 0504 83 ϭϬϭ

Instruction book

þ
ï ð ÿ î í ë
õ ø ü ÷ ú ü ù ø õ õ ý ù õ ö ÷ ø ù ú ú õ ø ú

Þ 0 Þ Ü Þ ç 1 Þ M Þ 3 Ø è ç 6 Ù Ø ß ç
1 Switch off the voltage and depressurize the compressor before starting maintenance or
repairs
2 Keep the doors closed during operation
3 Switch off the voltage before removing protecting cover inside electric cubicle
4 Warning, voltage
5 Automatic condensate drain
6 Stop the compressor before cleaning the coolers
7 Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx. half a turn)
8 Before connecting the compressor electrically, consult the Instruction book for the motor
rotation direction
9 Compressor remains pressurized for 180 seconds after switching off the voltage
10 Torques for steel (Fe) or brass (CuZn) bolts
11 Switch off the voltage and wait at least 6 minutes before removing the screen
12 Oil outlet (option DD/PD filters)
Pictographs on water-cooled compressors

Þ 0 Þ Ü Þ ç 1 Þ M Þ 3 Ø è ç 6 Ù Ø ß ç
15 Cooling water inlet

16 Cooling water outlet
ϭϬϮ 1904 0504 83

Instruction book
ò ï
The operator must apply all applicable Safety precautions.
For the location of the air outlet valve and the drain connections, see
sections Introduction and Condensate system Important note.
î ï í ò î ò ë ð

1. Consult the sections Electrical cable size, Installation proposal and Dimension drawings.
2.
ï ë ó ó ë ) î ò ð í ë î ñ î ï ð l í ò ï î ï l ì ð * ï î ï ì ë ï +
' (
• Bolts or bolts and bushes under the oil separator vessel (1)
• Bolts and bushes under the gear casing (2)
• Bolt and bushes or support under the motor (3)
ø ü ú ÷ õ ø û ø ù ú õ ü

3. Check that the electrical connections correspond to the applicable codes and that all wires are
clamped tight to their terminals.
The installation must be earthed and protected against short circuits by fuses of the inert type in all
phases. An isolating switch must be installed near the compressor.
4. On air-cooled compressors, check the setting of circuit breaker (Q15). Also check that the switch on
the circuit breaker is in position I.
5. Check the voltage selecting wires at the primary side of transformer T1.
1904 0504 83 ϭϬϯ

Instruction book
ý ù ø ü ù õ ü ÷ ü ý ù û ü ö ÷ ý ù

6. Fit air outlet valve (AV). See section Introduction for the location of the valve. Close the valve.
Connect the air net to the valve.
On compressors equipped with a dryer bypass, fit the air outlet valve to the dryer bypass pipe.
7. Connect the condensate drain outlet(s) to a drain collector. See section Condensate system.
The drain pipes to the drain collector must not dip into the water. If there is a risk for freezing, the
pipes must be insulated.
For draining of pure condensate water, install an oil/water separator which is available from Atlas
Copco as an option. See section OSCi
8. For compressors with a DD or a DD and PD filter: connect the automatic drain of the filters to a
suitable drain collector.
9. On water-cooled compressors, drain valves, shut-off valves and a regulating valve should be fitted
by the customer in the cooling water piping.
10.
î ë ï ó ò * ï ó ð l ) ò î ï ë í ï î ò ë î ò +
( (
• The compressor may automatically restart after voltage failure (if activated, consult Atlas Copco).
• The compressor is automatically controlled and may be restarted automatically.
ϭϬϰ 1904 0504 83

Instruction book
ò ó ð ò î í î ë ÿ ï î ï
If the compressor has not run for the past 6 months, it is strongly
recommended to improve the lubrication of the compressor element before
starting. To do so:
1. Loosen the hose clip (2) and disconnect the inlet hose (3).
2. Remove the unloader (1)
3. Pour 0.75 l (0.20 US gal, 0.17 Imp gal) of compressor oil into the
inlet arrestor (1). For oil specifications, see section Oil specifications.
4. Reinstall the inlet hose.
Make sure that all connections are tight.
1. Check the oil level before starting.

The oil level should be between the oil filler neck (FC) and the top of the sight glass (Gl).
1904 0504 83 ϭϬϱ

Instruction book
2. On water-cooled compressors, close the cooling water drain valves. Open the cooling water inlet
valve and the regulation valve.
3. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation
direction of drive motor (M1) while the motor is coasting to a stop. The correct rotation
direction of the drive motor is indicated by an arrow shown on the motor fan cowl.
If the rotation direction of the drive motor is incorrect, open the isolating switch and reverse
two incoming electric lines.
ÿ ë î î ï ÿ î ë ò ë î ï ÿ ë ë
(
ï î ï ì ë ë î ì ò ÿ ò ð ï ò ì ò ï ë
(
ï ÿ ë ì í î ï ð ð ë î o
4. On air-cooled compressors, check also the rotation direction of the fan motor. Rotation
arrows, visible through the grating in the roof, are provided on the plate below the fan to
indicate the correct rotation direction of the fan motor.
If the rotation direction of the fan motor is incorrect, open the isolating switch and reverse
two incoming electric connections at the terminals of circuit breaker (Q15).
5. Check the programmed settings. For compressors equipped with an Elektronikon® Graphic
controller, consult section Programmable settings.
6. Start and run the compressor for a few minutes. Check that the compressor operates normally.
î ë ÿ ï î ï

1. If the compressor has not run for the past 6 months, it is strongly recommended to improve the
lubrication of the compressor element before starting. See section Initial start.
2. Check the oil level. Top up if necessary. See section Initial start.
3. If necessary, empty the dust trap of the filter; see section Air filter.
If the red part of the air filter service indicator shows full out, replace the air filter element.
Reset the service indicator (VI) by pushing the knob in the extremity of the indicator.
4. On water-cooled compressors, also:

• Check that the cooling water drain valves in the inlet and outlet pipes are closed.
• Open the cooling water inlet valve.
• Open the water flow regulating valve. This step can be skipped if the setting of this valve
has not been changed.
ϭϬϲ 1904 0504 83

Instruction book
î ë ÿ ï î ï

For the location of the air outlet valve and the drain connections, see
sections Introduction and Condensate system.
ô õ ø õ ý ÷ ü ù ý ý ù ø õ õ ø ü ÷

1. Open the air outlet valve.

2. Switch on the voltage. Check that voltage on LED (6) lights up.
3. Press start button (1) on the control panel. The compressor starts running and the automatic
operation LED 8) lights up. Ten seconds after (starting, the drive motor switches over from
star to delta and the compressor starts running loaded.
4. On water-cooled compressors, the cooling water is used to cool the compressor oil and
compressed air. Regulate the cooling water flow during loaded operation to obtain the most
suitable temperature at the outlet of the compressor element. This temperature is determined by
the condensation point of water at operating conditions (lower temperature limit) and the
maximum desirable oil temperature (100 °C / 212 °F) as upper limit. For good practice, regulate
the cooling flow to obtain an element outlet temperature approximately 5° C above the relevant
(lower limit) temperature obtained from the figure below. If the calculated temperature is higher
than 100° C, this will lead to more rapid oil deterioration, which will have an impact on oil service
intervals. Consult Atlas Copco for best practices in this case. Also consult Atlas Copco in case
condensate should form in the oil.
For optimal operation, the cooling water outlet temperature must never exceed the value
specified in section Reference conditions and limitations.
1904 0504 83 ϭϬϳ

