Instruction book

Oil-injected screw compressors

GA 75
Atlas Copco
Oil-injected screw compressors

GA 75

Instruction book
Original instructions

COPYRIGHT NOTICE
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.

January 2022

www.atlascopco.com
 Instruction book

Table of contents

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

1.1 Safety icons................................................................................................................................ 6

1.2 General safety precautions.................................................................................................... 6

1.3 Safety precautions during installation................................................................................ 7

1.4 Safety precautions during operation.................................................................................... 8

1.5 Safety precautions during maintenance or repair............................................................ 10

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

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

2.2 Air flow..................................................................................................................................... 14

2.3 Oil system..................................................................................................................................15

2.4 Cooling system.........................................................................................................................16

2.5 Condensate system..................................................................................................................17

2.6 Regulating system................................................................................................................... 20

2.7 Electrical system.................................................................................................................... 21

3 Elektronikon™ Touch controller................................................................................. 23

3.1 Controller................................................................................................................................23

3.2 Control panel.......................................................................................................................... 25

3.3 Icons used................................................................................................................................. 26

3.4 Main screen............................................................................................................................... 30

3.5 Quick access screen................................................................................................................31

3.6 Shutdown warning...................................................................................................................32

3.7 Shutdown.................................................................................................................................. 33

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3.8 Menu screen..............................................................................................................................35

3.9 Data menu.................................................................................................................................. 37

3.10 Service menu............................................................................................................................. 40

3.11 Week timer menu.......................................................................................................................41

3.12 Event history menu..................................................................................................................42

3.13 Machine settings menu............................................................................................................ 43

3.14 Controller settings menu..................................................................................................... 46

3.15 Access level..............................................................................................................................49

3.16 Web server................................................................................................................................50

3.17 Programmable settings.......................................................................................................... 56

4 Installation.....................................................................................................................58

4.1 Dimension drawings................................................................................................................. 58

4.2 Installation proposal............................................................................................................. 59

4.3 Electrical connections.......................................................................................................... 62

4.4 Pictographs.............................................................................................................................. 63

5 Operating instructions................................................................................................. 66

5.1 Initial start-up..........................................................................................................................66

5.2 Before starting........................................................................................................................69

5.3 Starting ....................................................................................................................................70

5.4 During operation..................................................................................................................... 71

5.5 Checking the display............................................................................................................... 73

5.6 Stopping ....................................................................................................................................75

5.7 Taking out of operation..........................................................................................................76

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6 Maintenance.................................................................................................................. 77

6.1 Preventive maintenance schedule.........................................................................................77

6.2 Oil specifications..................................................................................................................... 80

6.3 Drive motor ..............................................................................................................................82

6.4 Air filter....................................................................................................................................82

6.5 Oil and oil filter change.........................................................................................................83

6.6 Coolers..................................................................................................................................... 85

6.7 Safety valves............................................................................................................................86

6.8 Service kits............................................................................................................................... 86

6.9 Storage after installation.................................................................................................... 87

6.10 Disposal of used material...................................................................................................... 87

7 Problem solving............................................................................................................88

8 Technical data............................................................................................................... 91

8.1 Readings on display................................................................................................................. 91

8.2 Electric cable size and fuses................................................................................................ 92

8.3 Protection settings................................................................................................................ 94

8.4 Reference conditions and limitations.................................................................................. 95

8.5 Compressor data..................................................................................................................... 95

8.6 Technical data controller.................................................................................................... 95

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9 Instructions for use...................................................................................................... 97

10 Guidelines for inspection.............................................................................................98

11 Pressure equipment directives................................................................................... 99

12 Declaration of conformity.......................................................................................... 100

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1 Safety precautions

1.1 Safety icons

Explanation

Danger to life

Warning

Important note

1.2 General safety precautions

1. The operator must employ safe working practices and observe all related work safety
requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of
the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel. The personnel should apply safe working practices by use of
personal protection equipment, appropriate tools and defined procedures.
4. The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to the applicable
legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• 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 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.

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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6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
9. If compressed air is used in the food industry and more specifically for direct food contact, it is
recommended, for optimal safety, to use certified Class 0 compressors in combination with
appropriate filtration depending on the application. Please contact your customer center for
advice on specific filtration.
10. The service switch should only be operated by a trained service specialist from the
manufacturer.

1.3 Safety precautions during installation

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

Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with the applicable
safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly
forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and
deceleration must be kept within safe limits. Wear a safety helmet when working in the area of
overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be
taken. Consult your supplier.
3. In case the device is a compressor, place the machine where the ambient air is as cool and
clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be
taken to minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the
pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors
and particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people
cannot be drawn in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to
expand under heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of
strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This
machine is remotely controlled and may start without warning.

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The operator has to make sure that the machine is stopped and depressurized and that the
electrical isolating switch is open, locked and labelled with a temporary warning before any
maintenance or repair. As a further safeguard, persons switching on or off remotely controlled
machines shall take adequate precautions to ensure that there is no one checking or working
on the machine. To this end, a suitable notice shall be affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted air does not recirculate to the compressor air inlet or cooling
air inlet.
12. The electrical connections must correspond to the applicable codes. The machines must be
earthed and protected against short circuits by fuses in all phases. A lockable power isolating
switch must be installed near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after voltage
failure is activated, a sign stating "This machine may start without warning" must be affixed
near the instrument panel.
14. In multiple compressor systems, manual valves must be installed to isolate each compressor.
Non-return valves (check valves) must not be relied upon for isolating pressure systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure relieving device or devices as required.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other
high temperature piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet
pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the
dryer, safety valves must be installed in the vessels of the dryer.

Also consult the following safety precautions: Safety precautions during

operation and Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment;
hence some statements may not apply to your machine.

1.4 Safety precautions during operation

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

Precautions during operation

1. Never touch any piping or components of the machine during operation.

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

Also consult following safety precautions: Safety precautions during installation

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.

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1.5 Safety precautions during maintenance or repair

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

Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all
damage or injuries caused by the use of non-genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to
the starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure
that there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or
disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering
the parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be
completely purged, e.g. by steam cleaning, before carrying out such operations. Never weld on,
or in any way modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapor
when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure
vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating
pressures, temperatures and time settings are correct. Check that all control and shut-down
devices are fitted and that they function correctly. If removed, check that the coupling guard of
the compressor drive shaft has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the
oil separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.

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19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If
damaged, replace it by genuine material from the manufacturer to prevent the sound pressure
level from increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate
bowls.
21. Only if applicable, the following safety precautions are stressed when handling
refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the
latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed
away; then seek medical first aid.

Also consult following safety precautions: Safety precautions during installation

and Safety precautions during operation.
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.

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2 General description

2.1 Introduction
GA 55+ up to GA 90 are single-stage, oil-injected screw compressors driven by an electric motor.
The compressors are available in air-cooled and water-cooled version.
™
The compressors are controlled by an Elektronikon controller.

GA Workplace
GA Workplace compressors are enclosed in a sound-insulated bodywork. The Elektronikon control
module is fitted to the panel on the right hand side. An electric cabinet comprising the motor starter
is located behind this panel. A condensate trap with Electronic Water Drain (EWD) is provided.

Figure 1: Front view, GA 55+ up to GA 90

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Figure 2: Rear view, GA 55+ up to GA 90

Reference Name
AV Air outlet valve
Ca Air cooler
Co Oil cooler
CV/Vs Check valve/oil stop valve
E Compressor element
ER Elektronikon™ controller
FN Cooling fan
M1 Drive motor
S3 Emergency stop button
UA Unloader
Da (Dm) Condensate outlets

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2.2 Air flow

Flow diagrams

Figure 3: Flow diagram, GA Workplace

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

Description
Air drawn through filter (AF) and open inlet valve (IV) of unloader is compressed in compressor
element (E). A mixture of compressed air and oil flows into the air receiver/oil separator (AR) via
check valve (CV). The air is discharged through outlet valve (AV) via minimum pressure valve (Vp)
and air cooler (Ca).
The air cooler is provided with a moisture trap (MT).
In all circumstances, minimum pressure valve (Vp) keeps the pressure in the separator tank (AR)
above a minimum value, required for lubrication. An integrated check valve prevents the
compressed air downstream the valve from being vented to atmosphere during unloaded operation.
When the compressor is stopped, check valve (CV) and inlet valve (IV) close, preventing
compressed air (and oil) to be vented into the air filter.

