GA22VSD Instruction Book Atlas Capco Air Compressor

Atlas Copco
GA 22 VSD
AIF999999
Instruction book
Atlas Copco
GA 22 VSD
AIF999999
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.
2013 - 06
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................5
1.1 SAFETY ICONS...................................................................................................................................5
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................5
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................6
1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................7
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................8
2 General description......................................................................................................10
2.1 INTRODUCTION.................................................................................................................................10
2.2 AIR FLOW.......................................................................................................................................12
2.3 OIL SYSTEM....................................................................................................................................13
2.4 COOLING SYSTEM.............................................................................................................................14
2.5 CONDENSATE SYSTEM.......................................................................................................................15
2.6 REGULATING SYSTEM........................................................................................................................16
2.7 ELECTRICAL SYSTEM.........................................................................................................................16
2.8 ELECTRICAL DIAGRAMS......................................................................................................................18
2.9 AIR DRYER......................................................................................................................................20
3 Elektronikon® Graphic controller...............................................................................22
3.1 ELEKTRONIKON® GRAPHIC CONTROLLER...............................................................................................22
3.2 CONTROL PANEL..............................................................................................................................24
3.3 ICONS USED....................................................................................................................................25
3.4 MAIN SCREEN..................................................................................................................................29
3.5 CALLING UP MENUS..........................................................................................................................34
3.6 INPUTS MENU...................................................................................................................................35
3.7 OUTPUTS MENU...............................................................................................................................38
3.8 COUNTERS......................................................................................................................................40
3.9 CONTROL MODE SELECTION................................................................................................................41
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3.10 SERVICE MENU................................................................................................................................43
3.11 MODIFYING THE SETPOINT..................................................................................................................47
3.12 EVENT HISTORY MENU.......................................................................................................................49
3.13 MODIFYING GENERAL SETTINGS...........................................................................................................50
3.14 INFO MENU......................................................................................................................................52
3.15 WEEK TIMER MENU...........................................................................................................................53
3.16 TEST MENU.....................................................................................................................................62
3.17 USER PASSWORD MENU.....................................................................................................................64
3.18 WEB SERVER..................................................................................................................................65
3.19 PROGRAMMABLE SETTINGS.................................................................................................................73
4 Installation.....................................................................................................................75
4.1 DIMENSION DRAWINGS.......................................................................................................................75
4.2 INSTALLATION PROPOSAL...................................................................................................................76
4.3 ELECTRICAL CONNECTIONS.................................................................................................................79
4.4 PICTOGRAPHS.................................................................................................................................81
5 Operating instructions.................................................................................................82
5.1 INITIAL START-UP..............................................................................................................................82
5.2 BEFORE STARTING............................................................................................................................85
5.3 STARTING ......................................................................................................................................85
5.4 DURING OPERATION..........................................................................................................................86
5.5 CHECKING THE DISPLAY.....................................................................................................................87
5.6 STOPPING ......................................................................................................................................87
5.7 TAKING OUT OF OPERATION................................................................................................................88
6 Maintenance..................................................................................................................89
6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................89
6.2 OIL SPECIFICATIONS..........................................................................................................................91
6.3 STORAGE AFTER INSTALLATION...........................................................................................................92
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6.4 SERVICE KITS..................................................................................................................................92
6.5 DISPOSAL OF USED MATERIAL.............................................................................................................92
7 Adjustments and servicing procedures.....................................................................93
7.1 DRIVE MOTOR .................................................................................................................................93
7.2 AIR FILTER......................................................................................................................................93
7.3 OIL AND OIL FILTER CHANGE...............................................................................................................94
7.4 COOLERS.......................................................................................................................................95
7.5 SAFETY VALVE.................................................................................................................................96
7.6 DRYER MAINTENANCE INSTRUCTIONS....................................................................................................97
8 Problem solving............................................................................................................98
9 Technical data.............................................................................................................101
9.1 READINGS ON DISPLAY....................................................................................................................101
9.2 ELECTRIC CABLE SIZE AND FUSES......................................................................................................102
9.3 SETTINGS OF FAN MOTOR CIRCUIT BREAKER........................................................................................105
9.4 DRYER SWITCHES...........................................................................................................................105
9.5 REFERENCE CONDITIONS AND LIMITATIONS..........................................................................................105
9.6 COMPRESSOR DATA........................................................................................................................106
9.7 TECHNICAL DATA ELEKTRONIKON® CONTROLLER..................................................................................107
10 Air receiver instructions............................................................................................108
11 Guidelines for inspection...........................................................................................109
12 Pressure equipment directives.................................................................................110
13 Declaration of conformity..........................................................................................111
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1 Safety precautions
1.1 Safety icons
Explanation
Danger for life
Warning
Important note
1.2 Safety precautions, general
General precautions
1. The operator must employ safe working practices and observe all related work safety requirements and
regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two
shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality,
the compressed air must be adequately purified according to the applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,
press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the
power isolating switch must be opened and locked.
On units powered by a frequency converter, wait 10 minutes before starting any electrical repair.
If the machine is equipped with an automatic restart after voltage failure function and if this
function is active, be aware that the machine will restart automatically when the power is
restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme
caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall
be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
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1.3 Safety precautions during installation

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

1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within
safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. 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.
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.
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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 following safety precautions: Safety precautions during operation and Safety
precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation

manufacturer.
Precautions during operation

1. Never touch any piping or components of the compressor during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure
that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or
particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to
carry out routine checks. Wear ear protectors when opening a door.
On compressors without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• No leaks occur
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free
of wear or abuse
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• 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.
1.5 Safety precautions during maintenance or repair

manufacturer.
Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the starting
equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or disconnecting
a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify,
pressure vessels.
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12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that
they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been
reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator
vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering
them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork
and in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by
genuine material from the manufacturer to prevent the sound pressure level from increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use
breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical
first aid.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
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2 General description
2.1 Introduction
Introduction
GA 15 VSD up to GA 30 VSD are single-stage, oil-injected screw compressors driven by an electric motor.
The compressors are air-cooled.
GA Workplace Full-Feature
GA Workplace Full-Feature (FF) are enclosed in a sound-insulated bodywork. The compressors are controlled
by the Atlas Copco Elektronikon® regulator. The electronic control module is fitted to the door at the front
side. An electric cabinet comprising fuses, transformers, relays, etc. is located behind this panel. An automatic
condensate drain system is provided.
The compressors are provided with an air dryer which is integrated in the sound-insulated bodywork. The
dryer removes condensate from the compressed air by cooling the air to near freezing point.
GA 15 VSD up to GA 30 VSD Workplace Full-Feature
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AV Location of air outlet valve

Ca Air cooler
Co Oil cooler
DR Dryer
FN Cooling fan
M1 Drive motor
VP Vent plug
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2.2 Air flow
Flow diagrams
References
Reference Description
A Air inlet
B Air/oil mixture
C Compressed air
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Reference Description
D Oil
E Wet compressed air (100 % saturated)
F Condensate
G Dry compressed air
Description
Air drawn in through filter (AF) and inlet arrestor (1) is compressed in compressor element (E) .
A mixture of compressed air and oil flows into the air receiver/oil separator (AR). The air is discharged through
the outlet valve via minimum pressure valve (Vp), air cooler (Ca) and condensate trap (MT).
Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure and
includes a check valve which prevents blow-back of compressed air from the net.
Full-Feature compressors are provided with a dryer (DR).
(1): DD and PD filters (option).
2.3 Oil system
Flow diagrams
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References
Ref Description
A Air inlet
B Air/oil mixture
C Compressed air
D Oil
Description
In air receiver (AR) most of the oil is removed from the air/oil mixture by centrifugal action. The remaining
oil is removed by oil separator (OS). The oil collects in the lower part of air receiver/oil separator (AR) which
serves as oil tank.
The oil system is provided with a thermostatic bypass valve (BV). When the oil temperature is below 60 ˚C
(140 ˚F), the bypass valve shuts off the oil supply from oil cooler (Co). Air pressure forces the oil from air
receiver (AR) through oil filter (OF) and oil stop valve (Vs) to compressor element (E). Oil cooler (Co) is
bypassed. When the oil temperature has increased to 60 ˚C (140 ˚F), bypass valve (BV) starts opening the
supply from oil cooler (Co). At approx. 75 ˚C (167 ˚F), all the oil flows through the oil cooler.
2.4 Cooling system
Flow diagrams
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References
Ref Description
A Air inlet
B Air/oil mixture
C Compressed air
D Oil
Description
The cooling system comprises air cooler (Ca) and oil cooler (Co).
Air-cooled compressors have a cooling fan (FN). The cooling fan (FN) is switched on and off depending on
the operating conditions according a specific algorithm.
2.5 Condensate system
Condensate drains
Workplace Full-Feature compressors have a condensate trap after the air cooler and a condensate trap on the
integrated dryer. Both condensate traps are connected to an electronic drain (EWD) for automatic draining of
the condensate. The drains are respectively connected to automatic drain outlets (Da and Da1) and to manually
operated valves (Dm and Dm1) for draining after stopping the compressor.
Automatic drain, air cooler
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Condensate drain connections
Reference Designation
Da Automatic drain connection, compressor
Da1 Automatic drain connection, dryer (only on Full-Feature units)
Dm Manual drain connection, compressor
Dm1 Manual drain connection, dryer (only on Full-Feature units)
(1) Drain connection of the filters (option)
2.6 Regulating system
Description
If the consumption is less than the air output of the compressor, the net pressure increases. When the net
pressure is higher than the set-point (desired net pressure), the regulator will decrease the motor speed. If the
net pressure keeps on rising when the motor runs at minimum speed, the regulator stops the motor. If the
motor is stopped automatically and the net pressure approaches the set-point, the regulator will restart the
motor.
2.7 Electrical system
General
Also consult sections Electrical diagrams and Electrical connections.
Electric cabinet
The electric cabinet comprises the frequency converter and all other electric components.
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Electric cabinet for GA15 VSD up to GA 30 VSD
References, GA 15 VSD up to GA 30 VSD
F... Fuses
K15 Contactor, fan motor
K21 Line contactor
PE Earth terminal
Q15 Circuit breaker
T1 Transformer
U1 Frequency converter
Z1 EMC filter
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2.8 Electrical diagrams
Diagrams
Service diagram for GA 15 VSD up to GA 30 VSD
(1) Emergency stop
(2) Remote start/stop
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(3) Overload, fan motor
(7) Remote pressure set selection
(8) Remote emergency stop
(9) Auxiliary contacts
(10) Manual operation
(11) Automatic operation
(12) General warning
(13) General shut-down
Designations
Reference Compressor
A1 Dryer
M1 Compressor motor
M2 Fan motor
PT20 Pressure sensor, delivery air
TT11 Temperature sensor, element outlet
TT53/54 Temperature sensor, energy recovery water inlet/outlet (option)
TT90 Temperature sensor, dew-point (Full-Feature)
TT01 Temperature sensor, ambient
B1 EWD
Y1 Solenoid valve
Reference Starter cubicle