Instruction book
ö ö õ ö ÷ ø ù ú ú õ ø ù ý ù ö ù ù ö ÷ ù ø ü ø ù õ ø ü ù ø õ õ ý ù ú

(A): Air inlet temperature

(B): Condensation temperature

(C): Working pressure

(D): Relative air humidity
If operating at a pressure of 10 bar(e) in an ambient temperature of 20 °C and at a

ñ ò ì í ó ï +

relative air humidity of 100%, the minimum temperature to prevent condensate from forming is 68
°C. Regulate the cooling water flow during loaded operation to obtain a temperature between 70 and
approx. 75 °C at the outlet of the compressor element.
ò î ð

The operator must apply all relevant Safety precautions. Also consult section
Problem solving.
Keep the doors closed during operation; they may be opened for short periods
only to carry out checks.
When the motors are stopped and LED (8) (automatic operation) is alight, the
motors may start automatically.
ϭϬϴ 1904 0504 83

Instruction book
ê ï ÿ ï ë ó ó ï ï ó
( (

Regularly check the oil level. To do so:

1. Press stop button (9).
2. A few minutes after stopping, the oil level should be between the oil filler neck (FC) and the
top of the sight glass (Gl).
3. If the oil level is too low, push the emergency stop button (10) to avoid the
compressor to start unexpectedly.
4. Next, close the air outlet valve and open the manual drain valve (Dm) until the air system
between oil separator/air receiver vessel and outlet valve is fully depressurized. See section
Condensate system for location of the outlet valve and water drain.
5. Unscrew oil filler plug (FC) one turn to permit any pressure left in the system to escape.
Wait a few minutes.
6. Remove the plug and add oil until the level reaches the filler opening.
7. Fit and tighten the plug (FC).
.
On compressors with an Elektronikon® Graphic controller, unlock the emergency stop button (10), select
the STOP icon on the display and press reset (5) before restarting.
1904 0504 83 ϭϬϵ

Instruction book
î ó ï î
õ ú õ õ ù ú ù ø ù ü õ ø

Regularly check the service indicator. If the coloured part of service indicator (VI) shows full out,
replace the air filter element. Reset the service indicator by pushing the knob in the extremity of the
indicator body.
î ò ð
þ
Regularly check that condensate is discharged during operation. See section Condensate system. The
amount of condensate depends on environmental and working conditions.
ê ë ë ó ) ò ï î ó ë )
On water-cooled compressors, check regularly the cooling water flow, as indicated in section Starting.
ê ë ì í î ï ð ð ë î ð ) ó ï î ë ë . î ò í ÿ ÿ ë î ë ó ó ï î +
( (
ô õ ø õ ý ÷ ü ù ý õ ù ý ù ø õ õ õ ø õ ý ý ù ø

Check the display (2) regularly for readings and messages. The display normally shows the compressor
outlet pressure, while the status of the compressor is indicated by pictographs. Remedy the trouble if
alarm LED (7) is lit or flashes, see section Shutdown warning , Shutdown and Problem solving.
ϭϭϬ 1904 0504 83

Instruction book
The display (2) 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, see section Service warning.

î ë ÿ ï î ï

ï í ÿ ë
Press stop button (9). Automatic operation LED (8) goes out and the
compressor stops after 30 seconds of unloaded operation.

press emergency
ë ð ë í ï ÿ ë ì í î ï ð ð ë î ï ï ï ë ò ï ì ï î ï ÿ l
' ( (
stop button (10). Alarm LED flashes (7).

On compressors with an Elektronikon® Graphic controller:

Remedy the fault and unlock the button by pulling it out.

Navigate to the Stop icon on the display by means of the navigation keys
(3/4) and press the Select key.
Press reset.
See also
ë ë ð ï ï ì ï î ï ÿ ð ë í * ë A m n B ë î ë î ì ò ó ð ë í í
þ
section Emergency stop button .

Close air outlet valve (AV), see section Introduction.

) ò ï î ÿ ë ë ó ï ÿ ë ì í î ï ð ð ë î ð +
Close the cooling water inlet valve.

If freezing temperatures can be expected, drain the cooling system

completely.
1904 0504 83 ϭϭϭ

Instruction book
ò î

The operator must apply all relevant Safety precautions.
î ë ÿ ï î ï

ï í ÿ ë
Stop the compressor and close the air outlet valve.

- Open the manual drain valve.

Switch off the voltage and disconnect the compressor from the mains.
Unscrew the oil filler plug only one turn to permit any pressure in the
system to escape. Consult section Oil and oil filter change to locate the
j
filler plug.
j
Shut off and depressurise the part of the air net which is connected to the
outlet valve. Disconnect the compressor air outlet pipe from the air net.
) ò ï î ÿ ë ë ó ï ÿ ë ì í î ï ð ð ë î ð +
- Isolate and disconnect the water system from the cooling water net.

Drain the water circuit.

Drain the oil.
j
Drain the condensate circuit and disconnect the condensate piping from
the condensate net.
ϭϭϮ 1904 0504 83

Instruction book

ê ë î ë ó í ò ï ó

ò î

Only pressing the emergency stop button is not sufficient to make the
compressor voltage free.
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.
Always apply all relevant Safety precautions.
ï ë î ï ÿ ò î î ë ò ì ò ï ò ÿ ï l î ï í ò î ) ë î ë î ò ð ì ï ð l
í î ë ÿ ï ï ò ð ë ó ó ë ) ð +
• Stop the compressor.

• Close the air outlet valve and press the test button on top of the
electronic water drain(s) until the air system between air receiver and
outlet valve is fully depressurized.
• Press the emergency stop button (10).
• Switch off the voltage. Open and lock the isolating switch.
Depressurize the compressor by opening the oil filler plug one turn.
.
ï ë î ï ï ó ï ÿ î ÿ ò ó ì ò ï ò ÿ ï
Wait for at least 6 minutes before starting any electrical repairs as

dangerous high voltage remains on the capacitors of the start and speed
regulation unit during some minutes after switching off the voltage.
ò î î ò î ë ÿ ò * ó

Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not
covered by Warranty or Product Liability.
1904 0504 83 ϭϭϯ

Instruction book
ï î ÿ ï ð
For overhauling or carrying out preventive maintenance, service kits are available (see section Service
kits).
ï î ÿ ï ÿ ë î ò ÿ ð
Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance
work.Consult your Atlas Copco Customer Centre.
. ï ï î ò ó
When servicing, replace all removed gaskets, O-rings and washers.

