Atlas Copco GA18 VSD User manual

Atlas Copco Stationary Air Compressors
From serial number AII-297 500 onwards.
Important: This book must be used together with the "User manual or the Elektronikon
®
II regulator or
GA VSD compressors"
No. 2920 1454 00
Registration code: APC G18-30 VSD/2002 / 38 / 985
2002-08
GA18 VSD and GA30 VSD
Instruction Book
www.atlascopco.com
· Copyright 2002, Atlas Copco Airpower n.v., Antwerp, Belgium.
Any unauthorized use or copying o the contents or any part thereo is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings.
· This instruction book meets the requirements or instructions speci ied by the machinery
directive 98/37/EC and is valid or CE as well as non-CE labelled machines.

2920 1454 00
2
Instruction book
This instruction book describes how to handle the machines to ensure sa e operation, optimum e iciency and long service li e.
Read this book be ore putting the machine into operation to ensure correct handling, operation and proper maintenance rom
the beginning. The maintenance schedule comprises measures or keeping the machine in good condition.
Keep the book available or the operator and make sure that the machine is operated and that maintenance is carried out
according to the instructions. Record all operating data, maintenance per ormed, etc. in an operator's logbook available rom
Atlas Copco. Follow all relevant sa ety precautions, including those mentioned on the cover o this book.
Repairs must be carried out by trained personnel rom Atlas Copco who can be contacted or any urther in ormation.
In all correspondence always mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data".
The company reserves the right to make changes witho t prior notice.
Page
4.2 Compressor motor . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Oil and oil ilter change interval . . . . . . . . . . . . . 23
4.4 Oil speci ications . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4.1 Atlas Copco Roto-inject luid . . . . . . . . . 23
4.4.2 Mineral oil . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Oil ilter change . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.7 Storage a ter installation . . . . . . . . . . . . . . . . . . . 23
4.8 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5 Adj stments and servicing proced res . . . . . . . . . . 24
5.1 Air ilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1.1 Recommendations . . . . . . . . . . . . . . . . . . 24
5.1.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Sa ety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Readings on display . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Setting o sa ety valve. . . . . . . . . . . . . . . . . . . . . 26
7.3 Settings o circuit breakers . . . . . . . . . . . . . . . . . 26
7.4 Compressor speci ications . . . . . . . . . . . . . . . . . 26
7.4.1 Re erence conditions . . . . . . . . . . . . . . . . 26
7.4.2 Speci ic data o GA18 VSD . . . . . . . . . . 27
7.4.3 Speci ic data o GA30 VSD . . . . . . . . . . 27
7.5 Conversion list o SI units into US/British units 28
8 Instr ctions for se of air receiver . . . . . . . . . . . . . 28
Contents
Page
1 Leading partic lars . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Air low . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.3 Cooling and condensate drain systems . . . 6
1.2 Regulating system . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Elektronikon control module . . . . . . . . . . . . . . . . 6
1.3.1 Elektronikon regulator. . . . . . . . . . . . . . . . 7
1.3.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Electric cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Air dryer on GA Workplace Full- eature . . . . . . 12
1.5.1 Compressed air circuit . . . . . . . . . . . . . . . 12
1.5.2 Re rigeration circuit . . . . . . . . . . . . . . . . 12
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Installation proposal . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . 16
3 Operating instr ctions . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Be ore starting . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Taking out o operation. . . . . . . . . . . . . . . . . . . . 19
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Preventive maintenance schedule or the
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Instruction book
1 LEADING PARTICULARS
1.1 General description
trans ormers, an motor overload relay, etc. is located behind
this panel. The compressor is also provided with an automatic
condensate drain system.
GA Workplace F ll-feat re
GA Workplace Full- eature are additionally provided with an
air dryer (1-Fig. 1.4) which removes moisture rom the
compressed air by cooling the air to near reezing point and
automatically draining the condensate.
GA VSD (Variable Speed Drive) compressors are air-cooled
stationary, single-stage, oil-injected screw compressors, driven
by an electric motor.
GA Workplace (Fig. 1.1)
The compressors are enclosed in a sound-insulated bodywork.
The ront panel comprises an emergency stop button (S3) and
an Elektronikon control module (E1) including the start and
stop buttons. An electric cabinet comprising uses,
E1 Elektronikon control module
S3 Emergency stop button
Fig. 1.1 General view o GA18 VSD

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Instruction book
AF Air ilter
AO Dry air outlet
AR Air receiver/oil separator
BV Oil cooler by-pass valve
Ca Air cooler
Co Oil cooler
CV Check valve
CV1/Vs Check valve/oil stop valve
CV2 Non-return valve
DP1 Oil drain plug, air receiver
DP2 Oil drain plug, check valve/
oil stop valve
E Compressor element
E1 Elektronikon control module
FC Oil iller plug
FN Fan, compressor coolers
Gl Oil level gauge
M1 Compressor motor
M2 Fan motor, compressor
coolers
M3 Re rigerant compressor
M4 Condenser an motor
OF Oil ilter
OS Oil separator element
PDT1 Di erential pressure sensor,
oil separator
R 1 Nozzle
R 2 Restrictor
SV Sa ety valve
S2 Fan control switch
TT11 Temperature sensor,
compressor element outlet
Vp Minimum pressure valve
Y1 Solenoid valve, blow o
1 Condenser cooling an
2 Re rigerant condenser
3 Condensate separator
4 Condensate trap, dryer
5 Automatic condensate drain
hose
6 Manual condensate drain
valve
7 Capillary tube
8 Blow-o air lexible
9 Insulating block
10 Accumulator
11 Hot gas by-pass valve
12 Liquid re rigerant dryer/
ilter
13 Air/air heat exchanger
14 Oil scavenging line
15 Air/re rigerant heat
exchanger/evaporator
16 Condensate trap, air cooler
17 Manual condensate drain
valve
18 Automatic condensate drain
valve
Fig. 1.2 Flow diagram