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2.3 Oil system

Flow diagram

Figure 4: Oil system

References Description
1 Compressed air flow to the air outlet valve (Workplace units)
A Intake air
B Air/oil mixture
C Oil
D Wet compressed air

Description
In air receiver/oil separator (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 an oil tank.
The oil system is provided with a thermostatic bypass valve (BV). When the oil temperature is
below its set point, bypass valve (BV) shuts off the supply to oil cooler (Co) and the oil cooler is
bypassed.
Air pressure forces the oil from air receiver/oil separator (AR) through oil filter (OF) and oil stop
valve (Vs) to compressor element (E).
Bypass valve (BV) starts opening the supply from cooler (Co) when the oil temperature has
increased to the set point. At approx. 15 ˚C (27 ˚F) above the set point, all the oil flows through the
oil cooler.
Oil stop valve (Vs) prevents the compressor element from flooding with oil when the compressor is
stopped. The valve is opened by element outlet pressure when the compressor is started.

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2.4 Cooling system

Air-cooled compressors

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

Description
The cooling system on air-cooled compressors comprises air cooler (Ca) and oil cooler (Co).
The cooling air flow is generated by fan (FN).

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2.5 Condensate system

Drain connections

Figure 5: Electronic condensate drains, typical example

The compressors have an electronic water drain (EWD). 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).
On Full-Feature compressors, an additional electronic water drain (EWD1) is provided. The
condensate trap of the heat exchanger is drained by EWD1 and discharged through automatic
drain outlet (Da1).
See also section Air flow.
Testing the electronic water drain can be done by briefly pressing the test button (1) on top of the
device.

Figure 6: Condensate drain connections, typical example

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Reference Designation
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)

Beside each automatic drain outlet is a manual (Dm) condensate drain connection for manually
draining of the condensate.

Electronic drains
On some models, another model of electronic drains is used.
Operation
The condensate accumulates in the collector of the drain. When the condensate reaches a certain
level, it is discharged through the automatic drain outlet (Da).
The Test button on top of the drain can be used in three different ways, according the situation:
• When pressed during normal operation, it starts the manual drain test.
• When pressed during an alarm, it resets the control logic
• By pressing the Test button for at least 5 seconds, the self diagnosis routine will start.

Figure 7: Electronic condensate drains

Green LED on
Normal operation, drain is in standby and awaiting condensate.
Green LED blinking
Normal operation, drain valve is open to drain water.

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Green LED fading on/off

Water is not flowing in to the drain‘s tank. If the floater does not reach the upper level
for 3 hours, the solenoid is energized for 2 seconds. This cycle is repeated for 5 times
(so up to 15 hours). Afterwards, the green light starts fading on/off.
Causes:
• No condensate entering the tank.
• Float mounted incorrectly (upside down).
Checks:
• Is any condensate reaching the drain? Does the water separation take place in
the heat exchanger?
• Is the floater mounted in its correct position, for instance after maintenance?
Solution:
• Although this LED sign does not indicate any kind of failure, the drain can be
reset by pushing the test button (T) for 5 seconds.
Red LED blinking slowly: cleaning routine 1
The drain’s tank is filled and the water cannot be drained or can only be drained very
slowly.
In normal operation, the drain gets 20 seconds time to drain all water. If the drain is
not emptied within this time frame, a (first) cleaning routine is activated, alternatively
opening and closing the valve for 2 seconds, during maximum 30 cycles. This routine
is started in an attempt to unblock the drain.
If this first unlock routine is unsuccessful, a second routine will be started.
Causes:
• Filter mesh clogged.
• Not enough pressure on drain.
• Internal problem with the drain.
Checks:
• Is the filter clean and in good condition?
• Is there a minimum pressure of 0.2 bar (2.8 psi) in the drain?
Press the test button (T) for at least 5 seconds to reset the drain.

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Red LED blinking fast

If cleaning routine 1 is completed (after 30 cycles) but still unsuccessful, cleaning
routine 2 is activated. This routine will open (3 sec) and close (60 sec) the drain’s
valve until a floater is in lower position, so the water is completely drained.
Meanwhile, the external alarm signal is activated.
Causes:
• Filter mesh clogged.
• Not enough pressure on drain.
• Internal problem with the drain.
Checks:
• Is the filter clean and in good condition?
• Is there a minimum pressure of 0.2 bar (2.8 psi) in the drain?
From this point onwards, the drain will remain in this routine, even after restart. Press
the test button (T) for at least 5 seconds to reset the drain.
Red LED on
An irreversible error occurred. Replace the drain and keep the failed one for further
analysis.

Table 1: LED explanation

2.6 Regulating system

Load/unload regulating system

Figure 8: Regulating system (loaded condition)

Loading
When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results:

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• The space above unloading valve/blow-off valve (UV) is connected with the oil separator tank
pressure (1) via the solenoid valve.
• Unloading valve/blow-off valve (UV) moves downwards, closing off the connection to channels
(2) and (3).
• Underpressure from the compressor element causes loading plunger (LP) to move downwards
and inlet valve (IV) to open fully.
Air delivery is 100%, the compressor runs loaded.

Unloading
If the air consumption is less than the air output of the compressor, the net pressure increases.
When the net pressure reaches the unloading pressure, solenoid valve (Y1) is de-energised.
Results:
• The pressure above unloading valve/blow-off valve (UV) is released to atmosphere and the
space above valve (UV) is no longer in connection with the oil separator tank pressure (1).
• Unloading valve/blow-off valve (UV) moves upwards, connecting the oil separator tank pressure
(1) with channels (2) and (3).
• The pressure in channel (2) causes the loading plunger (LP) to move upwards, causing inlet
valve (IV) to close, while the pressure is gradually released to atmosphere.
• The pressure in the separator tank stabilises at low value. A small amount of air is kept drawn
in to guarantee a minimal pressure, required for lubrication during unloaded operation.
Air output is stopped, the compressor runs unloaded.

2.7 Electrical system

Electrical components
The electrical system comprises following components:

Figure 9: Typical Example of electric cubicle on GA 55+ up to GA 90

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Reference Designation
F1/2/3 Fuses
F21 Overload relay, compressor motor
Q15 Circuit breaker, fan motor (on air-cooled compressors)
K5 Auxiliary relay
K11 Auxiliary contactor
K12 Auxiliary contactor
K15 Auxiliary contactor, fan motor (on air-cooled compressors)
K21 Line contactor
K22 Star contactor
K23 Delta contactor
T1 Transformer
PE Earth terminal

Electrical diagram

9820 6500 01 Service diagram GA55-90

The complete electrical diagram can be found in the electric cubicle.

The complete electrical diagram can be found on the CD supplied with the machine.

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3 Elektronikon™ Touch controller

3.1 Controller

Figure 10: The Elektronikon™ Touch controller

Introduction
The controller has the following functions:
• Controlling the unit
• Protecting the unit
• Monitoring components subject to service
• Automatic Restart After Voltage Failure (ARAVF)

Automatic control of the unit

The controller maintains the net pressure between programmable limits by automatically loading
and unloading the unit (fixed speed units) or by adapting the motor speed (units with frequency
converter).
A number of programmable settings, e.g. the unloading and loading pressures (for fixed speed
units), the setpoint (for units with frequency converter), the minimum stop time, the maximum
number of motor starts and several other parameters are taken into account.
The controller stops the unit whenever possible to reduce the power consumption and restarts it
automatically when the net pressure decreases. If the expected unloading period is too short, the
unit is kept running to prevent too short standstill periods.

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It is possible to program a number of time-based commands for automatic start/

stop. Take into account that a start command will be executed (if programmed
and activated), even after manually stopping the unit.

Protecting the unit

Shutdown
Several sensors are provided on the unit. If one of the measured signals exceeds the programmed
shutdown level, the unit will be stopped.
Example: If the element outlet temperature exceeds the programmed shutdown level, the unit will
be stopped. This will be indicated on the display of the controller.
The unit will also be stopped in case of overload of the drive motor or fan motor.

Before remedying, consult the Safety precautions.

Before resetting a warning or shutdown message, always solve the problem.
Frequently resetting these messages without remedying may damage the unit.

Shutdown warning
A shutdown warning level is a programmable level below the shutdown level.
If one of the measurements exceeds the programmed shutdown warning level, a message will
appear on the display and the general alarm LED will light up to warn the operator before the
shutdown level is reached.
The message disappears as soon as the warning condition disappears.
When the shutdown warning is shown, press stop button to stop the unit and wait until the unit has
stopped. Switch off the voltage, inspect the unit and remedy if necessary. The warning message will
disappear as soon as the warning condition disappears.

Service warning
A number of service operations are grouped as a Service Plan. Each Service Plan has a
programmed time interval. If the service timer exceeds a programmed value, this will be indicated
on the display to warn the operator to carry out the service actions belonging to that Service Plan.
When the service warning is shown, stop the unit, switch off the voltage and contact your supplier
to schedule the necessary maintenance actions. See section Preventive maintenance schedule.