ï î ò ó ð
The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service
intervals, depending on the environmental and working conditions of the compressor.
The longer interval checks must also include the shorter interval checks.
î ï ï ï ì ò ï ò ÿ ï ð ÿ ï ó ï
(
Check list.
ï î ë í ï î ò ë

Daily Check oil level.

Check readings on display.
Check air filter service indicator.
Check that condensate is discharged during operation.
Drain condensate.
On water-cooled units: check for cooling water flow.
Check that condensate is discharged when pressing the test button on top of the
Monthly electronic
water drain.
On compressors with integrated dryer:
• Stop the compressor, close the air outlet valve and switch off the voltage.
• Remove any dirt from the condenser inlet with a vacuum cleaner.
• Next, clean with an air jet in the reverse direction of the normal flow. Use low
pressure
air. Keep the compressed air nozzle more than 30 cm away from the
condenser to
avoid damaging the of condenser fins.
• Remove dust from inside the dryer, e.g. with a vacuum cleaner.
Do not use water or solvents to clean the condenser.
3-monthly (1) Check coolers. Clean if necessary.
Remove the air filter element and inspect. If necessary, clean using an air jet.
Replace
damaged or heavily contaminated elements.
Check the filter element of the electric cabinet. Replace if necessary
Replace the wearing parts of the electronic water drain(s). A service kit is
Yearly or every available. Have the safety valve tested
8000 hours (2)
(1): More frequently when operating in a dusty atmosphere.
(2): Whichever comes first
ϭϭϰ 1904 0504 83

Instruction book
Apart from the above mentioned actions, the service interventions in the table below are programmed in
the memory of the Elektronikon® controller. Each plan has a programmed time interval at which all
service actions belonging to that plan are to be carried out. When reaching the interval, a message will
appear on the screen indicating which service plans are to be carried out. See section Service warning
Service menu.
After servicing, the intervals must be reset. See section Calling up/resetting the service timer Service
menu. Preventive maintenance schedule programmed in the Elektronikon®
Preventive Maintenance schedule
E

à ç ç Ø ç è Ú ß à Ü 3 â Þ Ü 6 Ù Ø ß ç
4000 (1) If Atlas Copco Roto-Foodgrade Fluid is used, change oil and oil filter.
If Atlas Copco Roto-Inject Fluid is used, change oil and oil filter.
Replace the air filter element.
Replace the filter element of the electric cabinet.
Check condition of the air intake hose between air filter and compressor element
(where
applicable).
Check pressure and temperature readings.
Do a LED and display test.
Test the temperature shut-down function.
On air-cooled compressors: clean coolers. Check and clean cooling fan
assembly.
Clean cooling fins of electric motors.
Inspect the restriction nozzle in the scavenging line for cleanness.
Check operation of cooling fans of converter.
Check blow-off solenoid valve after stopping and pressing the emergency stop
button.
On water-cooled units: check for possible water leakage
8000 (2) If Atlas Copco Roto-Xtend Duty Fluid is used, change oil and oil filter.
Have the oil separator element replaced.
The oil separator element must also be replaced when the pressure drop over it
exceeds
1 bar (14.5 psi). Check the pressure drop while the compressor is running
loaded and
preferably with a stable working pressure.
Visually inspect the oil separator vessel for damage and corrosion. The
minimum wall
thickness must be respected. See section Pressure equipment directives.
(1): or when the real time counter indicates the service plan, whichever comes first
(2): or when the real time counter indicates the service plan, whichever comes first
ë ë ï ó

¡
Oil temperature End pressure Recommended oil service interval* Max. time interval
(˚C) (bar) (running hours) (years)
< 110 <14 8000 2
>110 <14 6000 2
>105 >14 4000 2
GAR applications 4000 2
*Whichever comes first
1904 0504 83 ϭϭϱ

Instruction book
Roto-Xtend duty fluid is used as “General purpose lubricant” for GA/GR type compressors.
The indicated oil exchange intervals are valid for standard operating conditions (see section Reference
conditions and limitations) and nominal operating pressure (see section Compressor data). Exposure of
the compressor to external pollutants, operation at high humidity combined with low duty cycles or
operation at higher temperatures may require a shorter oil exchange interval. Contact Atlas Copco if in
doubt.
ì í ë î ò
Always consult Atlas Copco if a timer setting has to be changed.

For the change interval of oil and oil filter in extreme conditions of
temperature, humidity or cooling air, consult your Atlas Copco Customer
Centre.

Any leakage should be attended to immediately. Damaged hoses or

flexible joints must be replaced.
Never mix lubricants of different brands or types as they may not be

compatible and the oil mix will have inferior properties. A label, indicating
the type of oil filled ex-factory, stuck on the air receiver/oil tank.
Always drain the compressor oil at all drain points. Used oil left in the
compressor can contaminate the oil system and can shorten the lifetime of
the new oil.
It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of field
experience and research in our labs. See section Preventive maintenance schedule for replacement
intervals and section Service Kits for part number information.
ë ë ï ÿ ó
k
Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected
screw compressors. Its specific composition keeps the compressor in excellent condition. Roto-Inject
Fluid can be used for compressors operating at ambient temperatures between 0 °C and 40 °C. If
the compressor is regularly operating in ambient temperatures between 40 °C and 46 °C , oil lifetime
is reduced significantly. In such case it is recommended to use Roto-Xtend Duty Fluid.
ë ë ï ó
þ k
¡
Atlas Copco's Roto-Xtend Duty Fluid is a high-quality synthetic lubricant for oil-injected screw
compressors which keeps the compressor in excellent condition. Because of its excellent oxidation
stability, Roto-Xtend Duty Fluid can be used for compressors operating at ambient temperatures
between 0 °C and 46 °C.
Roto-Xtend Duty Fluid is the standard oil for compressors equipped with freeze protection.
ë ë ë ë î ò ï ó
k k
í ï ÿ ò ó ë ó l ï ó ï î ï ò ð ò ë í ë o
Atlas Copco's Roto-Foodgrade fluid is a unique high-quality synthetic lubricant, specially created for
oil- injected screw compressors that provide air for the food industry. This lubricant keeps the compressor
inexcellent condition. Roto-Foodgrade Fluid can be used for compressors operating at ambient
temperatures between 0°C and 40 °C .
ϭϭϲ 1904 0504 83

Instruction book
. ï ï î ò ó
Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a brush
and/ or compressed air jet.
ï ò î ì ò ï ò ÿ ï
The bearing at the non-drive end side is greased for life.

The bearing at the drive end side is lubricated by the oil system.
ë ÿ ò ë ë ò î ó ï î
ï ÿ ë ì ì ï ò ë ð

1. Never remove the element while the compressor is running.

2. For minimum downtime, replace the dirty element by a new one.
3. Discard the element when damaged.
î ë ÿ ï î ï

1. Stop the compressor. Switch off the voltage.

2. Release the snap clips of air filter (AF) and remove the cover and the air filter element.
Discard the filter element.
3. Fit the new element and the cover.
4. Reset service indicator (VI) by pushing the knob in the extremity of the body.
5. Reset the air filter service warning.
For compressors equipped with an Elektronikon® Graphic regulator, see section Service
menu.
1904 0504 83 ϭϭϳ

Instruction book
ò î

The operator must apply all relevant Safety precautions.