1X1/1X7 Terminal strips
F... Fuses
K11 Auxiliary contactor for dryer (Full-Feature)
K15 Contactor, fan motor
K21 Main contactor
Q15 Circuit breaker, fan motor
SS Service switch
T1 Transformer
Reference Control module (E1)

I Start button
K01 Auxiliary relay, fan motor
K02 Auxiliary relay
K03 Auxiliary relay
K04 Auxiliary relay, blow-off
K05 Auxiliary relay, general shut-down
K06 Auxiliary relay, dryer control
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Reference Control module (E1)

K07 Auxiliary relay, manual/automatic operation
K08 Auxiliary relay, general warning
K09 Auxiliary relay, frequency converter interlock
O Stop button
S3 Emergency stop button
Reference Converter cabinet for GA 15 VSD up to GA 30 VSD

L1 Line choke
U1 Frequency converter
Z1 EMC filter
2.9 Air dryer
Flow diagram
Air dryer, GA 15 VSD up to GA 30 VSD
Reference Name
AI Air inlet
AO Air outlet
1 Air/air heat exchanger
2 Air/refrigerant heat exchanger/evaporator
3 Condensate separator
4 Condensate outlet
5 Refrigerant compressor
6 Refrigerant condenser
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Reference Name
7 Liquid refrigerant dryer/filter
8 Capillary tube
9 Bypass valve
10 Condenser cooling fan
11 Liquid separator
P Pressure switch, fan control
Compressed air circuit

Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Water in the incoming
air starts to condense. The air then flows through heat exchanger/evaporator (2) where the refrigerant
evaporates causing the air to be cooled further to close to the evaporating temperature of the refrigerant. More
water in the air condenses. The cold air then flows through separator (3) where all the condensate is separated
from the air. The condensate is automatically drained through outlet (4).
The cold, dried air flows through heat exchanger (1) where it is warmed up by the incoming air.
Refrigerant circuit
Compressor (5) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most of
the refrigerant condenses.
The liquid refrigerant flows through liquid refrigerant dryer/filter (7) to capillary tube (8). The refrigerant
leaves the capillary tube at evaporating pressure.
The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further evaporation
at constant pressure. The heated refrigerant leaves the evaporator and is sucked in by the compressor (5).
Bypass valve (9) regulates the refrigerant flow. Liquid separator (11) prevents that liquid refrigerant is sucked
in by the compressor. Fan (10) is switched on or off by switch (P) depending on the loading degree of the
refrigerant circuit.
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3 Elektronikon® Graphic controller
3.1 Elektronikon® Graphic controller
Control panel
Display of the Elektronikon® Graphic controller
Introduction
The Elektronikon controller has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (made inactive)
Automatic control of the compressor operation

The controller maintains the net pressure between programmable limits by automatically loading and
unloading the compressor (on compressors running at a fixed speed) or by adapting the motor speed
(compressors with frequency converter). A number of programmable settings, e.g. the unloading and loading
pressures (for fixed speed compressors), the setpoint (for compressors with frequency converter), the
minimum stop time and the maximum number of motor starts and several other parameters are hereby taken
into account.
The controller stops the compressor whenever possible to reduce the power consumption and restarts it
automatically when the net pressure decreases. In case the expected unloading period is too short, the
compressor is kept running to prevent too short standstill periods.
A number of time based automatic start/stop commands may be programmed. Take into
account that a start command will be executed (if programmed and activated), even after
manually stopping the compressor.
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Protecting the compressor

Shut-down
Several sensors are provided on the compressor. If one of the measured signals exceeds the programmed shut-
down level, the compressor will be stopped. This will be indicated on display (1) and general alarm LED (2)
will blink.
Remedy the trouble and reset the message. See also the Inputs menu.
Before remedying, consult the applicable safety precautions.
Shut-down warning
A shut-down warning level is a programmable level below the shut-down level.
If one of the measured signals exceeds the programmed shut-down warning level, a message will appear on
display (1) and general alarm LED (2) will light up to warn the operator that the shut-down warning level is
exceeded.
The message disappears as soon as the warning condition disappears.
Warning
A warning message will appear if, on Full-Feature compressors, the dew point temperature is too high in
relation to the ambient temperature.
Service warning
A number of service operations are grouped (called Service Plans). Each Service Plan has a programmed time
interval. If a time interval is exceeded, a message will appear on display (1) to warn the operator to carry out
the service actions belonging to that Service Plan.
Automatic restart after voltage failure

The controller has a built-in function to automatically restart the compressor when the voltage is restored after
voltage failure. For compressors leaving the factory, this function is made inactive. If desired, the function
can be activated. Consult the Atlas Copco Customer Centre.
If the function is activated and provided the regulator was in the automatic operation mode,
the compressor will automatically restart if the supply voltage to the module is restored.
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3.2 Control panel
Elektronikon regulator
Control panel
Parts and functions
Reference Designation Function

1 Display Shows the compressor operating condition and a
number of icons to navigate through the menu.
2 Pictograph Automatic operation
3 Pictograph General alarm
4 Alarm LED Flashes in case of a shut-down, is lit in case of a
warning condition.
5 Pictograph Service
6 Service LED Lights up if service is needed
7 Automatic operation LED Indicates that the regulator is automatically controlling
the compressor.
8 Voltage on LED Indicates that the voltage is switched on.
9 Pictograph Voltage
10 Enter key Use this button to confirm the last action.
11 Escape key Use this button to go to previous screen or to end the
current action.
12 Scroll keys Keys to scroll through the menu.
13 Stop button Button to stop the compressor. LED (7) goes out.
14 Start button Button to start the compressor. LED (7) lights up
indicating that the Elektronikon regulator is operative.
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3.3 Icons used
Status icons
Name Icon Description

Stopped / Running When the compressor is stopped, the icon stands still.
When the compressor is running, the icon is rotating.
Compressor status Motor stopped
Running unloaded
Running loaded
Machine control mode Local start / stop
or
Remote start / stop
Network control
Automatic restart after voltage Automatic restart after voltage failure is active
failure
Week timer Week timer is active
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Name Icon Description

Active protection functions Emergency stop
Shutdown
Warning
Service Service required
Main screen display Value lines display icon
Chart display icon
General icons No communication / network problem
Not valid
Input icons
Icon Description
Pressure
Temperature
Digital input
Special protection
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System icons
Icon Description
Compressor element (LP, HP, ...)
Dryer
Fan
Frequency converter
Drain
Filter
Motor
Failure expansion module
Network problem
General alarm
Menu icons
Icon Description
Inputs
Outputs
Alarms (Warnings, shutdowns)
Counters
Test
or
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Icon Description
Settings
Service
Event history (saved data)
Access key / User password
Network
Setpoint
Info
Navigation arrows
Icon Description
Up
Down
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3.4 Main screen
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Function
The Main screen is the screen that is shown automatically when the voltage is switched on and one of the
keys is pushed. It is switched off automatically after a few minutes when no keys are pushed.
Typically, 5 different main screen views can be chosen:
1. Two value lines
2. Four value lines
3. Chart (High resolution)
4. Chart (Medium resolution)
5. Chart (Low resolution)
Two and four value lines screens

This type of Main screen shows the value of 2 or 4 parameters (see section Inputs menu).
Typical Main screen (2 value lines), fixed speed compressors
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Typical Main screen (2 value lines), compressors with frequency converter
Text on figures
(1) Compressor Outlet

(2) Element Outlet (fixed speed compressors)
Flow (compressors with frequency converter)
(3) Load, shutdown, ... (text varies upon the compressors actual condition)
(4) Menu
(5) Unload, ES,...(text varies upon the compressors actual condition)
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Text on figures
(1) Compressor Outlet