Automatic Restart After Voltage Failure (ARAVF)

The controller has a built-in function to automatically restart the unit when the voltage is restored
after voltage failure.
For units leaving the factory, this function is made inactive. If desired, the function can be activated.
Consult your supplier.

If the function is activated and provided the regulator was in the automatic
operation mode, the unit will automatically restart if the supply voltage to the
module is restored.
The ARAVF label shall be glued next to the controller.

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3.2 Control panel

Figure 11: Control panel

Parts and functions

Reference Designation Function

Shows the unit operating condition and several
1 Touch screen icons to navigate through the menu.
The screen can be operated by touch.
Flashes in case of a shut-down and is lit in case
2 Warning sign
of a warning condition.
3 Service sign Lit when service is needed.
Lit when the unit is running in automatic
4 Operation sign
operation.
5 Voltage sign Indicates that power is switched on.
6 Stop button Stops the unit.
Starts the unit. The operation sign (4) lights up.
7 Start button
The controller is operative.

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3.3 Icons used

Menu icons

Menu Icon Menu Icon Menu Icon

Status

Inputs

Data Outputs

Counters

Aux.
Equipment Converters
Parameters

Overview

Service Service Plan

Service
Service
History
Service
functions

Clean Screen

Week
Week Timer
Remaining
Running Time

Event History Saved Data

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Menu Icon Menu Icon Menu Icon

Alarms

Regulation

Control
Parameters
Machine
Converter(s)
Settings
Aux.
Equipment Fan
Parameters
Internal
SmartBox

Auto Restart

Ethernet
Network Settings
Settings
CAN Settings

Language

Localisation Date/Time
Controller
Settings
Units

User
Password

Help

Information

Status icons

Icon Description

Motor Stopped

Motor Stopped Wait

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Running Unloaded

Manual Unload

Running Unloaded Wait

Running Loaded

Failed to Load

Running Loaded Wait

Manual Stop

Machine Control Mode, Local

Machine Control Mode, Remote

Machine Control Mode, LAN

Automatic Restart After Voltage Failure

Week Timer Active

System icons

Icon Description

Basic User

Advanced User

Service User

Antenna 25%

Antenna 50%

Antenna 75%

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Antenna 100%

Change between screens (indication)

Energy recovery

Dryer

Element

Drain(s)

Analogue Output

Menu

Reset

Auto Restart

Filter(s)

Cooler

Valve(s)

Power Meter

Input icons

Icon Description

Pressure

Temperature

Special Protection

Open

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Closed

This chapter gives a general survey of available icons. Not all icons mentioned
in this chapter are applicable to every machine.

3.4 Main screen

Function
The Main screen is the screen that is shown automatically when the voltage is switched on. It is
switched off automatically after a few minutes when there is no touch input.

Description

Reference Designation Function

The home button is always shown and
1 Home button can be tapped to return to the main
screen.
On the main screen, the screen
information bar shows the serial
2 Screen information number of the machine. When scrolling
through menus, the name of the current
menu is shown.
The access level button is always
3 Access level button shown and can be tapped to change
the current user access level.
The alarm button can be tapped to
show the current alarms. If an alarm
4 Alarm button
occurs, the icon on the button will be
red.
The service button can be tapped to
5 Service button
show the service information.

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Reference Designation Function

This icon shows the current status of
6 Status
the unit.
Indicates which page you currently see.
The middle indication is the main
screen, left is the menu screen and at
7 Page indicator
the right the quick access screen.
Swipe left or right to go to another
screen.
Tap the field to view the type of
measurement. This will be shown in the
screen information bar.
Examples of inputs:
• Ambient temp
These fields can contain a history chart, an
8, 9, 10, 11 input or a counter value, depending on the • Outlet
type of the machine. • Dryer dewpoint
Examples of counters:
• Running hours
• Load relay
• Loaded hours
The menu button is always shown and
12 Menu button
can be tapped to go to the menu.

3.5 Quick access screen

Function
The screen is used to directly access some frequently used functions.

Procedure
The Quick access screen can be viewed by swiping left, starting from the main screen.

Description

Through this screen, several important settings can be viewed and modified.

Function Description
Setpoints Several setpoints can be modified by tapping this icon.

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Function Description
The control mode can be changed by tapping this icon.
• Local control via start/stop buttons
• Remote control via digital input(s)
Control mode
• LAN control via the network.
When in Remote or LAN control, the start/stop buttons on the controller will
not work.
Display language The display language of the controller can be changed by tapping this icon.
Manual unload
When tapped, the machine will go in Manual unload mode until the icon is
(only on fixed
tapped again.
speed units)
Week timer Week timers can be set by tapping this icon.
Remaining running
The Remaining running time can be set and modified by tapping this icon.
time
The reception quality of the internal antenna can be monitored.

Internal SmartBox
Each bar represents 25% reception strength. If the four bars are filled, the
reception strength is 100%. If only one bar is filled, the reception strength is
just 25%.
Auto restart Auto restart can be activated by tapping this icon.

3.6 Shutdown warning

If the element outlet temperature exceeds the shutdown warning level (see section Programmable
Settings), warning LED (2) will light up and a yellow warning icon (4) is shown in the upper side of
the display as in below image:

Tap on the select warning icon (4) to see the Status menu.

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In case of element outlet temperature warning, the display will appear as below:

It remains possible to scroll through other screens, to check the actual status of other parameters.
Press stop key (7) to stop the unit and wait until the unit has stopped. Switch off the voltage, inspect
the unit and remedy. The warning message will disappear as soon the warning condition
disappears.

3.7 Shutdown
Description
The unit will be shut down in following circumstances:
• In case the temperature at the outlet of the element exceeds the programmed shutdown level
(detected by temperature sensor (TT11) or by temperature switch (TSHH11)).
• In case of too high air/oil temperature (detected by additional temperature switch (TSHH21)).
• In case of overload of the motor (M1) or the fan motor (M2).
• In case of error of the outlet pressure sensor (PT20).
• In case of incorrect phase sequence, detected by phase sequence relay (K25).
• In case of overtemperature of the motor windings, detected by thermistor relay (K34).

Element outlet temperature (TT11)

If the element outlet temperature, measured by temperature sensor TT11, exceeds the shutdown
level (see section Programmable settings), the unit will be shutdown, alarm LED (2) will flash,
automatic operation LED (4) will go out and the following screen will appear:

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Figure 12: Status screen with shutdown indication

Press on shutdown indication on the screen.

Figure 13: Shutdown screen, element outlet temperature

The above screen shows that the temperature at the outlet of the element is 116 ˚C. Actions:
• Switch off the voltage and remedy the problem cause.
• After remedying and when the shutdown condition has disappeared, switch on the voltage and
restart the unit.

Other shutdown causes

In case the unit is shut down (or cannot start) by one of following causes:
• Too high element outlet temperature, detected by temperature switch (TSHH11) or additional
temperature switch (TSHH21).

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• Overload of the motor (M1) or the fan motor (M2).

• Incorrect phase sequence, detected by phase sequence relay (K25).
• In case of overtemperature of the motor windings, detected by thermistor relay (K34).
The unit will be shutdown, alarm LED (2) will flash, automatic operation LED (4) will go out and
following screen will appear:

Figure 14: Main screen with shutdown indication

Actions:
• Switch off the voltage and remedy the problem cause.
• In case of incorrect phase sequence, reverse two phases of the supply cable.
• If the additional temperature switch (TSHH21) has tripped, you must contact the Atlas Copco
customer center.
• After remedying and when the shutdown condition has disappeared, switch on the voltage and
restart the unit. The shutdown message will disappear automatically when the shutdown
condition has disappeared.

3.8 Menu screen

Function
This screen is used to display the different menus where settings can be viewed or changed.

Procedure
The Menu screen can be viewed by tapping the Menu button or by swiping right, starting from the
main screen.

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Description

Reference Designation Function

The data menu contains the status of the unit, information
(1) Data about the Inputs, Outputs and Counters. The Auxiliary
equipment can also be viewed through this menu.
The service menu contains the Service information. The ‘Clean
(2) Service
screen’ function can be used to clean the touchscreen.
Multiple Week timers and a Remaining running time can be set
(3) Week timer
through this menu.
In case of an alarm, the Status information of the unit is saved
(4) Event history
and can be viewed through this menu.
Alarms settings, Regulation settings and Control parameters
can be changed through this menu. Auxiliary equipment
(5) Machine settings parameters can also be changed.
The Auto restart function can be set through this menu. This
function is password protected.
Network settings, Localisation settings and a User password
(6) Controller settings can be set through this menu. There is also a Help page
available and the Controller information can be shown.