Always drain the compressor oil at all drain points. Used oil left in the
compressor can contaminate the oil system and can shorten the lifetime of
the new oil.
Never mix lubricants of different brands or types as they may not be
compatible and the oil mix will have inferior properties. A label, indicating the
type of oil filled ex-factory, is stuck on the air receiver/oil tank.
If the compressor is equipped with an Energy Recovery system, also consult
Maintenance for Energy Recovery Systems.
î ë ÿ ï î ï

¢ ý ø ü ü ý ý ù ø ÷ ý õ ù õ ý ú ù ÷ ü ø ü õ ø ù ú ú ù ý
ϭϭϴ 1904 0504 83

Instruction book
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ù ÷ ý õ ý õ õ ý ù ø
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þ
Run the compressor until warm. Stop the compressor after 3 minutes of unloaded
operation. Close the air outlet valve and switch off the voltage. Wait a few minutes
-
and depressurise by unscrewing oil filler plug (FC) just one turn to permit any
pressure in the system to escape.
Loosen the vent plug of the oil cooler and wait for 5 minutes. See section Introduction
-
for the position of the vent plug (VP).
Remove drain plug (DP1) and open drain valve (Dm).
Also drain the oil by removing the drain plug:
-
on the check valve (DP2)

on the gear casing (DP3)

Collect the oil in a collector and deliver it to the local collection service. Refit and
- tighten the drain and vent plugs after draining.
Close the drain valve (Dm).
Remove the oil filter (OF). Be aware that this filter has a left thread connection. Clean
the seat on the manifold. Oil the gasket of the new filter and screw it into place.
Tighten firmly by hand.
1904 0504 83 ϭϭϵ

Instruction book
ï í ï ð ÿ î í ë
þ
Remove filler plug (FC). Fill the air receiver (AR) with oil until the level
- reaches the filler neck. Take care that no dirt drops into the system.
Refit and tighten filler plug (FC).
Run the compressor loaded for a few minutes. Stop the compressor and wait a few
-
minutes to allow the oil to settle.
Depressurise the system by unscrewing filler plug (FC) just one turn to permit any
- pressure in the system to escape. Remove the plug. Fill the air receiver with oil
until the level reaches the filler neck. Tighten the filler plug.
Reset the service warning after carrying out all service actions in the relevant
- Service Plan:
For compressors with Elektronikon® Graphic controller, see section Service menu.
. ï ï î ò ó
Keep the coolers clean to maintain their efficiency.

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• Cover all parts under the coolers.
• Remove the service plates (1) at the fan compartment.
• Remove any dirt from the coolers with a fibre brush. Brush in the direction of the
cooling fins. Also remove any dirt from the fan with a fibre brush.
• Next, clean 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).
• If it is necessary to wash the coolers with a cleaning agent, consult Atlas Copco.
• Remove the cover used during cleaning.
• Mount the service plates (1) at the fan compartment.
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• Remove any dirt on the condenser inlet with a vacuum cleaner.
• Next, clean 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).
• Clean the condenser area with a vacuum cleaner.
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Consult Atlas Copco
ϭϮϬ 1904 0504 83

Instruction book

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õ ú õ õ ú ü ù ü ý ù

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'
Before removing the valve, depressurise the compressor.

See section Problem solving.
Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure stamped
on the valve, it needs to be replaced.
ò î

No adjustments are allowed. Never run the compressor without safety valve.
ò ï í î ï ÿ ò ë ð
Refrigeration dryers of ID type contain refrigerant HFC.

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( (
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• Contact of refrigerant with the skin will cause freezing. Special gloves must be worn. If contacted
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; always wear safety glasses.
• Refrigerant is harmful. Do not inhale refrigerant vapours. Check that the working area is
adequately ventilated.
1904 0504 83 ϭϮϭ

Instruction book
Be aware that certain components such as the refrigerant compressor and the discharge pipe can
become quite hot (up to 110 °C - 230 °F). Therefore, wait until the dryer has cooled down before
removing the panels.
Before starting any maintenance or repair work, switch off the voltage and close the air inlet and outlet
valves.
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• Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its
function must be undertaken by an authorised control body.
• The installation should be checked once a year by an authorised control body.
. ï ï î ò ó
For all references see section Introduction.

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• Keep the dryer clean.

• Brush or blow off the finned surface of condenser monthly.
• Inspect and clean the electronic condensate drain monthly.
ï î ÿ ï ð
For overhauling and for preventive maintenance, a wide range of service kits is available. Service kits
comprise all parts required for servicing the component and offer the benefits of genuine Atlas
Copco parts while keeping the maintenance budget low.
Also a full range of extensively tested lubricants, suitable for your specific needs is available to
keep the compressor in excellent condition.
Consult the Spare Parts List for part numbers.

ï î ÿ ï ð
If the compressor work cycle contemplates long pauses during which the machine cools down, a certain
amount of condensate will gather in the Oil tank. This happens, for example, when stopping overnight or
at weekends.
The condensate must be drained off every 50 hours or every week for continuous running machine. (
More than 50 % load).
The condensate must be drained daily for unit running less than 50% or running on intermittent operation.
Note – The above operation should be performed only when the machine is cold, that is when it has been
switched off for atleast 4 hours.
Condensate drain once in a week from gear casing.
ϭϮϮ 1904 0504 83

Instruction book

Before draining condensate it is obligatory to stop the machine and disconnect it
from the power mains

Proceed as follows:
• Stop the machine, turning in “OFF” position the isolating switch.
• Press the button switch (on the dryer if fitted).
• Turn on the differential supply switch, (on the screw-compressor) and (on the dryer if fitted)
î ë ÿ ï î ï

Run the compressor regularly, e.g. twice a week, until warm. Load and unload the compressor a few
times.
If the compressor is going to be stored without running from time to time,

protective measures must be taken. Consult your supplier.
Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.)
must be disposed of in an environmentally friendly and safe manner, and in line with the local
recommendations and environmental legislation.
1904 0504 83 ϭϮϯ

Instruction book
ò î

Before carrying out any maintenance, repair work or adjustment, press the
stop button, wait until the compressor has stopped (approx. 30 seconds) and
close the air outlet valve. Press the test button on top of the electronic water
drain unit the air system between the air receiver and outlet valve is fully
depressurized.
Press the emergency stop button and switch off the voltage.
Depressurize the compressor by opening the oil filler plug one
turn.
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Introduction

Condensate system

Initial start-up
The air outlet valve can be locked during maintenance or repair as follows:

Close the valve.

Remove the screw fixing the handle with the wrench delivered with the
compressor.

Lift the handle and turn it until the slot of the handle fits over the blocking
edge on valve body.

Fit the screw.