(2) Load relay (one of the input signals of fixed speed compressors)
Flow (compressors with frequency converter)
(3) Off, Shutdown,... (text varies upon the compressors actual condition)
(4) Menu
(5) Running hours
(6) Element outlet
(7) Load, Unload, ... (text varies upon the compressors actual condition)
• Section A shows information regarding the compressor operation (e.g. the outlet pressure or the
temperature at the compressor outlet). On compressors with a frequency converter, the load degree (flow)
is given in % of the maximum flow.
• Section B shows Status icons. Following icon types are shown in this field:
• Fixed icons
These icons are always shown in the main screen and cannot be selected by the cursor (e.g. Compressor
stopped or running, Compressor status (running, running unloaded or motor stopped).
• Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer, automatic
restart after voltage failure , etc.)
• Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To call up more information about the icons shown, select the icon concerned using the scroll keys and
press the enter key.
• Section C is called the Status bar
This bar shows the text that corresponds to the selected icon.
• Section D shows the Action buttons. These buttons are used:
• To call up or program settings
• To reset a motor overload, service message or emergency stop
• To have access to all data collected by the regulator
The function of the buttons depends on the displayed menu. The most common functions are:
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Designation Function
Menu To go to the menu
Modify To modify programmable settings
Reset To reset a timer or message
To activate an action button, highlight the button by using the Scroll keys and press the Enter key.
To go back to the previous menu, press the Escape key.
Chart views
Instead of viewing values, it is also possible to view a graph of one of the input signals (see section Inputs
menu) in function of the time.
When Chart (High Resolution) is selected, the chart shows the variation of the selected input (in this case the
pressure) per minute. Also the instantaneous value is displayed. The screen shows the last 4 minutes.
The switch button (icon) for selecting other screens is changed into a small Chart and is highlighted (active).
When the Chart (Medium Resolution) is selected, the chart shows the variation of the selected input per
hour. The screen shows the last 4 hours.
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When the Chart (Low Resolution) is selected, the chart shows the variation of the selected input per day. The
screen shows the evolution over the last 10 days.
Selection of a main screen view

To change between the different screen layouts, select the far right icon in the control icons line (see value
lines display icon or chart display icon in section Icons used) and press the Enter key. A screen similar to the
one below opens:
Select the layout required and press the Enter key. See also section Inputs menu.
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3.5 Calling up menus
Control panel
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Description
When the voltage is switched on, the main screen is shown automatically (see section Main screen):
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• To go to the Menu screen, highlight the Menu button (3), using the Scroll keys.
• Press the Enter key to select the menu. Following screen appears:
• The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings
(Regulation) icon is selected. The status bar shows the name of the menu that corresponds with the selected
icon.
• Use the Scroll keys to select an icon.
• Press the Escape key to return to the Main screen.
3.6 Inputs menu
Control panel
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(1) Scroll keys

(2) Enter key
(3) Escape key
Menu icon, Inputs
Function
• To display the actual value of the measured data (analog inputs) and the status of the digital inputs (e.g.
emergency stop contact, motor overload relay, etc.).
• To select the digital input to be shown on the chart in the main screen.
Procedure
Starting from the main screen,
• Move the cursor to the action button Menu and press the Enter key. Following screen appears:
Text on image
(1) Menu
(2) Regulation
• Using the Scroll keys, move the cursor to the Inputs icon (see above, section Menu icon).
• Press the Enter key. A screen similar to the one below appears:
Text on image
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(1) Inputs
(2) Compressor outlet
(3) Element outlet
(4) Ambient air
(5) Emergency stop
• The screen shows a list of all inputs with their corresponding icons and readings.
• If an input is in warning or shutdown, the original icon is replaced by the warning or shutdown icon
respectively (i.c. the Stop icon and the Warning icon in the screen shown above).
A small chart icon, shown below an item in the list means this input signal is shown on the chart at the main
screen. Any analog input can be selected.
Selecting another input signal as main chart signal

With the Modify button active (light grey background in above screen), press the Enter button on the controller.
A screen similar to the one below appears:
The first item in the list is highlighted. In this example, the Net Pressure is selected (chart icon).
To change, press the Enter button again: a pop-up window opens:
Press Enter again to remove this input from the chart. Another confirmation pop-up opens:
Select Yes to remove or No to quit the current action.

In a similar way, another input signal can be highlighted and selected as Main Chart signal:
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(1): Set as main chart signal
3.7 Outputs menu
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Menu icon, Outputs
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Function
To call up information regarding the actual status of some outputs such as the condition of the Fan overload
contact (on air cooled compressors), the Emergency stop contact, etc.
Procedure
Starting from the Main screen,
Text on figure
(1) Menu
(2) Regulation
• Move the cursor to the Outputs icon (see above, section Menu icon, using the Scroll keys.
• Press the Enter key. A screen similar to the one below appears:
Outputs screen (typical)
Text on image
(1) Outputs
(2) Fan motor contact
(3) Blow-off contact
(4) General shutdown
(5) Automatic operation
• The screen shows a list of all outputs with their corresponding icons and readings.
If an output is in warning or shutdown, the original icon is replaced by the warning or shutdown icon
respectively.
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3.8 Counters
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Menu icon, Counters
Function
To call up:
• The running hours
• The loaded hours
• The number of motor starts
• The number of hours that the regulator has been powered
• The number of load cycles
Procedure
Starting from the Main screen (see Main screen),
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Text on figure
(1) Menu
(2) Regulation
• Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon)
• Press the Enter key. Following screen appears:
Text on figure
(1) Counters
(2) Running hours
(3) Motor starts
(4) Load relay
(5) VSD 1-20 % rpm in % (the percentage of the time during which the motor speed
was between 1 and 20 %) (compressors with frequency converter)
The screen shows a list of all counters with their actual readings.
Note: the example above is for a frequency converter driven compressor. For a fixed speed compressor, the
actual screen will be somewhat different.
3.9 Control mode selection
Control panel
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(1) Scroll keys

(2) Enter key
(3) Escape key
Function
To select the control mode, i.e. whether the compressor is in local control, remote control or controlled via a
local area network (LAN).
Procedure
Starting from the main screen, make sure the button Menu (1) is selected:
Next, use the scroll buttons to go to the regulation icon (2) and press the enter button:
There are 3 possibilities:

• Local control
• Remote control
• LAN (network) control
After selecting the required regulation mode, press the enter button on the controller to confirm your selection.
The new setting is now visible on the main screen. See section Icons used for the meaning of the icons.
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3.10 Service menu
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Menu icon, Service
Function
• To reset the service plans which are carried out.
• To check when the next service plans are to be carried out.
• To find out which service plans were carried out in the past.
• To modify the programmed service intervals.
Procedure
• Using the Scroll keys, move the cursor to the Service icon (see above, section Menu icon).
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Text on image
(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History
• Scroll through the items to select the desired item and press the Enter key to see the details as explained
below.
Overview
Text on image
(1) Overview
(2) Running Hours
(3) Real Time hours
(4) Reset
Example for service level (A):

The figures at the left are the programmed service intervals. For Service interval A, the programmed number
of running hours is 4000 hours (upper row) and the programmed number of real time hours is 8760 hours,
which corresponds to one year (second row). This means that the controller will launch a service warning
when either 4000 running hours or 8760 real hours are reached, whichever comes first. Note that the real time
hours counter keeps counting, also when the controller is not powered.
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The figures within the bars are the number of hours to go till the next service intervention. In the example
above, the compressor was just started up, which means it still has 4000 running hours or 8280 hours to go
before the next Service intervention.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level stands for a number
of service actions to be carried out at the time intervals programmed in the Elektronikon® controller.
When a service plan interval is reached, a message will appear on the screen.
After carrying out the service actions related to the indicated levels, the timers must be reset.
From the Service menu above, select Service plan (3) and press Enter. Following screen appears:
Text on image
(1) Service plan

(2) Level
(3) Running hours
(4) Real time hours
(5) Modify
Modifying a service plan

Dependant on the operating conditions, it can be necessary to modify the service intervals. To do so, use the
Scroll keys to select the value to be modified. A screen similar to the one below appears:
Press the Enter key. Following screen appears:
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Modify the value as required using the ↑ or ↓ scroll key and press the Enter key to confirm.
Note: Running hours can be modified in steps of 100 hours, real time hours can be modified in steps of 1
hour.
Next Service
Text on image
(1) Next service

(2) Level
(3) Running hours
(4) Actual
In the example above, the A Service level is programmed at 4000 running hours, of which 0 hours have passed.
History
The History screen shows a list of all service actions done in the past, sorted by date. The date at the top is
the most recent service action. To see the details of a completed service action (e.g. Service level, Running
hours or Real time hours), use the Scroll keys to select the desired action and press the Enter key.
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3.11 Modifying the setpoint
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Menu icon, Setpoint
Function
On compressors with a frequency converter driven main motor, it is possible to program two different
setpoints. This menu is also used to select the active setpoint.
Procedure
• Highlight the action key Menu using the Scroll keys and press the Enter key. Following screen appears:
Text on image
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(1) Menu
(2) Regulation
• Activate the menu by pressing the enter key. A screen similar to the one below appears:
Text on image
(1) Regulation
(2) Setpoint 1
(3) Indirect stop level 1
(4) Direct stop level 1
(5) Setpoint 2
(6) Modify
• The screen shows the actual settings.