Menu structure
Operating the controller can be done by swiping through screens and tapping icons or menu items.

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This is the main menu structure. The structure can be different depending on the configuration of
the unit.

3.9 Data menu

Function
This screen is used to display the following submenus:
• Status
• Inputs
• Outputs
• Counters
• Aux. Equipment
These submenus can be entered by tapping the icons.

Procedure
To enter the Data menu screen:
1. Tap the Menu button
2. Tap the Data icon

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Description

Reference Designation
(1) Status menu
(2) Inputs menu
(3) Outputs menu
(4) Counters menu
(5) Auxiliary equipment menu

Status menu
Tap the Status icon to enter the Status menu.

This menu shows the current status of the unit.

If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the
reset button (1).

Before remedying, consult the Safety precautions.

Before resetting a warning or shutdown message, always solve the problem.
Frequently resetting these messages without remedying may damage the unit.

Inputs menu
Tap the Inputs icon to enter the Inputs menu.

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This menu shows information about all the inputs.

Outputs menu
Tap the Outputs icon to enter the Outputs menu.

This menu shows information about all the outputs.

Voltage-free outputs may only be used to control or monitor functional

systems. They should NOT be used to control, switch or interrupt safety
related circuits.
Check the maximum allowed load on the label.
Stop the unit and switch off the supply before connecting external equipment.
Check the Safety precautions.

Counters menu
Tap the Counters icon to enter the Counters menu.

This menu shows an overview of all actual hours and counters of the unit and controller.

Auxiliary equipment menu

Tap the Aux. Equipment icon to enter the Aux. equipment menu.

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This menu shows an overview of all auxiliary equipment fitted.

3.10 Service menu

Function
This screen is used to display the following submenus:
• Service
• Service functions (Only visible as advanced user)
• Clean screen
These submenus can be entered by tapping the icons.

Procedure
To enter the Service menu screen:
1. Tap the Menu button
2. Tap the Service icon

Description

Reference Designation
(1) Service
(2) Service functions (Only visible as advanced user)
(3) Clean screen

Service menu
Tap the Service icon to enter the Service menu.

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This menu shows the remaining Running Hours and the remaining Real Time Hours until the next
service. The first row (A) shows the Running Hours when the first service is needed (green), the
second row shows the Real Time Hours (blue)
A service overview can be viewed by tapping icon (1).
The service history can be viewed by tapping icon (3).
When a service plan interval is reached, a message will appear on the screen.

Clean screen
Tap the Clean Screen icon to start the 15 seconds countdown to perform cleaning of the
touchscreen.

The touchscreen and the start and stop button become inactive for 15 seconds.

3.11 Week timer menu

Function
This screen is used to set up to 4 different week timers with each up to 8 settings per day.
The week timers can be activated through this screen.
A Remaining Running Time can be set from 5 up to 240 minutes.

Procedure
To enter the Week Timer menu screen:
1. Tap the Menu button
2. Tap the Week Timer icon

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Description

Reference Designation Function

If less than 4 weeks are programmed, tap the ‘+’ button to add
(1) Add or select week
a week.
(2) Remove week Tap to remove a programmed week timer.
A selection screen pops up. The user can choose the correct
(3) Activate week timer week by tapping ‘–’ or ‘+’ and can confirm by tapping ‘V’ or
decline by tapping ‘X’.
A selection screen pops up. The user can change the
Remaining running
(4) remaining time by tapping ‘–’ or ‘+’ and can confirm by tapping
time
‘V’ or decline by tapping ‘X’.
A selection screen pops up. The user can change the setting
(5) Add setting by swiping up or down and confirm by tapping ‘V’ or decline by
tapping ‘X’.

3.12 Event history menu

Function
This screen is used to display the saved data in case of an alarm.
These submenus can be entered by tapping the icons.

Procedure
To enter the Event history menu screen:
1. Tap the Menu button
2. Tap the Event History icon

Description

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Reference Designation
(1) Saved Data

Saved data
Tap the Saved Data icon to enter the Saved Data menu.

Scroll through the items swiping up and down in this list. The event date and time is shown at the
right side of the screen.
Press on one of the items in the list for more information reflecting the status of the unit when the
shutdown occurred.

3.13 Machine settings menu

Function
This screen is used to display the following submenus:
• Alarms
• Regulation
• Control Parameters
Only visible if the machine has adaptable parameters.
• Aux. Equipment parameters
• Auto Restart
These submenus can be entered by tapping the icons.

Procedure
To enter the Machine settings menu screen:
1. Tap the Menu button
2. Tap the Machine Settings icon

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Description

Reference Designation
(1) Alarms menu
(2) Regulation menu
(3) Control Parameters menu
(4) Aux. Equipment Parameters menu
(5) Auto Restart menu

Alarms menu
Tap the Alarms icon to enter the Alarms menu.

A list of all alarms is shown.

When pressing on one of the items in this list, the warning and/or shutdown levels are shown for
this alarm.

Regulation menu
Tap the Regulation icon to enter the Regulation menu.

Setpoints or pressure bands can be modified through this menu.

Modify a setting

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When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by swiping
up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.

Control parameters menu

Tap the Control Parameters icon to enter the Control Parameters menu.

This menu shows information about the Control Parameters.

Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.

Auxiliary equipment parameters menu

Tap the Aux. Equipment Parameters icon to enter the auxiliary equipment parameters menu.

This menu shows an overview of all the auxiliary equipment fitted.

Through this menu, the parameters of the auxiliary equipment can be changed.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.

Auto restart menu

If the function is activated and provided the regulator was in the automatic
operation mode, the unit will automatically restart if the supply voltage to the
module is restored.
The ARAVF label shall be glued next to the controller.

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Tap the Auto restart icon to enter the Auto Restart menu.
The controller has a built-in function to automatically restart the unit when the voltage is restored
after voltage failure. For units leaving the factory, this function is made inactive. If desired, the
function can be activated. Consult your supplier.

Through this menu, the automatic restart can be activated. The activation is password protected.
The automatic restart settings can also be changed.
Enter a password
When tapping a password protected item, a selection screen pops up. The user can enter the
password by swiping up or down to select the desired number. Once the 4 digits are entered, the
user can confirm by tapping ‘V’ or decline by tapping ‘X’.
Modify a setting
When clicking a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.

3.14 Controller settings menu

Function
This screen is used to display the following submenus:
• Network Settings
• Localisation
• User Password
• Help
• Information
These submenus can be entered by tapping the icons.

Procedure
To enter the Controller Settings menu screen:
1. Tap the Menu button
2. Tap the Controller Settings icon

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Description

Reference Designation
(1) Network Settings menu
(2) Localisation menu
(3) User Password menu
(4) Help menu
(5) Information menu

Network settings menu

Tap the Network Settings icon to enter the Network Settings menu.

Ethernet Settings
The list of Ethernet Settings is shown. When ethernet is turned off, the settings can be modified.
CAN Settings
The list of CAN Settings is shown. When CAN is turned off, the settings can be modified.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by swiping
up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.

Localisation menu
Tap the Localisation icon to enter the Localisation menu.

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Language
The language setting of the controller can be modified through this menu.
Date/Time
The date and time settings of the controller can be modified through this menu.
Units
The units displayed can be modified through this menu.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by swiping
up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.

User password menu

Tap the User Password icon to enter the User Password menu.

The user password can be activated or deactivated through this menu. Enter and confirm a user
password to activate, repeat to deactivate.
Enter a password
When tapping a password protected item, a selection screen pops up. The user can enter the
password by swiping up or down to select the desired number. Once the 4 digits are entered, the
user can confirm by tapping ‘V’ or decline by tapping ‘X’.

Help menu
Tap the Help icon to enter the Help menu.

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This menu can show a link to the web page of your supplier, a helpdesk phone number or other
helpful information.

Information menu
Tap the Information icon to enter the Information menu.

This menu shows information about the controller.

3.15 Access level

Function
Through this pop-up screen the access level settings can be viewed or changed.

Procedure
The Access Level screen can be viewed or changed by tapping the Access Level button at the
upper right corner of the screen.

Description

Reference Designation Function

(1) User A basic set of parameters is visualized, no password required.
(2) Service This access level is only to be used by certified technicians.

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Reference Designation Function

(3) Full This access level is only to be used by certified technicians.
(4) Decline Tap to decline the selected user level.
(5) Confirm Tap to confirm the selected user level.

3.16 Web server

All 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 the display of the controller.

Getting started
Make sure you are logged in as administrator.
• Use the internal network card from your computer or a USB to LAN adapter.
• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).

Configuration of the network card

• Go to Network and Sharing Center (1).

• Click on Change adapter settings (1).

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• Select the Local Area Connection, which is connected to the controller.

• Click with the right button and select Properties (1).

• Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid conflicts,
uncheck other properties if they are checked. After selecting TCP/IPv4, click on the Properties
button (2) to change the settings.

• Use the following settings:

• IP Address 192.168.100.200 (1)
• Subnetmask 255.255.255.0 (2)
Click OK (3) and close network connections.

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Configure a company network (LAN) connection

• Ask your IT department to generate a fixed IP address in your company’s network.
• That IP address will be excluded from the DNS server, so it will be reserved for the controller.
• Also get the correct Gateway and Subnet mask settings. For example:
• IP = 10.25.43.200
• Gateway = 10.25.42.250
• Subnet mask = 255.255.254.0
• Connect the controller to the company's network (LAN) by using a UTP cable (min. CAT 5e).

• Adapt the network settings in the controller.

• Put the controller in “advanced status”, tap “Controller Settings”, ”Network settings”, and
at last “Ethernet settings”:

• Switch off the ethernet communication to allow editing the settings:

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• Adapt IP Address
• Adapt Gateway IP
• Adapt Subnetmask
• Switch on the Ethernet communication
• Wait a few minutes so the controller can be connected to the LAN network

Configuration of the web server

®
The internal web server is designed and tested for Microsoft Internet Explorer.
Also "Opera", "Mozilla Firefox", "Safari"and "Chrome" should work.
Viewing the controller data

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:

Figure 15: Screen shot (example!)

Navigation and options

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• The banner shows the unit 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.
If a license for ESi is foreseen, the menu contains 3 buttons.
• Machine: shows all generator settings.
• ES: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure unit.

Unit settings
All unit 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 can not be removed from the main screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference
button from the navigation menu.

Counters
Lists all current counter values from controller and unit.

Info status

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Machine status is always shown on the web interface.

Digital inputs
Lists all digital inputs and their status.

Digital outputs
Lists all digital outputs and their status.

Special protections
Lists all special protections of the unit.

Service plan
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.

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3.17 Programmable settings

Parameters

Minimum Factory Maximum

setting setting setting
Motor running time in star sec 5 10 10
Load delay time (star-delta) sec 0 0 10
Number of motor starts starts/day 0 240
Minimum stop time sec 10 20 30
Programmed stop time sec
Power recovery time (ARAVF) sec 3600
Restart delay sec 1200
Communication time-out sec 10 30 60

Service plan
The built-in service timers will give a Service warning message after their respective pre-
programmed time interval has elapsed.
Also see section .
Consult Atlas Copco if a timer setting has to be changed. The intervals must not exceed the
nominal intervals and must coincide logically. See section Modifying general settings.

Terminology

Term Explanation
Automatic Restart After Voltage Failure. See section Elektronikon regulator and
ARAVF
Modifying general settings.
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. To activate the
time
automatic restart function, consult Atlas Copco.
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
temperature sensor the setting can be decreased to 50 ˚C (122 ˚F). Reset the
value after testing.
Compressor
The regulator does not accept illogical settings, e.g. if the warning level is
element outlet
programmed at 95 ˚C (203 ˚F), the minimum limit for the shutdown level
changes to 96 ˚C (204 ˚F). The recommended difference between the warning
level and shutdown level is 10 ˚C (18 ˚F).

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Term Explanation
Delay at
Is the time for which the signal must exist before the compressor is shut down.
shutdown
If it is required to program this setting to another value, consult Atlas Copco.
signal
Use only Atlas Copco oil separators. The recommended maximum pressure
Oil separator
drop over the oil separator element is 1 bar (15 psi).
Once the compressor has automatically stopped, it will remain stopped for the
Minimum stop
minimum stop time, whatever happens with the net air pressure. Consult Atlas
time
Copco if a setting lower than 20 seconds is required.
The regulator does not accept inconsistent settings, e.g. if the unloading
Unloading/ pressure is programmed at 7.0 bar(e) (101 psi(g)), the maximum limit for the
Loading loading pressure changes to 6.9 bar(e) (100 psi(g)). The recommended
pressure minimum pressure difference between loading and unloading is 0.6 bar (9
psi(g)).

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4 Installation

4.1 Dimension drawings

The drawings are on the USB, supplied with your machine.

Dimension drawing Model

9820 9466 00 GA 55, GA 75, GA 90, GA 55+, GA 75+

Text on drawings Translation or Explanation

Compressor cooling air outlet Cooling air outlet of compressor and motor
Compressor cooling air inlet Cooling air inlet of compressor and motor
Compressed air outlet Compressed air outlet connection
Electrical cable passage Electrical cable passage
Cubicle cooling air outlet Cubicle cooling air outlet
Cubicle cooling air inlet Cubicle cooling air inlet
Doors fully open Dimensions with doors fully open
Cooling water outlet Cooling water outlet connection
Cooling water inlet Cooling water inlet connection
Prepared for manual drain Prepared for manual drain
Dryer cooling air inlet Dryer cooling air inlet
Dryer cooling air outlet Dryer cooling air outlet
Centre of gravity Centre of gravity
Mass Mass of the machine
Type Machine type
Water outlet (Energy recovery - option) Water outlet (Energy recovery - option)
Water inlet (Energy recovery - option) Water inlet (Energy recovery - option)
Automatic drain, dryer Automatic drain, dryer
Automatic drain, aftercooler Automatic drain, aftercooler
Manual drain, dryer Manual drain, dryer
Manual drain, aftercooler Manual drain, aftercooler
Compressed air connection for OSCi Compressed air connection for OSCi
Electrical connection for OSCi Electrical connection for OSCi
Ambient sensor Ambient sensor

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4.2 Installation proposal

Compressor room example

Figure 16: Compressor room example

(1) Air cooling

(2) Water cooling
(3) The direction of the cooling flows may never be inverted

Description

Compressor
1
Install the compressor unit on a solid, level floor, suitable for taking its weight.

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2 Position of the compressed air outlet valve.

The pressure drop over the air delivery pipe can be calculated from:
Δp = (L x 450 x Qc1.85) / (d5 x P), with
d = inner diameter of the pipe in mm
Δp = 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:
4 Qv = 1.06 N/ΔT
• For compressors with dryer:
Qv = (1.06 N + 1.2 D)/ΔT
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
ΔT = 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.
Apply separate outlet ducts for the compressor and the dryer.
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 environmental
5
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.

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Filter DD for general purpose filtration (particle removal down to 1 micron with a
maximum oil carry over of 0.5 mg/m3. A high-efficiency filter, type PD, may be installed
downstream of a DD filter. This filter traps solid particles down to 0.01 micron with a
maximum oil carry-over of 0.01 mg/m3. If oil vapors and odors are undesirable, a QD
9
type filter can be installed downstream of the PD filter.
It is recommended to install bypass pipes with ball valves over each filter in order to
isolate 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 ΔP x T1), with
V = volume of the air net in l
10
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)
ΔP = difference between unloading pressure and loading pressure in bar
T1 = compressor air inlet temperature in K
T0 = air receiver temperature in K
Bypass system to bypass the dryer during service operations (available as an option,
11
consult Atlas Copco).
Air-cooled compressors:
To prevent feedback of exhaust air into the cooling inlet, sufficient space should be
12a
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.
When a duct is foreseen on the air inlet, the ambient temperature sensor need to be
14
repositioned in such a way that the inlet temperature is monitored.
15 Safety valve

Safety

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

Outdoor/altitude operation
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.

Moving/lifting
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

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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.

4.3 Electrical connections

Important remark

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.

Electrical connections

Reference Designation
(1) Customer’s installation
(2) Option
(3) All voltages (50 and 60 Hz)
(4) GA 75-90 200-230 V (except GA75 230 V): 6 fuses
(5) All other versions: 3 fuses

Instructions
1. Provide an isolating switch.

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Instruction book

2. Check that the motor cables and wires inside the electric cabinet are clamped tight to their
terminals.
3. Check the fuses and the setting of the overload relay. See section Electrical cable size.
4. If terminals 1, 3 and 5 of motor contactors K21 and K23 are not bridged, connect power supply
cables to terminals 1, 3 and 5 of contactor K21 and to terminals 1, 3 and 5 of contactor K23.
If terminals 1, 3 and 5 of motor contactors K21 and K23 are bridged, connect power supply
cables to terminals L1, L2 and L3 of terminal strip 1X0.
The power cables must be connected stress-free to the terminals to avoid mechanical forces to
the terminals. For this reason, the use of flexible cables is strongly advised.
Also see section Electrical cable size
5. Connect earth conductor bolt (PE).