• Always switch off the voltage. Only pressing the emergency stop button is
not sufficient to make the compressor voltage free.
• 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..
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Wait for at least 6 minutes before starting any electrical repairs as dangerous
high voltage remains on the capacitors of the start and speed regulation unit
during some minutes after switching off the voltage.
Always switch off the voltage. Only pressing the emergency stop button is not
sufficient to make the compressor voltage free.
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.
ò ó ð ò î ï ì ï ï ð
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On compressors equipped with an Elektronikon® Graphic controller, if the alarm LED is lit or flashes,
consult sections Event history menu or Service menu.
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Compressor does not start or Find cause and remedy.

stops Motor overload relay (F21) open Replace
during operation. Elektronikon if necessary.
shows motor overload problem.
Circuit breaker (Q15) or fan Find cause and remedy.
motor Replace
overload (F15) open if necessary.
ϭϮϰ 1904 0504 83

Instruction book
C

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Compressor does not start or stops Too high temperature in oil the Check switch functionality.
during operation. Elektronikon separator vessel or temperature Check wiring.
shows <Main Motor Converter switch (TSHH1) defective Replace if necessary
Alarm>.
Condensate is not discharged from Discharge tube clogged Check and correct as necessary
condensate separator during
loading
Compressor air output or pressure Air consumption exceeds air Check the connected equipment.
below normal delivery of compressor
Choked air filter element Replace filter element
Solenoid valve malfunctioning Replace valve
Oil separator element clogged Have element replaced
Air leakage Have leaks repaired. Replace
leaking tubes
Safety valve leaking Replace valve
Compressor element out of order Consult Atlas Copco
Safety valve blows Minimum pressure valve Check and have defective parts
malfunctioning replaced
Oil separator element clogged Have element replaced
Safety valve out of order Have valve checked. Replace if
necessary
On Full-Feature compressors, Have system checked by Atlas
dryer piping clogged due to Copco Customer Centre
formation of ice
Compressor element outlet Oil level too low Check and correct
temperature or delivery air
temperature above normal
On air-cooled compressors, Check for cooling air restriction or
insufficient cooling air or cooling air improve ventilation of the
temperature too high compressor room. Avoid
recirculating of cooling air. If
installed, check capacity of
compressor room fan
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
1904 0504 83 ϭϮϱ

Instruction book
C

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Oil cooler clogged Clean cooler

Thermostatic valve malfunctioning Have valve tested. Replace if
necessary.
Air cooler clogged Clean cooler
Compressor element out of order Consult Atlas Copco Customer
Centre
Excessive oil consumption; oil Incorrect oil causing foam Change to correct oil
carry-over through discharge line
Oil level too high Check for overfilling. Release
pressure and drain oil to correct
level.
Oil separator defective Replace oil separator element
Malfunctioning of the scavenge line Replace non-return valve in the
scavenge line
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For all references hereafter, consult section Air dryer.
C

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Pressure dew point too high Air inlet temperature too high
Check and correct; if necessary, clean the
aftercooler of the compressor
Ambient temperature too high Check and correct; if necessary, draw
cooling air via a duct from a cooler place or
relocate the compressor
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
Condenser pressure too high Fan control switch out of order Replace
or too low
Fan blades or fan motor out of Have checked fan/fan motor, if necessary
order replace.
Ambient temperature too high Check and correct; if necessary, draw
cooling air via a duct from a cooler place or
relocate the compressor
Condenser externally clogged Clean condenser
Compressor stops or does not Electric power supply to Check and correct as necessary
start compressor is interrupted
Thermal protection of Motor will restart when motor windings have
refrigerant compressor motor cooled down
has tripped

ϭϮϲ 1904 0504 83

Instruction book

C

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Electronic condensate drain Electronic drain system Have system inspected

remains inoperative clogged Clean the filter of the automatic drain by
opening the manual drain valve. Check
functioning of the drain by pushing the test
button.
Condensate trap continuously Automatic drain out of order Have system checked. If necessary, replace
discharges air and water the automatic drain.
Evaporator pressure is too Hot gas bypass valve Have hot gas bypass valve adjusted
high or too low at unload incorrectly set or out of order
Condenser pressure too high See above
or too low
Have circuit checked for leaks and
Shortage of refrigerant recharged if necessary
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If a problem is detected by the converter, a specific code (Main motor converter alarm) will appear on
the Elektronikon display, together with a fault code. Below table lists the most important error codes. If
another code appears, please contact Atlas Copco.
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(1) Shutdown
Navigate to the Stop icon or to the Protections icon and press Enter.
(1) Protections
1904 0504 83 ϭϮϳ

Instruction book
(1) General
The display shows the problem (Main Motor Converter Alarm) and a fault code (31 in this case).
(1) Main Motor Converter Alarm

(2) Fault
C
á
6 à 2 Ù Þ ¥ Ù ß ç 6 à 3 Þ I 1 Ù Ø ß ç 3
1 ß Û Þ 1 ß ç 9 Þ Ü Ù Þ Ü
Û Ø 3 â 2 6 Ý
1 UU Too low voltage. The voltage on the Check the supply voltage.
converter is below the specifications. Contact Atlas Copco.
2 OU Too high voltage. The voltage on the Check the supply voltage.
converter is above the specifications. Contact Atlas Copco.
3 OI.AC Too high current. The converter is Contact Atlas Copco.
overloaded.
21 O.ht1 Converter overheating (IGBT) Check the ambient temperature.
Check the cubicle cooling.
Contact Atlas Copco.
22 O.ht2 Converter overheating (heat sink) Check the ambient temperature.
24 th Motor overheating (thermistor) Check the ambient temperature.
Clean the motor cooling fins.
27 O.ht3 Converter overheating (thermal model) Check the ambient temperature.
32 PH High input voltage phase imbalance or Check supply phases.
input phase loss Contact Atlas Copco.
102 O.ht4 Converter overheating (Power module) Check the ambient temperature.
(blank) (blank) Various Contact Atlas Copco.
ϭϮϴ 1904 0504 83

Instruction book
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þ (
ý ù ø õ õ ø ü ÷ õ ø õ ý ý ù ø

ì í ë î ò
The readings mentioned below are valid Reference conditions and

limitations). under the reference conditions (see condition)

Þ 0 Þ Ü Þ ç 1 Þ Þ 6 Û Ø ç è
Air outlet pressure Depends on the setpoint (desired net pressure).