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

(2) Enter key
(3) Escape key
Menu icon, Event History
Function
To call up the last shut-down and last emergency stop data.
Procedure
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• Using the Scroll keys, move the cursor to the Event History icon (see above, section Menu icon)
• The list of last shut-down and emergency stop cases is shown.
Example of Event History screen
• Scroll through the items to select the desired shut-down or emergency stop event.
• Press the Enter key to find the date, time and other data reflecting the status of the compressor when that
shut-down or emergency stop occurred.
3.13 Modifying general settings
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
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Menu icon, Settings
Function
To display and modify a number of settings.
Procedure
• Next, move the cursor to the Settings icon (see above, section menu icon).using the Scroll keys.
This screen shows again a number of icons. By default, the User Password icon is selected. The status bar
shows the description that corresponds with the selected icon. Each icon covers one or more items , such
as
• Access level
• Elements
• Dryer
• Fan
• Converter(s)
• Filter(s)
• Motor/Starter
• General
• Automatic restart after voltage failure (ARAF)
• Network
• Regulation
• Remote
For adapting certain parameters, a password may be necessary.
Example: Selecting the General Settings icon gives the possibility to change e.g. the language, the date,
the date format, etc.:
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Text on image
(1) General
(2) Language used
(3) Time
(4) Date
(5) Date format
(6) Modify
• To modify, select the Modify button using the Scroll keys and press the Enter key.
• A screen similar to the one above is shown, the first item (Language) is highlighted. Use the ↓ key of the
Scroll keys to select the setting to be modified and press the Enter key.
• A pop-up screen appears. Use the ↑ or ↓ key to select the required value and press the Enter key to confirm.
3.14 Info menu
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
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Menu icon, Info
Function
To show the Atlas Copco internet address.
Procedure
• Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon).
• Press the Enter key. The Atlas Copco internet address appears on the screen.
3.15 Week timer menu
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
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Menu icon, Week timer
Function
• To program time-based start/stop commands for the compressor
• To program time-based change-over commands for the net pressure band
• Four different week schemes can be programmed.
• A week cycle can be programmed, a week cycle is a sequence of 10 weeks. For each week in the cycle,
one of the four programmed week schemes can be chosen.
Important remark:
In the Elektronikon you can select different timers on one day.(up to 8 actions). It is
however not possible to program 2 actions at the same time. The solution: leave at least
1 minute in between 2 actions.
Example: Start Compressor: 5.00 AM, Pressure Setpoint 2: 5.01 AM (or later).
Procedure
• Move the cursor to the action button Menu and press the Enter key. Use the Scroll buttons to select the
Timer icon.
Text on figure
(1) Menu
(2) Week Timer
• Press the Enter key on the controller. Following screen appears:
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(1) Week Timer

(2) Week Action Schemes
(3) Week Cycle
(4) Status
(5) Week Timer Inactive
(6) Remaining Running Time
The first item in this list is highlighted in red. Select the item requested and press the Enter key on the
controller to modify.
Programming week schemes

• Select Week action schemes and press Enter. A new window opens. The first item in the list is highlighted
in red. Press the Enter key on the controller to modify Week Action Scheme 1.

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

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
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(6) Friday
(7) Saturday
(8) Sunday
• A new window opens. The Modify action button is selected. Press the enter button on the controller to
create an action.
(1) Monday
(2) Modify
• A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller.
When ready press the Enter key to confirm.
(1) Monday
(2) Actions
(3) Remove
(4) Start
(5) Stop
(6) Pressure Setpoint 1
(7) Modify
• A new window opens. The action is now visible in the first day of the week.
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(1) Monday
(2) Start
(3) Save
(4) Modify
• To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A pop-up window opens. Use the ↑ or ↓ key of Scroll keys to modify the values of the hours. Use the ←
or → Scroll keys to go to the minutes.
(1) Monday
(2) Time
(3) Save
(4) Modify
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• Press the Escape key on the controller. The action button Modify is selected. Use the Scroll keys to select
the action Save.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions. Press the
Enter key to confirm.
(1) Monday
(3) Are you sure?
(4) No
(5) Yes
(6) Save
(7) Modify
Press the Escape key to leave this window.

• The action is shown below the day the action is planned.
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(2) Monday - Start
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
Press the Escape key on the controller to leave this screen.
Programming the week cycle

A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week
schemes can be chosen.
• Select Week Cycle from the main Week Timer menu list.
(1) Week Timer

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

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

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

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

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

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

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

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

(2) Week action schemes
3.16 Test menu
Control panel
Menu icon, Test
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or
Function
• To carry out a display test, i.e. to check whether the display and LEDs are still intact.
Procedure
• Move the cursor to the action button Menu and press the enter key (2), following screen appears:
• Using the scroll keys (1), move the cursor to the test icon (see above, section Menu icon)
• Press the enter key (2), following screen appears:
• The safety valve test can only be performed by authorized personnel and is protected by a security code.
• Select the item display test and press the enter key. A screen is shown to inspect the display, at the same
time all LED's are lit.
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3.17 User password menu
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Menu icon, Password
Function
If the password option is activated, it is impossible for not authorized persons to modify any setting.
Procedure
• Move the cursor to <Menu> and press the Enter key (2). Following screen appears:
• Using the Scroll keys, select the <Settings> icon (see section Modifying general settings)
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• Move the cursor to the Password icon (see above, section Menu icon)
• Select <Modify> using the Scroll keys and press the Enter key. Next, modify the password as required.
3.18 Web server

All Elektronikon controllers have a built-in web server that allows direct connection to the company network
or to a dedicated PC via a local area network (LAN). This allows to consult certain data and settings via a PC
instead of via the display of the controller.
Getting started
Make sure you are logged in as administrator.
• Use the internal network card from your computer or a USB to LAN adapter (see picture below).
USB to LAN adapter
• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).
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Configuration of the network card

• Go to My Network places (1).
• Click on View Network connections (1).
• Select the Local Area connection (1), which is connected to the controller.
• Click with the right button and select properties (1).
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• Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other properties
if they are checked. After selecting TCP/IP, click on the Properties button (2) to change the settings.
• Use the following settings:

• IP Address 192.168.100.200
• Subnetmask 255.255.255.0
Click OK and close network connections.
Configuration of the web server

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

Open Internet Explorer and click on Tools - Internet options (2).
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• Click on the Connections tab (1) and then click on the LAN settings button (2).
• In the Proxy server Group box, click on the Advanced button (1).
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• In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given
but they must be separated with semicolons (;).
Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now you
add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1) (see picture).
Click OK (2) to close the window.
Viewing the controller data
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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:
Navigation and options

• The banner shows the compressor type and the language selector. In this example, three languages are
available on the controller.
• On the left side of the interface you can find the navigation menu (see picture below).
If a license for ESi is foreseen, the menu contains 3 buttons.
• Compressor (or machine): shows all compressor settings.
• Es: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure units.
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Compressor settings
All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it
will be displayed. Only the machine status is fixed and 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 compressor.
Info status
Machine status is always shown on the web interface.
Digital inputs
Lists all Digital inputs and their status.
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Digital outputs
Lists all Digital outputs and their status.
Special protections
Lists all special protections of the compressor.
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.
ES screen controller
If an ESi license is provided, the ES button is displayed in the navigation menu. At the left all compressors
in the ES are shown. At the right the ES status is shown.
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A possible ESi screen
3.19 Programmable settings
Compressor/motor
Minimum Factory Maximum

setting setting setting
Set-point 1 and 2, Workplace Full-Feature bar(e) 4 7 12.8
compressors
Indirect stop level bar 0.1 0.3 1
Direct stop level bar 0.3 1 1.5
Proportional band % 6 10 15
Integration time sec 5 6 10
Minimum motor speed GA22 VSD rpm 1500 1500 1600
Maximum speed reduction % 75 100 100
Parameters

Minimum stop time sec 5 5 30
Power recovery time sec 10 10 3600
Restart delay sec 0 0 1200
Communication time-out sec 10 30 60
Fan motor starts per day (air-cooled 1 240 240
compressors)
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Protections

Compressor element outlet temperature ˚C 50 112 (GA 15 119
(shut-down warning level) VSD up to GA
26 VSD)
Compressor element outlet temperature ˚C 111 120 120
(shut-down level)
Specific protections for Full-Feature compressors:

Dewpoint warning temperature ºC 25 99
Dewpoint warning temperature ºF 77 210
Service plan
The built-in service timers will give a Service warning message after their respective preprogrammed time
interval has elapsed.
For specific data, see section Preventive Maintenance.
Consult Atlas Copco if a timer setting needs to be changed. The intervals must not exceed the nominal intervals
and must coincide logically. See section Modifying general settings.
Terminology
Term Explanation
ARAVF Automatic Restart After Voltage Failure. See section Elektronikon regulator.
Power recovery Is the period within which the voltage must be restored to have an automatic restart. Is
time accessible if the automatic restart is activated. To activate the automatic restart function,
consult Atlas Copco.
Restart delay This parameter allows to programme that not all compressors are restarted at the same
time after a power failure (ARAVF active).
Compressor The recommended minimum setting is 70 ˚C (158 ˚F). For testing the temperature sensor
element outlet the setting can be decreased to 50 ˚C (122 ˚F). Reset the value after testing.
The regulator does not accept inconsistent settings, e.g. if the warning level is programmed
at 95 ˚C (203 ˚F), the minimum limit for the shut-down level changes to 96 ˚C (204 ˚F). The
recommended difference between the warning level and shut-down level is 10 ˚C (18 ˚F).
Delay at signal Is the time period during which the warning signal must exist before the warning message
appears.
Delay at start Is the time period after starting which must expire before generating a warning. The setting
should be less than the setting for the delay at signal.
Minimum stop Once the compressor has automatically stopped, it will remain stopped for the minimum
time stop time, whatever happens with the net air pressure.
Proportional band The settings for the Proportional band and integration time are determined by experiment.
and integration Altering these settings may damage the compressor. Consult Atlas Copco.
time
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4 Installation
4.1 Dimension drawings
GA 15 VSD up to GA 30 VSD
Reference Designation Reference Designation