Compressor control mode

The following control modes can be selected:
• Local control: The compressor will react to commands entered by means of the buttons on the
control panel. Compressor start/stop commands via Clock function are active, if programmed.
• Remote control: The compressor will react to commands from external switches. Emergency
stop remains active. Compressor start/stop commands via Clock function are still possible.
Options:
• Remote starting and stopping (switch S1')
• Remote loading/unloading (switch S4')
• Remote pressure sensing (switch S' combined with pressure switch S4')

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.

• LAN control: The compressor is controlled via a local network. Consult Atlas Copco.
See section Electrical system to locate the connectors.

4.4 Pictographs
Description

1 2

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3 4

5 6

7 8

9 10

11 12

13 14

15

Table 2: Pictographs

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Instruction book

Reference Designation
Warning: Always read the manual, switch off the voltage, depressurise
1
compressor and lock out/ tag out before repairing.
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
Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx.
7
half a turn)
Before connecting the compressor electrically, consult the Instruction book for
8
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)
15 Automatic Restart After Voltage Failure (ARAVF)

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5 Operating instructions

5.1 Initial start-up

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.

Preparations
1. Consult the sections Electrical cable size, Installation proposal and Dimension drawings.
2. The following transport fixtures, painted red, must be removed:
• 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)

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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. Check transformer (T1) for correct connection.
Check the settings of drive motor overload relay (F21).
Check that the motor overload relay is set for manual resetting.

Figure 17: Example of electric cubicle on GA 55+ up to GA 90

5. On air-cooled compressors, check the setting of circuit breaker (Q15). Also check that the
switch on the circuit breaker is in position I.
6. Fit air outlet valve (AV). See section Introduction for the location of the valve.

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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.
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. Provide labels, warning the operator that:
• The compressor may automatically restart after voltage failure (if activated, consult Atlas
Copco).
• The compressor is automatically controlled and may be restarted automatically.

Initial start procedure

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. Disconnect the inlet hose.
2. Remove the unloader (UA).
3. Pour approximately 0.75 l (0.20 US gal, 0.17 Imp gal) of compressor oil into
the compressor element inlet. For oil specifications, see section Oil
specifications.
4. Reinstall the unloader and reconnect the inlet hose.
Make sure that all connections are tight.

Figure 18: Location of unloader

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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).

2. 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.
Incorrect rotation direction of the drive motor may cause damage to the compressor.
3. 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).
4. Check the programmed settings.
5. Start and run the compressor for a few minutes. Check that the compressor operates normally.

5.2 Before starting

Procedure
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 oil level. Top up if necessary.

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Figure 19: Position of oil level sight glass

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.

Figure 20: Position of air filter and service indicator

5.3 Starting

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

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Figure 21: Control panel Elektronikon™ Touch

Procedure
1. Open the air outlet valve.
2. Switch on the voltage. Check that voltage on LED lights up.
3. Press the start button on the control panel. The compressor starts running and the automatic
operation LED lights up. Ten seconds after starting, the drive motor switches over from star to
delta and the compressor starts running loaded.

5.4 During operation

Warnings

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 (automatic operation) is alight, the
motors may start automatically.

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Checking the oil level

Figure 22: Control panel Elektronikon™ Touch

Regularly check the oil level. To do so:

1. Press the stop button on the control panel.
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 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.

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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).
Unlock the emergency stop button, select the STOP icon and press reset before starting.

Air filter

Figure 23: Position of the service indicator

Regularly check the service indicator. If the colored 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.

Drains
Regularly check that condensate is discharged during operation. See section Condensate system.
The amount of condensate depends on environmental and working conditions.

5.5 Checking the display

Compressors with Eletronikon™ Touch controller:

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Figure 24: Control panel Elektronikon™ Touch

Check the display (1) 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 (2) is lit or flashes.
The display (1) 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. The service LED is on. Carry out the
service actions of the indicated plans or replace the component and reset the relevant timer.

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5.6 Stopping
Control panel

Figure 25: Control panel Elektronikon™ Touch

Procedure

Step Action
For Elektronikon™ Touch, press stop button (6). Automatic operation LED (4) goes out
-
and the compressor stops after 30 seconds of unloaded operation.
To stop the compressor in the event of an emergency, for Elektronikon™ Touch,
press the emergency stop button. Alarm LED (2) flashes.
- • Remedy the problem cause and unlock the stop button by pulling it out.
• Reset the alarm.
Do not use the emergency stop button for normal stopping!
- Close the air outlet valve.
Press the test button on top of the electronic water drain(s) (if supplied) to the
depressurize the piping between air receiver and outlet valve, next open the manual
-
drain valve (Dm). See section Condensate system.
Switch off the voltage.

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5.7 Taking out of operation

Warning

The operator must apply all relevant Safety precautions.

Procedure

Step Action
- Stop the compressor and close the air outlet valve.
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. Consult section
Condensate system to locate the drain.
- 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 filler plug.
Shut off and depressurize the part of the air net which is connected to the outlet valve.
-
Disconnect the compressor air outlet pipe from the air net.
- Drain the oil.
Drain the condensate circuit and disconnect the condensate piping from the
-
condensate net.

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6 Maintenance

6.1 Preventive maintenance schedule

Warning

Figure 26: Control panel Elektronikon™ Touch

Always apply all relevant Safety precautions.

Before carrying out any maintenance, repair work or adjustments, proceed
as follows:
• 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.
• Switch off the voltage. Open and lock the isolating switch.
• Depressurize the compressor by opening the oil filler plug one turn.
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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Warranty - Product Liability

Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is
not covered by Warranty or Product Liability.

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

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

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

Intervals
The local Atlas Copco Customer Center 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.

Preventive maintenance schedule

Following actions have to be done on a regular basis:

Period Action
Check oil level.
Check readings on display.
Daily Check air filter service indicator.
Check that condensate is discharged during operation.
Drain condensate.
Check that condensate is discharged when pressing the test button on top of the
Monthly
electronic water drain.
Check coolers. Clean if necessary.
Remove the air filter element and inspect. If necessary, clean using an air jet.
3-monthly (1)
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.
8000 hours (2) Refer to the motor data plate for greasing instructions of the motor bearings (for
motors equipped with grease nipples).
Every 24000
Check and replace the motor bearings.
hours
Every 5 years
or 40000 hours Replace all rubber hoses.
(2)

Table 3: Maintenance checklist

(1): More frequently when operating in a dusty atmosphere

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Instruction book

(2): Whichever comes first

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 menu for compressors with an Elektronikon™ Touch controller.
After servicing, the service timer must be reset.

Running
Action
hours
If Atlas Copco Roto-Inject Fluid NDURANCE is used, change oil and oil filter. (3)
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.
4000 (1) Test the temperature shutdown function.
On air-cooled compressors: clean coolers. Check and clean the 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.
If Roto synthetic Fluid ULTRA or Roto Synthetic Fluid XTEND DUTY is used,
change oil and oil filter. (3)
Have the oil separator element replaced.
The oil separator element must also be replaced when the pressure drop over it
8000 (2)
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.

Table 4: Preventive Maintenance schedule programmed in the Elektronikon™ controller

(1): or yearly, whichever comes first

(2): or every 2 years, whichever comes first
(3): See also section Oil Specifications for oil exchange intervals in non standard working
conditions.
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.

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 Instruction book

• Never modify a timer setting without approval from Atlas Copco.

• For the change interval of oil and oil filter in extreme conditions consult your
Atlas Copco Customer Center.
• Any leakage should be attended to immediately. Damaged hoses or flexible
joints must be replaced.

6.2 Oil specifications

In order to achieve the best machine performance and guarantee the reliability, it is required to use
genuine Atlas Copco Lubricants. Their tailor made formulation is the result of years of field
experience, research and in-house development. Consult the Spare Parts list for part number
information.

Avoid mixing lubricants of different brands or types as they may not be

compatible and the oil mix may have inferior properties. A label, indicating the
type of oil filled ex factory, is stuck on the air receiver/oil tank.