Compressor element Approx. 60 ˚C (108 ˚F) above ambient temperature.
outlet temperature
Dewpoint temperature Approx. 4 ˚C (39 ˚F).
(on Full-Feature
compressors
Cooling water outlet Approx. 50 ˚C (122 ˚F).
temperature
ì í ë î ò
1904 0504 83 ϭϮϵ

Instruction book
• The voltage on the compressor terminals must not deviate more than 10%
of the nominal voltage. It is however highly recommended to keep the
voltage drop over the supply cables. At nominal current below 5% of the
nominal voltage (IEC 60204-1). If cables
• Use the original cable entry. See section Dimension drawings. To preserve
the protection degree of the electric cubicle and to protect its components
from dust from the environment, it is mandatory to use a proper cable
gland when connecting the supply
• Local regulations remain applicable if they are stricter than the values
proposed below.
• Currents are calculated with the full service factor but we suggest to add
10% due to over- and under-voltage.
Fuses are maximum allowed values calculated for full service factor and
10% over-and under-voltage.
• Caution:
Always double-check the fuse size versus the calculated cable size. If
required, reduce fuse size or enlarge cable size.
Cable length should not exceed the maximum length according to
IEC60204 table 10
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C G G
ß 4 â Ü Þ 3 3 ß Ü Ù Ý â Þ ¦ D 5 6 ¥ 0 à 3 Þ ¦ D 5 6 ¥ 0 à 3 Þ
~

G G
D D
~

è è
å ¨ I I I I
GA 37 VSD 400 50 73.4 100 77 100

GA 37 VSD 380 60 76.8 100 81.6 100
GA 37 VSD 460 60 63.9 80 67.5 80
I: current in the supply lines at maximum load and nominal voltage

(1): compressors without integrated dryer
(2): compressors with integrated dryer
are done according to 60364-4-43 electrical installations of buildings, part 4:
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protection for safety- section 43: protection against overcurrent. Fuse sizes are calculated in order to
protect the cable against short circuit.
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IEC approval
C G G
ß 4 â Ü Þ 3 3 ß Ü Ù Ý â Þ ¦ D 5 6 ¥ 0 à 3 Þ ¦ D 5 6 ¥ 0 à 3 Þ
~

G G
D D
~

è è
å ¨ I I I I
GA 45 VSD 400 50 90.7 100 94.3 125

GA 45 VSD 380 60 96.3 125 101.1 125
GA 45 VSD 460 60 80.3 100 84.4 100
ϭϯϬ 1904 0504 83

Instruction book
I: current in the supply lines at maximum load and nominal voltage

(1): compressors without integrated dryer
(2): compressors with integrated dryer
are done according to 60364-4-43 electrical installations of buildings, part 4:
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protection for safety- section 43: protection against overcurrent. Fuse sizes are calculated in order to
protect the cable against short circuit.
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The tables below indicate the current carrying capacities of cables for 3 commonly used installation
methods, calculated according to standard 60364-5-52 - electrical installations of buildings part 5 - selection
and erection equipment and section 52 - current carrying capacities in wiring systems.
The allowed currents are valid for PVC insulated cables with three loaded copper conductors
(maximum conductor temperature 70 °C).
Installation method B2 according table B.52.1.

Multi-core cable in conduit on a wooden wall
Maximum allowed current in function of the ambient temperature for installation method B2
I 4 ¤ Ø Þ ç Ù Ù Þ 4 â Þ Ü 6 Ù à Ü Þ
C C © C © C C C
6 ¤ 2 Þ 3 Þ 1 Ù Ø ß ç N N N N N

> @ @ @ @
4 mm² < 27 A < 23 A < 21 A < 19 A < 16 A

6 mm² < 34 A < 30 A < 27 A < 24 A < 21 A
10 mm² < 46 A < 40 A < 36 A < 33 A < 28 A
16 mm² < 62 A < 54 A < 49 A < 44 A < 38 A
25 mm² < 80 A < 70 A < 63 A < 57 A < 49 A
35 mm² < 99 A < 86 A < 78 A < 70 A < 60 A
50 mm² < 118 A < 103 A < 93 A < 84 A < 72 A
70 mm² < 149 A < 130 A < 118 A < 106 A < 91 A
95 mm² < 179 A < 156 A < 141 A < 127 A < 109 A
120 mm² < 206 A < 179 A < 163 A < 146 A < 126 A
Installation method C according table B.52.1.

Single-core or multi-core cable on a wooden wall
1904 0504 83 ϭϯϭ

Instruction book
Maximum allowed current in function of the ambient temperature for installation method C
C C © C © C C C
6 ¤ 2 Þ 3 Þ 1 Ù Ø ß ç N N N N N

> @ @ @ @
4 mm² < 32 A < 28 A < 25 A < 23 A < 20 A

6 mm² < 41 A < 36 A < 32 A < 29 A < 25 A
10 mm² < 57 A < 50 A < 45 A < 40 A < 35 A
16 mm² < 76 A < 66 A < 60 A < 54 A < 46 A
25 mm² < 96 A < 84 A < 76 A < 68 A < 59 A
35 mm² < 119 A < 104 A < 94 A < 84 A < 73 A
50 mm² < 144 A < 125 A < 114 A < 102 A < 88 A
70 mm² < 184 A < 160 A < 145 A < 131 A < 112 A
95 mm² < 223 A < 194 A < 176 A < 158 A < 136 A
120 mm² < 259 A < 225 A < 205 A < 184 A < 158 A
Installation method F according table B.52.1.

Single-core cables, touching in free air
Clearance to wall not less than one cable diameter
Maximum allowed current in function of the ambient temperature for installation method F
C C © C © C C C
6 ¤ 2 Þ 3 Þ 1 Ù Ø ß ç N N N N N

> @ @ @ @
25 mm² < 110 A < 96 A < 87 A < 78 A < 67 A

35 mm² < 137 A < 119 A < 108 A < 97 A < 84 A
50 mm² < 167 A < 145 A < 132 A < 119 A < 102 A
70 mm² < 216 A < 188 A < 171 A < 153 A < 132 A
95 mm² < 264 A < 230 A < 209 A < 187 A < 161 A
120 mm² < 308 A < 268 A < 243 A < 219 A < 188 A
ê ò ó ÿ ó ò ë ì ï ë ë î ê +
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• Single supply cables (3 phases + PE - configuration (1)):

• Add 10 % to the total compressor current (ItotPack or ItotFF from the tables)
• Install the prescribed fuse on each cable
• Parallel supply cable (2 x 3 phases + PE - configuration (2)):
• Add 10 % to the total compressor current (ItotPack or ItotFF from the tables) and divide
by 2
• Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1))
• Install fuses of half the size of the recommended maximum fuse size on each cable.
• When using 2 x 3 phases + PE as in (3):
• Add 10 % to the total compressor current (ItotPack or ItotFF from the tables) and divide by ¥3
• Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1))
• Fuse size: the recommended maximum fuse size divided by ¥3 on each cable.
• Size of the PE cable:
• For supply cables up to 35 mm²: same size as supply cables
ϭϯϮ 1904 0504 83

Instruction book
• For supply cables larger than 35 mm²: half the size of the supply wires
Always check the voltage drop over the cable (less than 5 % of the nominal voltage is
recommended). Itot = 89 A, maximum ambient temperature is 45 °C,
ñ ò ì í ó ï +

recommended fuse = 100 A

• Single supply cables (3 phases + PE - configuration (1)):
• I = 89 A + 10 % = 89 x 1.1 = 97.9 A
• The table for B2 and ambient temperature = 45 ° C allows a maximum current of 93 A for
a 50 mm² cable. For a cable of 70 mm², the maximum allowed current is 118 A, which is
sufficient. Therefore, use a 3 x 70 mm² + 35 mm² cable.
If method C is used, 50 mm² is suffficient. (35 mm² for method F) => cable 3 x 50 mm² + 25
mm².
• Parallel supply cable (2 x 3 phases + PE - configuration (2)):
• I = (89 A + 10 %)/2 = (89 x 1.1)/2 = 49 A
• For a cable of 25 mm², B2 at 45 °C, the maximum current is 63 A x 0.8 = 50.4 A. So 2
parallel cables of 3 x 25 mm² + 25 mm² are sufficient.
• Install 50 A fuses on each cable instead of 100 A.
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IEC
50 400 3.0 3.6
50 380 2.6 3.9
60 460 2.6 3.5
. ï ï î ò ó
The regulating and safety devices are factory-adjusted to give optimum performance of the dryer.
Do not alter the setting of any of the devices.
1904 0504 83 ϭϯϯ