1 Cooling air outlet, cooler 8 Manual drain
2 Cooling air outlet, motor 9 Cooling air inlet, motor
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Reference Designation Reference Designation

3 Cooling air outlet, dryer 10 Automatic drain
4 Cooling air inlet, cooler 11 Cooling air inlet, cubicle
5 Compressed air outlet 12 Supply cable
6 Compressor air inlet 13 Dimensions in mm
7 Cooling air inlet, dryer
4.2 Installation proposal
Safety
The operator must apply all relevant safety precautions, including those mentioned in this
book.
Important
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.
Outdoor/altitude operation
Compressors controlled with frequency converters (VSD) are intended to be installed

indoors only, with adequate ventilation and filtration to limit the dust load from the
environment. If such a compressor is to be installed in an application where conductive
dust is present, the appropriate measures should be taken in either the installation or
adaptation of the machine. Please contact Atlas Copco. The rain protection option is not
foreseen for frequency converter driven compressors.
If the compressor is installed where the ambient temperature can be below 0 ˚C (32 ˚F), precautions must be
taken. In this case, and also if operating above 1000 m (3300 ft), consult Atlas Copco.
Moving/lifting
The compressor can be moved by a lift truck on the side of the frame. Take care not to damage the bodywork
during lifting or transport. Make sure that the forks support the frame sufficiently.
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GA 15 VSD up to GA 30 VSD
Compressor room example GA 15 VSD up to GA 30 VSD
Text on drawing
(1) Ventilation proposals

(2) Minimum free area to be reserved for the compressor installation
Installation guidelines
1 Install the compressor unit on a solid, level floor suitable for taking its weight.
2 Position of the compressed air outlet valve.
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3 The pressure drop over the air delivery pipe can be calculated as follows:
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))
L = Length of the pipe in m
P = Absolute pressure at the compressor outlet in bar
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 minimise carry-over of possible condensate residue.
4 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 allowed air
velocity through the grids is 5 m/s (16.5 ft/s).
The maximum air temperature at the compressor intake is 46˚C (115˚F) (minimum 0˚C /
32˚F). If it exceeds this value, a fan is needed at the outlet of the ducts. Consult Atlas Copco.
For ventilation alternatives 1 and 3, the required ventilation capacity to limit the
compressor room temperature can be calculated as follows:
• Qv = 1.06 N/ΔT for Workplace versions
• Qv = (1.06 N + 1.3)/ΔT for Workplace Full-Feature versions
Qv = Required ventilation capacity in m3/s
N = Shaft input of compressor 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 across the cooling air ducts.
The ducting for the air outlet of the dryer (12a) also should be separated from the ducting
for the cooling air outlet of the coolers (12b) and the cooling air outlet of the compressor
compartement (12c). The maximum allowable pressure drop in ducting before or after the
compressor is 30 Pa.
5 The drain pipes to the drain collector must not dip into the water of the drain collector.
Atlas Copco has oil/water separators to separate the major part of the oil from the
condensate to ensure that the condensate meets the requirements of the environmental
codes. See section OSD.
6 Control module with monitoring panel.
7 Position of the main cable entry. The supply cable is to be sized and installed by a qualified
electrician. In case of IT network, consult Atlas Copco.
8 Provision for inlet and outlet of the energy recovery system (system is optional).
9 Filter, type DD for general purpose filtration. The filter traps solid particles 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 vapours and odours are undesirable, a QD
type filter should be installed downstream of the PD filter.
It is recommended to install bypass pipes over each filter together with ball valves, in order
to isolate the filters during service operations without disturbing the compressed air delivery.
11 Bypass system to bypass the dryer during service operations (available as an option,
consult Atlas Copco).
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4.3 Electrical connections
Important remark
Working with machinery controlled by a frequency converter requires special safety

precautions. These safety precautions depend on the kind of network used (TN, TT, IT
system). Consult Atlas Copco.
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(1) Customer’s installation
(2) Option
(3) Dryer (Full-Feature units)
(4) For RS-485 communication
(5) Star connection: all other voltages
(6) Delta connection: 200/220/230 V - 50/60 Hz
(7) Dryer
Description
1. Provide an isolating switch.
2. Check that the motor cables and wires inside the electric cabinet are clamped tight to their terminals.
3. Check the fuses. See section Electric cable size
4. Connect the power supply cables to terminals (1, 3 and 5) on contactor (K21).
5. Connect the earth conductor to the earth bolt (PE).
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.
Compressor control modes

See also section Control mode selection.
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.
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.
Compressor status indication

The Elektronikon controller is provided with potential-free auxiliary NO contacts (NO = normally open) (K05,
K07 and K08) for remote indication of:
• Manual or automatic operation (K07)
• Warning condition (K08)
• Shut-down condition (K05)
Example: K05 is a NO (NO = normally open) contact. It will be closed if all conditions are normal and will
open in case of power failure or shutdown.
Maximum contact load: 10 A / 250 V AC.
Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas Copco.
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4.4 Pictographs
1 Switch off the voltage and depressurize the compressor before starting maintenance or
repairs
2 Keep the doors closed during operation
3 Switch off the voltage before removing protecting cover inside electric cubicle
4 Manual condensate drain
5 Automatic condensate drain
6 Stop the compressor before cleaning the coolers
7 Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx. half a turn)
8 Warning, voltage
9 Consult instruction book before greasing
10 Before connecting the compressor electrically, consult the Instruction book for the motor
rotation direction
11 Compressor remains pressurized for 30 seconds after switching off the voltage
12 Torques for steel (Fe) or brass (CuZn) bolts
13 Switch off the voltage and wait at least 6 minutes before removing the screen
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5 Operating instructions
5.1 Initial start-up
Safety
The operator must apply all relevant Safety precautions. Also consult section Problem solving.
Procedure
For the position of the air outlet valve and the drain connections, see sections Introduction
and Condensate system
Transport fixtures
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Position of oil level sight-glass
Electric cabinet
- Consult the sections Electric cable size, Installation proposals and Dimension drawings
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- The following transport fixtures, painted red, must be removed:

• Bolts (1)
• Bushes (2)
• Supports (3)
Remove the red-painted bushes from both gear casing supports and both air receiver supports.
- Check that the electrical connections correspond to the local codes and that all wires are clamped tight
to their terminals.
The installation must be earthed and protected against short circuits by fuses of the inert type in all
phases. An isolating switch must be installed near the compressor.
- Check the voltage selecting wires at the primary side of transformers:
• T1
- Check the setting of circuit breaker (Q15). Also check that the switch on the circuit breaker is in position
I.
- Fit the air outlet valve (AV); see section Introduction for the position of the valve.
Close the valve.
Connect the air net to the valve.
- Fit the manual condensate drain valve (Dm).
Close the valve(s).
- Connect the manual and automatic condensate drain outlets to a drain collector. See section
Condensate system and (if an OSD is installed) see section Installation OSD.
The drain pipes to the drain collector must not dip into the water. For draining of pure condensate, install
an oil/water separator which is available from Atlas Copco as an option; see section OSD unit. If the
pipes have been fitted outside the room where freezing is possible, they must be insulated.
- Check the oil level.
The oil level in the sight glass should be in the upper region or higher.
- Where applicable, provide labels, warning the operator that:
• The compressor may restart automatically after voltage failure (if activated, consult Atlas Copco).
• The compressor is automatically controlled and may be restarted automatically.
• The compressor may be remotely controlled.
- Switch on the voltage. Start the compressor and stop it immediately.
On air-cooled compressors, check the rotation direction of the fan motor. Rotation arrows, visible
through the grating in the roof, are provided on the fan plate. If the rotation direction is wrong, open the
isolating switch in the voltage supply line, switch off the voltage and reverse two incoming electric lines.
Check the rotation direction of the drive motor (M1) while the motor is coasting to a stop; the correct
direction is indicated by an arrow on the gear casing. If the rotation direction is wrong, stop the motor,
open the isolating switch in the voltage supply line and reverse two incoming connections on the drive
motor.
- Check the programmed settings. Consult section Programmable settings.
- Start and run the compressor for a few minutes. Check that the compressor operates normally.
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5.2 Before starting
Remarks
If the compressor has not run for the past 6 months, it is strongly recommended to improve
the lubrication of the compressor element at starting:
• Loosen the hose clip (3) and disconnect the inlet hose (2).
• Pour 0.75 l (0.20 US gal, 0.17 Imp gal) of oil into the inlet arrestor (1).
• Reinstall the inlet hose (2).
Procedure
- See section Initial start-up for location of the oil system components.
Check the oil level. Top up if necessary. See section Initial start up for details.
5.3 Starting
Procedure
For the position of the air outlet valve and the drain connections, see sections Introduction
and Condensate system
Control panel
- Switch on the voltage. Check that voltage on LED (6) lights up.
- Open air outlet valve (AV).
- Close condensate drain valve (Dm).
On GA 15 VSD up to GA 30 VSD Full-Feature also close condensate drain valve (Dm1).
- Press start button (1) on the control panel. The compressor starts running and the automatic operation
LED (8) lights up.
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5.4 During operation
Procedure
In order to ensure sufficient motor cooling, the doors must be closed during operation and
may be opened for short periods only to carry out checks.
When the motors are stopped and LED (8) is alight, the motors may start automatically.
Control panel
Position of oil level sight glass
Regularly check the oil level. During operation, the oil level should be in the centre of the sight glass. If the
level is too low, press the stop button, wait until the compressor has stopped, depressurise the oil system by
unscrewing oil filler plug (FC) one turn and wait a few minutes. Remove the plug and top up oil, until the
sight-glass is full. Fit and tighten the plug (FC).
When automatic operation LED (8) is alight, the regulator is automatically controlling the compressor, i.e.
matching the compressor speed to the net pressure, starting and stopping the compressor whenever necessary.
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Regularly check that condensate is discharged during operation. See section Condensate system and in case
of an OSD, also check the level in the oil collector; see section OSD Maintenance and operating
instruction. The amount of condensate depends on environmental and working conditions.
When the compressor regularly runs in low load conditions, operator should ensure that the nominal oil
temperature is reached.
5.5 Checking the display
Procedure
Control panel
Check the display (2) regularly for readings and messages. Normally, the display shows the compressor outlet
pressure, the motor speed and the abbreviations of the functions of the keys below the display.
Always check the display (2) and remedy the trouble if alarm LED (7) is alight or blinks. See section
Elektronikon regulator.
The display (2) will show a service message if a service plan interval has been exceeded or if a service level
for a monitored component has been exceeded. Carry out the service actions of the indicated plans or replace
the component and reset the relevant timer.
5.6 Stopping
Elektronikon regulator
Control panel
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Procedure
- Press stop button (9). Automatic operation LED (8) goes out. The compressor stops.
- To stop the compressor in case of emergency, press emergency stop button (10). Alarm
LED blinks (7).
After remedying the problem cause, unlock the button by pulling it out and press ‘Rset’ key
(5) before restarting.
Do not use the emergency stop button (10) for normal stopping! !
- Close air outlet valve (AV) (see section Introduction) and switch off the voltage.
5.7 Taking out of operation
Warning
The operator must apply all relevant Safety precautions.
Procedure
- Stop the compressor, press the emergency stop button and close the air outlet valve.
- Switch off the voltage and disconnect the compressor from the mains.
- Open the manual drain valve(s), see section Condensate system for the position of the
valve(s). Wait until the compressor has depressurised. Unscrew the 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
Control panel
Warning
Before carrying out any maintenance, repair work or adjustments, proceed as