Ambient temperature Humid Dust Duty type

Below 30 °C (86 °F) No No Mild
Below 30 °C (86 °F) Yes No Mild
Below 30 °C (86 °F) No Yes Mild
Below 30 °C (86 °F) Yes Yes Demanding
Between 30 °C (86 °F)
No No Demanding
and 40 °C (104 °F)
Between 30 °C (86 °F)
Yes No Demanding
and 40 °C (104 °F)
Between 30 °C (86 °F)
No Yes Demanding
and 40 °C (104 °F)
Between 30 °C (86 °F)
Yes Yes Extreme
and 40 °C (104 °F)
Above 40 °C (104 °F) - - Extreme

Table 5: Relation between the operating conditions and the duty type

Roto-Inject Fluid NDURANCE

Atlas Copco's Roto-Inject Fluid NDURANCE is a premium mineral oil based 4000 hours lubricant,
specially developed for use in single stage oil injected screw compressors running in mild
conditions. Its specific formulation keeps the compressor in excellent condition. Roto-Inject Fluid
NDURANCE can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F)
and 40 ˚C (104 ˚F). If the compressor is regularly operating in ambient temperatures above 35 °C
(95 °F), it is recommended to use Roto Synthetic Fluid ULTRA or Roto Synthetic Fluid XTEND
DUTY.
See the table below for recommended oil exchange intervals:

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Instruction book

Ambient temperature Element outlet Exchange interval Maximum time

temperature interval
up to 30°C (86°F) up to 95°C (203°F) 4000 1 year
from 30°C (86°F) up to from 95°C (203°F) up
3000 1 year
35°C (95°F) (see note) to 100°C (212°F)
from 35°C (95°F) up to
from 100°C (212°F) up
40°C (104°F) (see 2000 1 year
to 105°C (221°F)
note)
use Roto Synthetic use Roto Synthetic
above 40°C (104°F) above 105°C (221°F)
Fluid XTEND DUTY Fluid XTEND DUTY

Note: the presence of dust and/or high humidity may require a shorter exchange interval. Consult
Atlas Copco.

Roto Synthetic Fluid ULTRA

Roto Synthetic Fluid ULTRA is a synthetic oil based 4000 hours lubricant, specially developed
for use in single stage oil injected screw compressors running in demanding conditions. Roto
Synthetic Fluid ULTRA can be used for compressors operating at ambient temperatures between 0
˚C (32 ˚F) and 40 ˚C (104 ˚F). For more extreme conditions, or when continuously operating at
temperatures above 40 °C (104 °F), it is recommended to use Roto Synthetic Fluid XTEND DUTY.
See the table bloew for recommended oil exchange intervals:

Ambient temperature Element outlet Exchange interval Maximum time

temperature interval
up to 35°C (95°F) up to 100°C (212°F) 6000 2years
from 35°C (95°F) up to
from 100°C (212°F) up
40°C (104°F) (see 4000 2years
to 105°C (221°F)
note)
from 40°C (104°F) up
from 105°C (221°F) up
to 45°C (113°F) (see 2000 2years
to 110°C (230°F)
note)

Note: the presence of dust and/or high humidity may require a shorter exchange interval. Consult
Atlas Copco.

Roto Synthetic Fluid XTEND DUTY

Atlas Copco's Roto Synthetic Fluid XTEND DUTY is a high quality synthetic 8000 hours lubricant
for oil injected screw compressors which keeps the compressor in excellent condition. Because of
its excellent oxidation stability, Roto Synthetic Fluid XTEND DUTY can be used for compressors
operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F).
See the table below for oil exchange intervals:

Ambient temperature Element outlet Exchange interval Maximum time

temperature interval
up to 35°C (95°F) up to 100°C (212°F) 8000 2 years

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Ambient temperature Element outlet Exchange interval Maximum time

temperature interval
from 35°C (95°F) up to
from 100°C (212°F) up
40°C (104°F) (see 6000 2 years
to 105°C (221°F)
note)
above 40°C (104°F) above 105°C (221°F) 5000 2 years

Note: the presence of dust and/or high humidity may require a shorter exchange interval. Consult
Atlas Copco.
* Whichever comes first.

6.3 Drive motor

General
Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a
brush and/or compressed air jet.

Bearing maintenance
The bearing at the drive end side is lubricated by the oil system and requires no periodic
maintenance.
The non drive end side bearing of motors without grease nipples requires no periodic maintenance.
Motors with a grease nipple at the non drive end side must follow the maintenance interval as
mentioned on the motor data plate.

6.4 Air filter

Location of air filter

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Recommendations
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.

Procedure
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.

6.5 Oil and oil filter change

Warning

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.

Procedure

Figure 27: Oil drain and filler plug on the oil separator vessel

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Figure 28: Oil drain plugs, check valve and gear casing

Figure 29: Vent plug, oil cooler

Step Description
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.
- Air cooled units: loosen the vent plug (VP) of the oil cooler and wait for 5 minutes.
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.

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Step Description
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.

6.6 Coolers
General
Keep the coolers clean to maintain their efficiency.

Instructions for air-cooled compressors

• Stop the compressor, close the air outlet valve and switch off the voltage.
• 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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6.7 Safety valves

Location of safety valve

Figure 30: Position of safety valve (typical view)

Operating
Operate the safety valve from time to time by unscrewing the cap one or two turns. Retighten it
afterwards.

Testing
Before removing the valve, depressurize the compressor. See also section Problem solving.
The safety 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.

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

6.8 Service kits

Service kits
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.

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6.9 Storage after installation

Procedure
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.

6.10 Disposal of used material

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.

Electronic components are subject to the EU Directive 2012/19/EC for Waste Electrical and
Electronic Equipment (WEEE). As such, these parts must not be disposed of at a municipal waste
collection point. Refer to local regulations for directions on how to dispose of this product in an
environmental friendly manner.

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7 Problem solving
Warning

Always apply all relevant Safety precautions.

Before carrying out any maintenance, repair work or adjustment, press the stop
button, wait until the compressor has stopped and close the air outlet valve.
Open the manual drain valve(s).
Press the emergency stop button and switch off the voltage. Open and lock the
isolating switch.
Depressurise the oil separator vessel by opening the oil filler plug one turn.
For location of components: see sections Introduction, Condensate system and
Initial start.
The air outlet valve can be locked during maintenance or repair as follows:
• Close the valve.
• Remove the screw fixing the handle with the wrench delivered with the
compressor.
• Lift the handle and turn it until the slot of the handle fits over the blocking
edge on the valve body.
• Fit the screw.
• 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.

Faults and remedies, compressor

Condition Fault Remedy

Compressor does not start or
stops during operation. Find cause and remedy.
Motor overload relay (F21) open
Elektronikon shows motor Replace if necessary.
overload problem.
Circuit breaker (Q15) or fan Find cause and remedy.
motor overload (F15) open Replace if necessary.

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Condition Fault Remedy

Too high temperature in oil
separator vessel or temperature
switch (TSHH1) defective

Find cause and remedy.

Replace if necessary.

Motor thermistor (K34) tripped or Find cause and remedy.

defective Replace if necessary.
Phase sequence relay (K25) Find cause and remedy.
open Replace if necessary.
Find cause and remedy.
Wiring interrupted
Replace if necessary.
Compressor starts running, but
does not load after a delay Solenoid valve out of order Replace valve
time
Inlet valve stuck in closed
Have valve checked
position
Leak in control air tubes Replace leaking tubes
Minimum pressure valve leaking
Have valve checked
(when air net is depressurised)
Compressor does not unload, Solenoid valve out of order Replace valve
safety valve blows Inlet valve does not close Have valve checked
Condensate is not discharged
Check and correct as
from condensate separator Discharge tube clogged
necessary
during loading
Compressor air output or Air consumption exceeds air Check the connected
pressure below normal delivery of compressor equipment.
Choked air filter element Replace filter element
Solenoid valve malfunctioning Replace valve
Oil separator element clogged Have element replaced
Have leaks repaired. Replace
Air leakage
leaking tubes
Safety valve leaking Replace valve
Inlet valve does not fully open Have valve checked
Compressor element out of order Consult Atlas Copco
Excessive oil flow through air Check valve leaking or oil stop Replace defective parts.
inlet filter after stopping valve jammed Replace air filter element
Excessive oil consumption; oil
carry-over through discharge Incorrect oil causing foam Change to correct oil
line

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Condition Fault Remedy

Check for overfilling. Release
Oil level too high pressure and drain oil to
correct level.
Oil separator defective Replace oil separator element
Malfunctioning of the scavenge Replace non-return valve in
line the scavenge line
Safety valve blows after
Inlet valve malfunctioning Have valve checked
loading
Minimum pressure valve
Have valve checked
malfunctioning
Safety valve out of order Have valve replaced
Have oil separator element
Oil separator element clogged
replaced
Compressor element out of order Consult Atlas Copco
Compressor element outlet
temperature or delivery air Oil level too low Check and correct
temperature above normal
Check for cooling air
restriction or improve
On air-cooled compressors, ventilation of the compressor
insufficient cooling air or cooling room. Avoid recirculation of
air temperature too high cooling air. If installed, check
capacity of compressor room
fan
Oil cooler clogged Clean cooler
Bypass valve malfunctioning Have valve tested
Air cooler clogged Clean cooler
Compressor element out of order Consult Atlas Copco

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8 Technical data

8.1 Readings on display

Control panel

Figure 31: Control panel Elektronikon™ Touch

Important

The readings mentioned below are valid under the reference conditions (see
section Reference conditions and limitations).