Instruction book
ï ï î ï ÿ ï ÿ ë ë ð

Air inlet pressure (absolute) bar 1

Air inlet pressure (absolute) psi 14.5
Air inlet temperature ˚C 20
Air inlet temperature ˚F 68
Relative humidity % 0
Working pressure See section Compressor data.
) ò ï î ÿ ë ë ó ï ð ò ó ð ë +
Cooling water inlet temperature ˚C 20

Cooling water inlet temperature ˚F 68
ì ð
Maximum working pressure See section Compressor data.

Minimum working pressure bar(e) 4
Minimum working pressure psig 58
Maximum air inlet temperature ˚C 46
Maximum air inlet temperature ˚F 115
Minimum ambient temperature ˚C 0
Minimum ambient temperature ˚F 32
Maximum altitude operation (1) m 1000 m above sea level
Maximum altitude operation (1) ft 3281 ft above sea level
(1): For operation at higher altitude: contact Atlas Copco

E
ç × 6 Ù Þ Ü K 1 ß ß 2 Þ Û à ç Ø Ù 3 6 2 3 ß
Maximum cooling water outlet temperature ˚C 50

Maximum cooling water outlet temperature ˚F 122
Maximum cooling water inlet pressure bar(e) 5
Maximum cooling water inlet pressure psig 72.5
ϭϯϰ 1904 0504 83

Instruction book
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All data specified below apply under reference conditions, see section
Reference conditions and limitations.
. ® ¯
þ
¤ 6 Ü ¤ 6 Ü ¤ 6 Ü
~ ~ ~
> > >
â 3 Ø â 3 Ø â 3 Ø
~ ~ ~
? @ ? @ ? @
Frequency Hz 50 50 50
60 60 60
Number of compression stages 1 1 1
Normal effective working pressure bar(e) 7 9.5 12.5
Normal effective working pressure psig 102 138 181
Maximum effective working pressure, Workplace bar(e) 7.5 10 13
Maximum effective working pressure, Workplace psig 109 145 189
Maximum effective working pressure, Workplace Full- bar(e) 7.3 9.8 12.8
Feature
Maximum effective working pressure, Workplace Full- psig 106 142 186
Feature
Maximum motor shaft speed rpm 3066 2683 2224
Minimum motor shaft speed rpm 780 780 1172
Temperature of air leaving the outlet valve (approx.), ˚C 27 27 27
Workplace
Temperature of air leaving the outlet valve (approx.), ˚F 81 81 81
Workplace
Workplace Full-Feature
Nominal motor power kW 37 37 37
Nominal motor power hp 50 50 50
Dryer power at full load, Workplace Full-Feature units kW . . .
50 Hz 1.34 1.34 1.34
60 Hz 1.62 1.62 1.62
Dryer power at full load, Workplace Full-Feature units hp . . .
50 Hz 1.8 1.8 1.8
60 Hz 2.2 2.2 2.2
Refrigerant type, Workplace Full-Feature R410A R410A R410A
Refrigerant quantity, Workplace Full-Feature kg . . .
50 Hz 0.97 0.97 0.97
60 Hz 1.01 1.01 1.01
Refrigerant quantity, Workplace Full-Feature lb . . .
50 Hz 2.14 2.14 2.14
60 Hz 2.23 2.23 2.23

1904 0504 83 ϭϯϱ

Instruction book

¤ 6 Ü ¤ 6 Ü ¤ 6 Ü
~ ~ ~
> > >
â 3 Ø â 3 Ø â 3 Ø
~ ~ ~
? @ ? @ ? @
Oil capacity, air-cooled l 21 21 21

Oil capacity, air-cooled US gal 5.55 5.55 5.55
Oil capacity, air-cooled Imp gal 4.62 4.62 4.62
Oil capacity, water-cooled l 17.9 17.9 17.9
Oil capacity, water-cooled US gal 4.73 4.73 4.73
Oil capacity, water-cooled Imp gal 3.94 3.94 3.94
Cooling water consumption (at water inlet temperature l/min 39 39 39
below 35 ˚C and temperature rise of 15 ˚C), water-cooled
units
Cooling water consumption (at water inlet temperature cfm 1.38 1.38 1.38
below 95 ˚F and temperature rise of 27 ˚F), water-cooled
units
between 35 and 40 ˚C and temperature rise of 10 ˚C),
water-cooled units
between 95 and 104 ˚F and temperature rise of 18 ˚F),
water-cooled units
Sound pressure level, 50 Hz (according to ISO 2151 dB(A) 66 66 66
(2004))
(2004))

. ¯
þ
- °
¤ 6 Ü ¤ 6 Ü ¤ 6 Ü
~ ~ ~
> > >
â 3 Ø â 3 Ø â 3 Ø
~ ~ ~
? @ ? @ ? @
Frequency Hz 50 50 50
60 60 60
Number of compression stages 1 1 1
Normal effective working pressure bar(e) 7 9.5 12.5
Normal effective working pressure psig 102 138 181
Maximum effective working pressure, Workplace bar(e) 7.5 10 13
Maximum effective working pressure, Workplace psig 109 145 189
Maximum effective working pressure, Workplace Full- bar(e) 7.3 9.8 12.8
Feature
Maximum effective working pressure, Workplace Full- psig 106 142 186
Feature
Maximum motor shaft speed rpm 3627 3218 2727
Minimum motor shaft speed rpm 780 780 1172
Workplace
Workplace