follows:
• Stop the compressor.
• Press the emergency stop button (10).
• Switch off the voltage.
• Close the air outlet valve and open the manual condensate drain valves.
• Depressurise the compressor.
For detailed instructions, see section Problem solving.
Before mechanical maintenance
Open the manual condensate drain valves and wait for at least 30 seconds (time needed
for the compressor to depressurize).
For location of components, see section Condensate system
Before electrical maintenance
Wait for at least 6 minutes before starting maintenance as hazardous high voltage remains
on the DC-link capacitors of the frequency converter some time after switching off the
voltage.
Warranty - Product Liability

Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered
by Warranty or Product Liability.
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Service kits
For overhauling or carrying out preventive maintenance, service kits are available (see section Service kits).
Service kits contain all parts needed for servicing components and offer the benefits of genuine Atlas Copco
parts while keeping the maintenance budget low.
Service contracts
Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance work.
Consult your Atlas Copco Customer Centre.
General
When servicing, replace all removed gaskets, O-rings and washers.
Intervals
The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service
intervals, depending on the environmental and working conditions of the compressor.
The longer interval checks must also include the shorter interval checks.
Service plans
Besides the daily and 3-monthly checks, preventive service operations are specified in the schedule below.
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. After servicing, the intervals must be reset, see section Service menu.
Preventive maintenance schedule

General
Period Operation
Daily Check oil level.
Check readings on display.
Check air filter service indicator.
Check that condensate is discharged during operation.
Drain condensate.
3-monthly (1) Check coolers, clean if necessary.
Remove the air filter element and inspect. If necessary, clean using an air jet. Replace
damaged or heavily contaminated elements.
Visually inspect the filter pads of the converter cabinet. Clean with an air jet or replace if
necessary.
On compressors with integrated dryer: check condenser of dryer and clean if necessary.
(1): more frequently if the compressor is operated in a dusty environment.

Programmed service interventions
Running hours Service plan Operation

4000 (1) A If Atlas Copco Roto-Inject Fluid is used, change oil and oil filter.
4000 B Replace air filter element.
4000 B Check pressure and temperature readings.
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Running hours Service plan Operation

4000 B Carry out a LED/display test.
4000 B Replace air filter pads of converter cabinet.
4000 B Check for possible leakage.
4000 B On air-cooled compressors: clean coolers.
4000 B Remove, dismantle and clean float valve of condensate trap. See
section Condensate system.
4000 B Test temperature shut-down function.
4000 B Have safety valve tested.
4000 B Clean cooling fins of electric motor.
4000 B Inspect the scavenging line and the the non-return valve for cleanness.
4000 B Check operation of cooling fans of converter.
4000 B Regrease drive motor bearings.
4000 B Check the functioning of the blow-off solenoid valve after stopping and
after pressing the emergency stop button.
8000 C Have oil separator replaced.
(1) or yearly, whichever comes first.

(2) or every 2 years, whichever comes first
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.
Important
• Always consult Atlas Copco if a timer setting has to be changed.

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

It is strongly recommended to use genuine Atlas Copco Lubricants. They are the result of years of field
experience and research. See section Preventive maintenance schedule for the advised replacement intervals
and 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.
Roto-Inject Fluid
Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw
compressors. Its specific composition keeps the compressor in excellent condition. Roto-Inject Fluid can be
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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), oil lifetime is reduced
significantly. In such case it is recommended to use Roto-Xtend Duty Fluid.
6.3 Storage after installation
Procedure
Run the compressor regularly, e.g. twice a week, until warm.
If the compressor is going to be stored without running from time to time, protective
measures must be taken. Consult Atlas Copco.
6.4 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.
6.5 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.
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7 Adjustments and servicing procedures
7.1 Drive motor

Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a brush and/
or compressed air jet.
Maintenance instructions
The motor bearings do not requires specific maintenance:
The bearing at the non-drive end side is greased for life.
The bearing at the drive end side is lubricated by the compressor oil circuit.
7.2 Air filter
Location of air filter
Air filter
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.
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Procedure
1. Stop the compressor. Switch off the voltage.
2. Remove the cover of air filter (AF) by turning it anti-clockwise. Remove the filter element. If necessary,
clean the cover.
3. Fit the new element and the cover.
4. If applicable, reset the air filter service warning.
After carrying out all service actions in the relevant ‘Service Plan’, reset the service warning; see section
Service menu.
7.3 Oil and oil filter change
Warning

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
Oil system components
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Drain plugs
- Run the compressor until warm, close the air outlet valve and let the compressor run for 3 minutes
at minimum speed. Stop the compressor, press the emergency stop button, open manual drain
valve(s) (Dm, Dm1) and wait until the compressor has depressurized.
Unscrew oil filler plug (FC) only one turn to permit any pressure in the system to escape.
- Loosen the top connection of the oil cooler and wait for 5 minutes.
- Drain the oil by removing the drain plugs:
• On the air receiver (DP1)
• On the check valve (DP2)
• On the gearbox (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.
- Remove the oil filter (OF). Clean the seat on the manifold. Oil the gasket of the new filter and screw
it into place. Tighten firmly by hand.
- 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) only 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 timer:
After carrying out all service actions in the relevant ‘Service Plan’, reset the service warning;
7.4 Coolers
Cleaning
Keep the coolers clean to maintain efficiency.
On air-cooled compressors:
• Stop the compressor, close the air outlet valve and switch off the voltage.
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• Cover all parts underneath the coolers.

• Remove the side baffle that encloses 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.
• Then 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.
• Reposition the side baffle that encloses the fan compartment.
7.5 Safety valve
Location of safety valve
Operating
Operate the safety valve by unscrewing the cap one or two turns and retighten it.
Testing
Before removing the valve, depressurize the compressor. See section Problem solving.
Valve (SV) can be tested on a separate air line. If the valve does not open at the set pressure specified on the
valve, it needs to be replaced. Consult Atlas Copco.
Warning
No adjustments are allowed. Never run the compressor without safety valve.
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7.6 Dryer maintenance instructions
Safety precautions
Refrigeration dryers of ID type contain refrigerant HFC.
When handling refrigerant, all applicable safety precautions must be observed. Please be specifically
aware of the following points:
• Contact of refrigerant with the skin will cause freezing. Special gloves must be worn. If contacted with
the skin, the skin should be rinsed with water. On no account may clothing be removed.
• Fluid refrigerant will also cause freezing of the eyes; always wear safety glasses.
• Refrigerant is harmful. Do not inhale refrigerant vapours. Check that the working area is adequately
ventilated.
Be aware that certain components such as the refrigerant compressor and the discharge pipe can become quite
hot (up to 110 °C - 230 °F). Therefore, wait until the dryer has cooled down before removing the panels.
Before starting any maintenance or repair work, switch off the voltage and close the air inlet and outlet valves.
Local legislation
Local legislation may stipulate that:
• Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function
must be undertaken by an authorised control body.
• The installation should be checked once a year by an authorised control body.
General
For all references see section Introduction.
The following remarks should be kept in mind:
• Keep the dryer clean.
• Brush or blow off the finned surface of condenser monthly.
• Inspect and clean the electronic condensate drain monthly.
• Functioning of the drains can be checked by pushing the TEST button of the drain.
• Cleaning of the drain filter can be done by opening the manual drain valve during a few seconds.
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8 Problem solving
Warning
Before carrying out any maintenance, repair work or adjustment, press the stop button,
wait until the compressor has stopped, press the emergency stop button and switch off
the voltage.
For interventions in the compressed air circuit, close the air outlet valve and open the
manual condensate drain valve. Depressurise the compressor by opening the oil filler plug
one turn.
For location of components, see sections:
• Introduction
• Condensate system
• Initial start-up
Open and lock the isolating switch.
The air outlet valve can be locked during maintenance or repair as follows:
• Close the valve.
• Remove the screw fixing the handle with the wrench delivered with the compressor.
• Lift the handle and turn it until the slot of the handle fits over the blocking edge on the
valve body.
• Fit the screw.
Before electrical maintenance
Wait for at least 6 minutes before starting any electrical repairs as dangerous high voltage
remains on the capacitors of the start and speed regulation unit during some minutes after
switching off the voltage.
Faults and remedies

If the alarm LED is lit or flashes, consult sections Status data menu and Service menu.
- Condition Fault Remedy

Condensate is not discharged Discharge flexible clogged Check and correct as
from condensate separator during necessary
loaded operation
Automatic drain malfunctioning Open the manual drain valve(s)
to clean the filter of the EWD. If
necessary, disassemble and
check.