Reference Reading
Air outlet pressure Modulates between programmed unloading and loading pressures.
Compressor element For air-cooled units: approx. 60 ˚C (108 ˚F) above cooling air inlet
outlet temperature temperature

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8.2 Electric cable size and fuses

Important

• 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 are grouped together with other power cables, it may be necessary
to use cables of a larger size than those calculated for the standard
operating conditions.
• 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 cable to the
compressor.
• 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

Currents and fuses

Compressor type I (1) Max. fuse (1) I (2) Max. fuse (2)
K5/ K5/
HRC form II HRC form II
V Hz A A A A
GA 75 460 60 134 150 142 200

Table 6: UL/cUL approval

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

(1): compressors without integrated dryer
(2): compressors with integrated dryer
Fuse calculations for cUL and UL: The indicated fuse size is the maximum fuse size in order to
protect the motor against short circuit. For cUL fuse HRC form II, for UL fuse class RK5.

Possible configurations
There are 3 possible cabling layouts:

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• (1): Single supply cables.

• (2): Parallel supply cables
• (3) is only valid for Y-D versions

Cable sizing according UL/cUL

Calculation method according UL 508A, table 28.1 column 5: allowable ampacities of insulated
copper conductors (75 °C (167 °F)).

AWG or kcmil Maximum current

10 < 30 A
8 < 50 A
6 < 65 A
4 < 85 A
3 < 100 A
2 < 115 A
1 < 130 A
1/0 < 150 A
2/0 < 175 A
3/0 < 200 A

Table 7: Maximum allowed current in function of the wire size

Calculation method for UL:

• Single supply cables (3 phases + 1 PE - configuration (1)):
• Add 25 % to the total current from the tables (see UL 508A 28.3.2: "Ampacity shall have
125 % of the full load current")
• Install the prescribed maximum fuse on each cable
• Parallel supply cable (2 x 3 phases + 2 PE - configuration (2)):
• Add 25 % to the total current from the tables and divide by 2
• Multiply the ampacity of the cables with 0.8 (see UL 508A table 28.1 continued)
• Install fuses of half the size of the recommended maximum fuse size on each cable.
• When using 2 x 3 phase + 2 PE as in (3):
• Add 25 % to the total current from the tables and divide by √3
• Multiply the ampacity of the cables with 0.8 (see UL 508A table 28.1 continued)
• Fuse size: the recommended maximum fuse size divided by √3 on each cable.

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• Size PE cable:
• For supply cables up to AWG8: same size as the supply cables
• For supply cables larger than AWG8: use maximum allowed ampacity of the selected
supply cables and compare with value in table below (see CEC Part 1 table 17)

< 100 A: use AWG8

< 200 A: use AWG6
< 300 A: use AWG4

Always check the voltage drop over the cable (less than 5 % of the nominal voltage is
recommended).
Example of supply cable calculation: Itot = 128 A, maximum ambient temperature is 45 °C,
recommended fuse = 150 A
• Single supply cables (3 phases + 1 PE - configuration (1)):
• I = 128 A + 25 % = 128 x 1.25 = 160 A
• For AWG2/0, the maximum current is 175 A, which is sufficient => use AWG2/0
• Install the prescribed maximum fuse (150 A) on each cable
• Parallel supply cable (2 x 3 phases + 2 PE - configuration (2)):
• I = (128 A + 25%)/2 = (128 x 1.25)/2 = 80 A
• For a AWG4, the maximum current is 85 A x 0.8 = 68 A, which is insufficient. For an
AWG3, the maximum current is 100 x 0.8 = 80 A. So 2 parallel cables of 3 x AWG3 + 2 x
AWG8 are sufficient.
• Install 80 A fuses on each cable.

8.3 Protection settings

Setting motor overload relay (F21)
IE2 motor

Frequency (Hz) Voltage (V) GA 75

F21 (A)
UL/cUL
60 460 82

Settings for fan motor overload protection (Q15)

Frequency (Hz) Voltage (V) GA 75

Q15 (A)
UL/cUL
60 460 5.1

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8.4 Reference conditions and limitations

Reference conditions

Air inlet pressure (absolute) bar 1

Air inlet temperature ˚C 20
Relative humidity % 0
Working pressure See section Compressor data.

Limits

Maximum working pressure See section Compressor data.

Minimum working pressure bar(e) 4
Maximum air inlet temperature ˚C 46
Minimum ambient temperature ˚C 0

8.5 Compressor data

Reference conditions

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

GA 75

125
psi
Frequency Hz 60
Maximum (unloading) pressure, Workplace units bar(e) 9.1
Reference working pressure bar(e) 8.6
Set point of thermostatic valve ˚C 40
Motor shaft speed r/min 3570
Nominal motor power kW 75
Temperature of air leaving outlet valve, Workplace units ˚C 27
Oil capacity, air-cooled units l 27
Sound pressure level (according to ISO 2151 (2004)) dB(A) 73

8.6 Technical data controller

General

24 V AC /16 VA 50/60Hz (+40%/-30%)

Supply voltage
24 V DC/0.7 A
IP54 (front)
Type of protection
IP21 (back)

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• Operating temperature
range • -10°C…..+60°C (14 °F .....140 °F)
• Storage temperature • -30°C…..+70°C (-22 °F ......158 °F)
range
Relative humidity 90%
Permissible humidity
No condensation
Mounting Cabinet door

Digital outputs

Number of outputs 9 (Elektronikon™ Touch controller)

Type Relay (voltage free contacts)
Rated voltage AC 250 V AC / 10 A max.
Rated voltage DC 30 V DC / 10 A max.

Digital inputs

Number of inputs 10 (Elektronikon™ Touch controller)

Supply by controller 24 V DC
Supply protection Short circuit protected to ground
Input protection Not isolated

Analog inputs

Number of pressure inputs 2 (Elektronikon™ Touch controller)

Number of temperature
5 (Elektronikon™ Touch controller)
inputs

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9 Instructions for use

Oil separator vessel

This vessel can contain pressurized air. This can be potentially dangerous if the equipment is
misused.
This vessel must only be used as a compressed air/oil separator tank and must be operated within
the limits specified on the data plate.
No alterations must be made to this vessel by welding, drilling or other mechanical methods
without the written permission of the manufacturer.
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 allowable
operating pressure. It should guarantee that the pressure will not permanently exceed the
maximum allowable operating pressure of the vessel.
Use only oil as specified by the manufacturer.
Original bolts have to be used after opening for inspection. The maximum torque has to be taken
into consideration: for M12 bolts 73 Nm (53.8 lbf.ft)), for M16 bolts 185 Nm (136.4 lbf.ft).

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10 Guidelines for inspection

Guidelines
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this compressor.
Local legal requirements and/or use outside the limits and/or conditions as specified by the
manufacturer may require other inspection periods as mentioned below.

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11 Pressure equipment directives

Components subject to 97/23/EC Pressure Equipment Directive (until 20/07/2014) or 2014/68/EU
(from 20/07/2014 onwards)
The following table contains the necessary information for the inspection of all pressure equipment
of category II and higher according to the Pressure Equipment Directive 97/23/EC (2014/68/EU)
and all pressure equipment according to the Simple Pressure Vessel Directive 2009/105/EC
(2014/29/EU).

Minimum and
Compressor Design maximum PED
Component Description Volume
type pressure design Class
temperature
GA 55 + up to
1629 0338 11 Vessel 62 l 15 bar(e) -10 ˚C/ 120 ˚C II
GA 90
1202 5401 00 Safety valve - - - IV
1205 5749 00 Safety valve - - - IV
1613 5452 00 Safety valve - - - IV
1613 7810 00 Safety valve - - - IV

Number Minimum Inspection

Compressor type Component Description of cycles wall frequency
(1) thickness (2)
GA 55+ up to GA 90 1629 0338 11 Vessel 2 x 106 8 mm 10 years
1202 5401 00 Safety valve - - -
1202 5749 00 Safety valve - - -
1613 5452 00 Safety valve - - -
1613 7810 00 Safety valve - - -

The compressors conform to PED smaller than category II.

(1) The number of cycles refers to the number of cycles from 0 bar(e) to maximum pressure.
(2) The minimum wall thickness must be respected at all times. Inspection techniques such as
ultrasonic or X-ray are equivalent to hydrostatic testing for this equipment.

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12 Declaration of conformity

Figure 32: Typical example of a Declaration of Conformity document

(1): Contact address:

Atlas Copco Airpower n.v.
P.O. Box 100
B-2610 Wilrijk (Antwerp)
Belgium
(2): Applicable directives
(3): Standards used
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this device.

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© Printed in Atlas Copco Airpower N.V.. All rights reserved. Designs and specifications are subject to change
without notice or obligation… January 2022