ϭϯϲ 1904 0504 83

Instruction book

¤ 6 Ü ¤ 6 Ü ¤ 6 Ü
~ ~ ~
> > >
â 3 Ø â 3 Ø â 3 Ø
~ ~ ~
? @ ? @ ? @

Nominal motor power kW 45 45 45
Nominal motor power hp 60 60 60
Dryer power at full load, Workplace Full-Feature units kW . . .
50 Hz 1.34 1.34 1.34
60 Hz 1.62 1.62 1.62
Dryer power at full load, Workplace Full-Feature units hp . . .
50 Hz 1.8 1.8 1.8
60 Hz 2.2 2.2 2.2
Refrigerant type, Workplace Full-Feature R410A R410A R410A
Refrigerant quantity, Workplace Full-Feature kg . . .
50 Hz 0.97 0.97 0.97
60 Hz 1.01 1.01 1.01
Refrigerant quantity, Workplace Full-Feature lb . . .
50 Hz 2.14 2.14 2.14
60 Hz 2.23 2.23 2.23
Oil capacity, air-cooled l 23 23 23
Oil capacity, air-cooled US gal 6.08 6.08 6.08
Oil capacity, air-cooled Imp gal 5.06 5.06 5.06
Oil capacity, water-cooled l 17.9 17.9 17.9
Oil capacity, water-cooled US gal 4.73 4.73 4.73
Oil capacity, water-cooled Imp gal 3.94 3.94 3.94
below 35 ˚C and temperature rise of 15 ˚C), water-cooled
units
below 95 ˚F and temperature rise of 27 ˚F), water-cooled
units
between 35 and 40 ˚C and temperature rise of 10 ˚C),
water-cooled units
between 95 and 104 ˚F and temperature rise of 18 ˚F),
water-cooled units
(2004))
(2004))

1904 0504 83 ϭϯϳ

Instruction book

. ï ï î ò ó
Supply voltage 24 V AC /16 VA 50/60Hz (+40%/-30%)

24 V DC/0.7 A
Type of protection IP54 (front)
IP21 (back)
Ambient and temperature IEC60068-2
conditions
• Operating temperature • -10°C…..+60°C (14 °F .....140 °F)
range • -30°C…..+70°C (-22 °F ......158 °F)
Storage temperature
• range
Permissible humidity Relative humidity 90%
No condensation
Noise emission IEC61000-6-3
Noise immunity IEC61000-6-2
Mounting Cabinet door
ò ó ë í ð
þ
9(Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900 5200

Number of outputs 19)
Type Relay (voltage free contacts)

Rated voltage AC 250 V AC / 10 A max.
Rated voltage DC 30 V DC / 10 A max.
ò ó í ð
þ
10 (Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900

Number of inputs 5200 19)
Supply by controller 24 V DC
Supply protection Short circuit protected to ground
Input protection Not isolated
ò ó ë í ð
2 (Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900

Number of pressure inputs 5200 19)
Number of temperature 5 (Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900
inputs 5200 19)

ϭϯϴ 1904 0504 83

Instruction book
ð î ÿ ë ð
This vessel can contain pressurized air; this can be potentially dangerous if the
1
equipment is misused.
This vessel must only be used as a compressed air/oil separator and must be
2
operated within the limits specified on the data plate.
No alterations must be made to this vessel by welding, drilling or other
3
mechanical methods without the written permission of the manufacturer.
4 The pressure and temperature of this vessel must be clearly indicated.
The safety valve must correspond with pressure surges of 1.1 times the maximum
5 allowable operating pressure. It should guarantee that the pressure will not
permanently exceed the maximum allowable operating pressure of the vessel.
6 Use only oil as specified by the manufacturer.
1904 0504 83 ϭϯϵ

Instruction book
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ϭϰϬ 1904 0504 83

Instruction book
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1904 0504 83 ϭϰϭ

Instruction book
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ϭϰϮ 1904 0504 83

In order to be First in Mind-First in Choice® for all your quality
compressed air needs, Atlas Copco delivers the products
and services that help to increase your business’ efficiency
and profitability.
Atlas Copco's pursuit of innovation never ceases,
driven by our need for reliability and effeciency.
Always working with you, we are committed to providing
you the customized quality air solution that is the driving
force behind your business.
No. 9095 0504 83 / 2015 - 01 Printed in India
www.atlascopco.com

Aib Ga 37-45 VSD 9095 0504 83

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Oil-injected rotary screw compressors

Oil-injected rotary screw compressors

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

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

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

1.4 SAFETY PRECAUTIONS DURING OPERATION .................................................................... 9

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ......................................... 10

2.1 INTRODUCTION .................................................................................................................... 13

2.2 AIR FLOW .............................................................................................................................. 17

2.3 OIL SYSTEM .......................................................................................................................... 19

2.4 COOLING SYSTEM ............................................................................................................... 20

2.5 CONDENSATE SYSTEM ....................................................................................................... 22

2.6 REGULATING SYSTEM......................................................................................................... 23

2.7 ELECTRICAL SYSTEM .......................................................................................................... 23

2.8 AIR DRYER ............................................................................................................................ 24

2.9 SMARTBOX AND SMARTLINK.............................................................................................. 25

3.1 ELEKTRONIKON® GRAPHIC CONTROLLER ....................................................................... 28

3.2 CONTROL PANEL ................................................................................................................. 30

3.3 ICONS USED ......................................................................................................................... 31

3.4 MAIN SCREEN....................................................................................................................... 35

3.5 CALLING UP MENUS ............................................................................................................ 39

3.6 INPUTS MENU ....................................................................................................................... 40

3.7 OUTPUTS MENU ................................................................................................................... 43

3.8 COUNTERS ........................................................................................................................... 45

4.1 ENERGY RECOVERY UNIT .................................................................................................. 82

4.2 ENERGY RECOVERY SYSTEMS.......................................................................................... 83

4.3 OPERATION .......................................................................................................................... 84

4.4 MAINTENANCE ..................................................................................................................... 88

4.5 ENERGY RECOVERY DATA ................................................................................................. 88

5.1 DIMENSION DRAWINGS ....................................................................................................... 90

5.2 INSTALLATION PROPOSAL.................................................................................................. 92

5.3 ELECTRICAL CONNECTIONS .............................................................................................. 95

5.4 COOLING WATER REQUIREMENTS .................................................................................... 97

5.5 PICTOGRAPHS ....................................................................................................................102

6.1 BEFORE INITIAL START-UP ................................................................................................103

6.2 BEFORE STARTING .............................................................................................................106

6.3 STARTING ............................................................................................................................107

6.4 DURING OPERATION ..........................................................................................................108

6.5 CHECKING THE DISPLAY....................................................................................................110

6.6 STOPPING ............................................................................................................................111

6.7 TAKING OUT OF OPERATION .............................................................................................112

7.1 PREVENTIVE MAINTENANCE SCHEDULE .........................................................................113

7.2 OIL SPECIFICATIONS ..........................................................................................................116

7.4 AIR FILTER ...........................................................................................................................117

7.5 OIL AND OIL FILTER CHANGE ............................................................................................118

7.6 COOLERS .............................................................................................................................120

7.7 SAFETY VALVES..................................................................................................................121

7.8 DRYER MAINTENANCE INSTRUCTIONS............................................................................121

7.9 SERVICE KITS ......................................................................................................................122

ϰ 1904 0504 83

7.10 DRAINING CONDENSATE FROM THE OIL TANK ...............................................................122

7.11 STORAGE AFTER INSTALLATION ......................................................................................123

7.12 DISPOSAL OF USED MATERIAL .........................................................................................123

9.1 READINGS ON DISPLAY .....................................................................................................129

9.2 ELECTRIC CABLE SIZE AND MAIN FUSES ........................................................................129

9.3 PROTECTION SETTINGS ....................................................................................................133

Danger for life

= > > ? ? > @

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

= ? _ @ > > ? >