Compressor air output or pressure Air consumption exceeds air Check equipment connected
below normal delivery of compressor
Choked air filter element Replace filter element
Solenoid valve malfunctioning Replace valve
Oil separator clogged Have element replaced
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Air leakage Have leaks repaired
Safety valve leaking Have valve replaced
Compressor element out of order Consult Atlas Copco Customer
Centre

Safety valve blows Minimum pressure valve Check and have defective
malfunctioning parts replaced
Oil separator clogged Have element replaced
Safety valve out of order Have valve checked. Replace
if necessary
On Full-Feature compressors, Have system checked by Atlas
dryer piping clogged due to Copco Customer Centre
formation of ice

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

For all references hereafter, consult section Air dryer.
Condition Fault Remedy

1 Pressure dewpoint too high Air inlet temperature too high Check and correct; if necessary, clean
the air cooler of the compressor
Ambient temperature too high Check and correct; if necessary, draw
cooling air via a duct from a cooler
place or relocate the compressor
Shortage of refrigerant Have circuit checked for leaks and
recharged
Refrigerant compressor (M1) See 3
does not run
Evaporator pressure too high See 5
AIF999999 99
Instruction book
Condition Fault Remedy

Condenser pressure too high See 2
2 Condenser pressure too high Fan control switch out of order Replace
or too low
Fan blades or fan motor out of Check fan/fan motor
order
Ambient temperature too high Check and correct; if necessary, draw
cooling air via a duct from a cooler
place or relocate the compressor
Condenser externally clogged Clean condenser
3 Compressor stops or does not Electric power supply to Check and correct as necessary
start compressor is interrupted
Thermal protection of Motor will restart when motor windings
refrigerant compressor motor have cooled down
has tripped
4 Electronic condensate drain Electronic drain system Have system inspected
remains inoperative clogged Clean the filter of the automatic drain
by opening the manual drain valve.
Check functioning of the drain by
pushing the test button.
Condensate trap continuously Automatic drain out of order Have system checked. If necessary,
discharges air and water replace the automatic drain.
5 Evaporator pressure is too high Hot gas bypass valve Have hot gas bypass valve adjusted
or too low at unload incorrectly set or out of order
Condenser pressure too high See 2
or too low
Shortage of refrigerant Have circuit checked for leaks and
recharged
100 AIF999999
Instruction book
9 Technical data
9.1 Readings on display
Display of Elektronikon regulator
Elektronikon® Graphic controller
Important
The readings mentioned below are valid under the reference conditions (see section
Reference conditions and limitations).
Reference Reading
Air outlet pressure Depends on the setpoint (desired net pressure).
Compressor element Approx. 60 ˚C (108 ˚F) above ambient temperature.
outlet temperature
Dewpoint temperature Approx. 4 ˚C (39 ˚F).
(on Full-Feature
compressors
AIF999999 101
Instruction book
9.2 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 and fuses
Type V Hz Approval ItotPack (1) ItotFF (1) Fuse (A)

GA 22 VSD 400 50 IEC 49 58 63
(1): current in the supply lines at maximum load and nominal voltage
Possible configurations
There are 3 possible configurations:
• (1): Single supply cables. (For DOL and VSD versions, only K21 is used).
• (2): Parallel supply cables
• (3) is only valid for Y-D versions
Cable sizing according IEC

The tables below indicate the current carrying capacities of cables for 3 commonly used installation methods,
calculated according to standard 60364-5-52 - electrical installations of buildings part 5 - selection and erection
equipment and section 52 - current carrying capacities in wiring systems.
The allowed currents are valid for PVC insulated cables with three loaded copper conductors (maximum
conductor temperature 70 °C).
102 AIF999999
Instruction book
Installation method B2 according table B.52.1.

Multi-core cable in conduit on a wooden wall
Maximum allowed current in function of the ambient temperature for installation method B2
Ambient temperature
Cable section 30 °C 40 °C 45 °C 50 °C 55 °C
4 mm² < 27 A < 23 A < 21 A < 19 A < 16 A
6 mm² < 34 A < 30 A < 27 A < 24 A < 21 A
10 mm² < 46 A < 40 A < 36 A < 33 A < 28 A
16 mm² < 62 A < 54 A < 49 A < 44 A < 38 A
25 mm² < 80 A < 70 A < 63 A < 57 A < 49 A
35 mm² < 99 A < 86 A < 78 A < 70 A < 60 A
50 mm² < 118 A < 103 A < 93 A < 84 A < 72 A
70 mm² < 149 A < 130 A < 118 A < 106 A < 91 A
95 mm² < 179 A < 156 A < 141 A < 127 A < 109 A
120 mm² < 206 A < 179 A < 163 A < 146 A < 126 A
Installation method C according table B.52.1.

Single-core or multi-core cable on a wooden wall
Maximum allowed current in function of the ambient temperature for installation method C
Ambient temperature
4 mm² < 32 A < 28 A < 25 A < 23 A < 20 A
6 mm² < 41 A < 36 A < 32 A < 29 A < 25 A
10 mm² < 57 A < 50 A < 45 A < 40 A < 35 A
16 mm² < 76 A < 66 A < 60 A < 54 A < 46 A
25 mm² < 96 A < 84 A < 76 A < 68 A < 59 A
35 mm² < 119 A < 104 A < 94 A < 84 A < 73 A
50 mm² < 144 A < 125 A < 114 A < 102 A < 88 A
70 mm² < 184 A < 160 A < 145 A < 131 A < 112 A
95 mm² < 223 A < 194 A < 176 A < 158 A < 136 A
120 mm² < 259 A < 225 A < 205 A < 184 A < 158 A
AIF999999 103
Instruction book
Installation method F according table B.52.1.

Single-core cables, touching in free air
Clearance to wall not less than one cable diameter
Maximum allowed current in function of the ambient temperature for installation method F
Ambient temperature
25 mm² < 110 A < 96 A < 87 A < 78 A < 67 A
35 mm² < 137 A < 119 A < 108 A < 97 A < 84 A
50 mm² < 167 A < 145 A < 132 A < 119 A < 102 A
70 mm² < 216 A < 188 A < 171 A < 153 A < 132 A
95 mm² < 264 A < 230 A < 209 A < 187 A < 161 A
120 mm² < 308 A < 268 A < 243 A < 219 A < 188 A
Calculation method for IEC:

• Single supply cables (3 phases + PE - configuration (1)):
• Add 10 % to the total compressor current (ItotPack or ItotFF from the tables)
• Install the prescribed fuse on each cable
• Parallel supply cable (2 x 3 phases + PE - configuration (2)):
• Add 10 % to the total compressor current (ItotPack or ItotFF from the tables) and divide by 2
• Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1))
• Install fuses of half the size of the recommended maximum fuse size on each cable.
• When using 2 x 3 phases + PE as in (3):
• Add 10 % to the total compressor current (ItotPack or ItotFF from the tables) and divide by √3
• Multiply the ampacity of the cables with 0.8 (see table A.52.17 (52-E1))
• Fuse size: the recommended maximum fuse size divided by √3 on each cable.
• Size of the PE cable:
• For supply cables up to 35 mm²: same size as supply cables
• For supply cables larger than 35 mm²: half the size of the supply wires
Always check the voltage drop over the cable (less than 5 % of the nominal voltage is recommended).
Example: Itot = 89 A, maximum ambient temperature is 45 °C, recommended fuse = 100 A
• Single supply cables (3 phases + PE - configuration (1)):
• I = 89 A + 10 % = 89 x 1.1 = 97.9 A
• The table for B2 and ambient temperature = 45 ° C allows a maximum current of 93 A for a 50 mm²
cable. For a cable of 70 mm², the maximum allowed current is 118 A, which is sufficient. Therefore,
use a 3 x 70 mm² + 35 mm² cable.
If method C is used, 50 mm² is suffficient. (35 mm² for method F) => cable 3 x 50 mm² + 25 mm².
• Parallel supply cable (2 x 3 phases + PE - configuration (2)):
• I = (89 A + 10 %)/2 = (89 x 1.1)/2 = 49 A
• For a cable of 25 mm², B2 at 45 °C, the maximum current is 63 A x 0.8 = 50.4 A. So 2 parallel cables
of 3 x 25 mm² + 25 mm² are sufficient.
• Install 50 A fuses on each cable instead of 100 A.
104 AIF999999
Instruction book
Fuse calculations for IEC are done according to 60364-4-43 electrical installations of buildings, part 4:
protection for safety- section 43: protection against overcurrent. Fuse sizes are calculated in order to protect
the cable against short circuit. Fuse type aM is recommended but gG/gL is also allowed.
9.3 Settings of fan motor circuit breaker
Circuit breaker settings (Q15)
GA 22 VSD
Frequency (Hz) Voltage (V) Setting Q15
(A)
IEC
50 400 1.2
9.4 Dryer switches
General
The regulating and safety devices are factory-adjusted to give optimum performance of the dryer.
Do not alter the setting of any of the devices.
Settings
Condenser fan control switch

Cut-out pressure bar(e) 8.5
Switch-on pressure bar(e) 10.5
9.5 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
AIF999999 105
Instruction book
Limitations
Maximum working pressure for GA 15 VSD up to GA 30 See section Compressor data

VSD
Minimum working pressure bar(e) 4
Maximum air inlet temperature ˚C 46
Minimum ambient temperature ˚C 0
Maximum altitude operation (1) m 1000 m above sea level
(1): For operation at higher altitude: contact Atlas Copco
9.6 Compressor data
Note
All data specified below are valid at reference conditions; see section Reference conditions
and limitations.
GA 22 VSD
Unit 13 bar 13 bar 13 bar

Frequency Hz 50 50 50
Number of compression stages 1 1 1
Normal effective working pressure bar(e) 7 9.5 12.5
Maximum effective working pressure, bar(e) 12.75 12.75 12.75
Workplace Full-Feature
Maximum motor shaft speed @ Nominal rpm 6000 5278 4411
pressure
Minimum motor shaft speed@ Nominal rpm 1500 1708 1958
pressure
Temperature of air leaving outlet valve ˚C 20 20 20
(approx.), Workplace Full-Feature
Nominal motor rating kW 22 22 22
Refrigerant type, Workplace Full-Feature R134a R134a R134a
Total amount (refrigerant), Workplace Full- kg 0.53 0.53 0.53
Feature
Oil capacity, approx. l 7.95 7.95 7.95
Sound pressure level, Workplace and dB(A) 68 68 67
Workplace Full-Feature (according to ISO
2151 (2004))
106 AIF999999
Instruction book
9.7 Technical data Elektronikon® controller
General
Supply voltage 24 V AC /16 VA 50/60Hz (+40%/-30%)

24 V DC/0.7 A
Type of protection IP54 (front)
IP21 (back)
Ambient and temperature IEC60068-2
conditions
• Operating temperature • -10°C…..+60°C (14 °F .....140 °F)
range • -30°C…..+70°C (-22 °F ......158 °F)
• Storage temperature range
Permissible humidity Relative humidity 90%
No condensation
Noise emission IEC61000-6-3
Noise immunity IEC61000-6-2
Mounting Cabinet door
Digital outputs
Number of outputs 9 (Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900 5200 19)
Type Relay (voltage free contacts)
Rated voltage AC 250 V AC / 10 A max.
Rated voltage DC 30 V DC / 10 A max.
Digital inputs
Number of inputs 10 (Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900 5200 19)
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® Graphic controller - p.n. 1900 5200 10 …. 1900 5200 19)
Number of temperature inputs 5 (Elektronikon® Graphic controller - p.n. 1900 5200 10 …. 1900 5200 19)
AIF999999 107
Instruction book
10 Air receiver instructions
Instructions
1 This vessel can contain pressurised air; this can be potentially dangerous if the equipment is
misused.
2 This vessel must only be used as a compressed air/oil separator and must be operated within
the limits specified on the data plate.
3 No alterations must be made to this vessel by welding, drilling or any other mechanical
methods without the written permission of the manufacturer.
4 The pressure and temperature of this vessel must be clearly indicated.
5 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.
6 Use only oil as specified by the manufacturer.
7 This vessel has been designed and built to guarantee an operational liftetime in excess of 20
years and an infinite number of pressure load cycles. There is no intrinsic need for in service
inspection of the vessel when used within the design limits for its intended application.
However, national legislation may require in service inspection.
8 Original bolts have to be used after opening for inspection. The maximum torque has to be
taken into consideration: for M12 bolts 73 Nm (+/- 18) / 54 lbf.ft (+/- 13), for M16 bolts 185 Nm
(+/- 45) / 136.5 lbf.ft (+/- 33).
108 AIF999999
Instruction book
11 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.
AIF999999 109
Instruction book
12 Pressure equipment directives
Components subject to 97/23/EC Pressure Equipment Directive

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 and all pressure equipment according
to the Simple Pressure Vessel Directive 87/404/EEC.
Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to category II
Part number Description Volume Design Min and max PED Class
pressure design
temperature
0830 1010 03 Safety valve IV
1622 6912 99 Vessel 16 l 15 bar(e) 0 °C/120 °C II
Part number Description Number of Minimum wall Visual inspection Hydrostatic

cycles (1) thickness requirements (2) inspection
requirements (2)
0830 1010 03 Safety valve - - - -
1622 6912 99 Vessel 2 x 106 6 mm 10 years 10 years
(1) The number of cycles refers to the number of cycles from 0 bar(e) to maximum pressure.
(2) Other inspection techniques such as ultrasonic or X-ray are equivalent to hydrostatic testing for this
equipment.
Overall rating
The compressors are conform to PED category II.
110 AIF999999
Instruction book
13 Declaration of conformity
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
AIF999999 111
In order to be First in Mind—First in Choice® for all your quality
compressed air needs, Atlas Copco delivers the products and
services that help to increase your business’ efficiency and
profitability.
Atlas Copco's pursuit of innovation never ceases, driven by our
need for reliability and efficiency. Always working with you, we are
committed to providing you the customized quality air solution that
is the driving force behind your business.
www.atlascopco.com

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Atlas Copco

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

1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................5

1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................6

1.4 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................7

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................8

2.2 AIR FLOW.......................................................................................................................................12

2.3 OIL SYSTEM....................................................................................................................................13

2.4 COOLING SYSTEM.............................................................................................................................14

2.5 CONDENSATE SYSTEM.......................................................................................................................15

2.6 REGULATING SYSTEM........................................................................................................................16

2.7 ELECTRICAL SYSTEM.........................................................................................................................16

2.8 ELECTRICAL DIAGRAMS......................................................................................................................18

2.9 AIR DRYER......................................................................................................................................20

3 Elektronikon® Graphic controller...............................................................................22

3.1 ELEKTRONIKON® GRAPHIC CONTROLLER...............................................................................................22

3.2 CONTROL PANEL..............................................................................................................................24

3.3 ICONS USED....................................................................................................................................25

3.4 MAIN SCREEN..................................................................................................................................29

3.5 CALLING UP MENUS..........................................................................................................................34

3.6 INPUTS MENU...................................................................................................................................35

3.7 OUTPUTS MENU...............................................................................................................................38

3.9 CONTROL MODE SELECTION................................................................................................................41

3.10 SERVICE MENU................................................................................................................................43

3.11 MODIFYING THE SETPOINT..................................................................................................................47

3.12 EVENT HISTORY MENU.......................................................................................................................49

3.13 MODIFYING GENERAL SETTINGS...........................................................................................................50

3.14 INFO MENU......................................................................................................................................52

3.15 WEEK TIMER MENU...........................................................................................................................53

3.16 TEST MENU.....................................................................................................................................62

3.17 USER PASSWORD MENU.....................................................................................................................64

3.18 WEB SERVER..................................................................................................................................65

3.19 PROGRAMMABLE SETTINGS.................................................................................................................73

4.1 DIMENSION DRAWINGS.......................................................................................................................75

4.2 INSTALLATION PROPOSAL...................................................................................................................76

4.3 ELECTRICAL CONNECTIONS.................................................................................................................79

5.1 INITIAL START-UP..............................................................................................................................82

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

5.3 STARTING ......................................................................................................................................85

5.4 DURING OPERATION..........................................................................................................................86

5.5 CHECKING THE DISPLAY.....................................................................................................................87

5.6 STOPPING ......................................................................................................................................87

5.7 TAKING OUT OF OPERATION................................................................................................................88

6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................89

6.2 OIL SPECIFICATIONS..........................................................................................................................91

6.3 STORAGE AFTER INSTALLATION...........................................................................................................92

6.4 SERVICE KITS..................................................................................................................................92

6.5 DISPOSAL OF USED MATERIAL.............................................................................................................92

7 Adjustments and servicing procedures.....................................................................93

7.1 DRIVE MOTOR .................................................................................................................................93

7.2 AIR FILTER......................................................................................................................................93

7.3 OIL AND OIL FILTER CHANGE...............................................................................................................94

7.5 SAFETY VALVE.................................................................................................................................96

7.6 DRYER MAINTENANCE INSTRUCTIONS....................................................................................................97

9.1 READINGS ON DISPLAY....................................................................................................................101

9.2 ELECTRIC CABLE SIZE AND FUSES......................................................................................................102

9.3 SETTINGS OF FAN MOTOR CIRCUIT BREAKER........................................................................................105

9.4 DRYER SWITCHES...........................................................................................................................105

9.5 REFERENCE CONDITIONS AND LIMITATIONS..........................................................................................105