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Instruction book
1.1.1 Air flow (Fig. 1.2)
Air drawn through ilter (AF) and check valve (CV) into
compressor element (E) is compressed. Compressed air and
oil low into air receiver/oil separator (AR). The air is
discharged through the outlet valve via minimum pressure
valve (Vp), air cooler (Ca) and condensate trap (4).
Minimum pressure valve (Vp) prevents the receiver pressure
rom dropping below a minimum pressure and includes a check
valve which prevents blow-back o compressed air rom the
air net.
1.1.2 Oil system (Fig. 1.2)
In air receiver/oil separator (AR), most o the oil is removed
rom the air/oil mixture centri ugally. The balance is removed
by oil separator element (OS). The oil collects in the lower
part o air receiver/oil separator (AR), which serves as oil
tank.
The oil system is provided with a by-pass valve (BV). When
the oil temperature is below 60 degrees Celsius, by-pass valve
(BV) shuts o the oil supply rom oil cooler (Co). Air pressure
orces the oil rom air receiver/oil separator (AR) through oil
ilter (OF) and oil stop valve (Vs) to compressor element (E)
and its lubrication points. Oil cooler (Co) is by-passed.
1 Air ilter
2 Oil ilter
3 By-pass valve, oil cooler
4 Oil iller plug
5 Oil drain plug, air receiver
6 Oil level gauge
7 Air receiver/oil separator
8 Minimum pressure valve
9 Air cooler
10 Oil cooler
M1 Compressor motor
S3 Emergency stop button
Fig. 1.3 Front view o GA18 VSD

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Instruction book
By-pass valve (BV) starts opening the oil supply rom cooler
(Co) when the oil temperature has increased to 60 degrees
Celsius. At approx. 75 degrees Celsius all the oil lows through
the oil cooler.
1.1.3 Cooling and condensate drain systems (Fig.
1.4)
The cooling system comprises air cooler (2) and oil cooler
(6). The compressors are air-cooled; the cooling air is
generated by an (3).
A condensate trap (12) is provided in the air outlet system.
Full- eature compressors have an extra condensate trap on the
integrated dryer. Each trap is equipped with a valve or
automatic condensate draining during operation (2 and 5-Fig.
1.5) and a manually operated valve (1 and 4-Fig. 1.5) or
draining a ter stopping the compressor.
1.2 Regulating system
I the air consumption is less than the air output o the
compressor, the net pressure increases. When the net pressure
is higher than the setpoint (desired net pressure), the regulator
will decrease the motor speed. I the net pressure keeps on
rising when the motor runs at minimum speed, the regulator
will stop the motor. I the motor is stopped automatically and
the net pressure approaches the setpoint, the regulator will
restart the motor.
1.3 Elektronikon control module
The control module consists o an Elektronikon regulator and
a control panel.
1 Dryer
2 Air cooler
3 Fan, compressor coolers
4 Fan motor
5 Vent plug, oil cooler
6 Oil cooler
7 Check valve, air inlet
8 Oil drain plug
9 Check valve/oil stop valve
10 Compressor element
11 Arrow, rotation direction
12 Condensate trap
M1 Compressor motor
Fig. 1.4 Rear view o GA18 VSD

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Instruction book
1.3.1 Elektronikon regulator (E1 Fig. 1.1)
The regulator has ollowing unctions:
Controlling the compressor
The regulator matches the compressor output to the air
consumption by speed regulation o the motor.
The regulator stops the compressor whenever necessary:
- Indirect stop: i.e. the compressor runs at minimum speed
and the net pressure rises to the indirect stop level
- Direct stop: i.e. the compressor runs at a speed in between
minimum and maximum and the net pressure rises above
the direct stop setpoint.
Both settings are programmable; consult the "User manual
or Elektronikon regulator", section "Modi y settings
submenu".
Note: to prevent the sa ety valve rom opening too requently
on 13 bar compressors, the setting o the direct stop setpoint
should never be more than 1 bar.
Protecting the compressor
I the compressor element outlet temperature exceeds the
programmed shut-down level, the compressor will be stopped.
This will be indicated on the control panel (Fig. 1.7). The
compressor will also be stopped in case o overload o an
motor (4-Fig. 1.4).
I the compressor element outlet temperature exceeds a
programmed value below the shut-down level, this will also
be indicated to warn the operator be ore the shut-down level
is reached.
Service plans
A number o service operations are grouped in plans (called
Service plans A, B and C). Each Service plan has a
programmed time interval. I a time interval is exceeded, a
message will appear on display (12-Fig. 1.7) to warn the
operator to carry out the service actions belonging to that plan.
See section 4.1.
A tomatic restart after voltage fail re
For compressors leaving the actory, this unction is made
inactive. I desired, the unction can be activated. Consult
Atlas Copco.
Warning If activated and provided the module was in the
automatic operation mode, the compressor will
automatically restart if the supply voltage to the
module is restored within a programmed time
period.
The power recovery time (the period within which
the voltage must be restored to have an automatic
restart) can be set between 10 and 3 00 seconds
or to Infinite. If the power recovery time is set to
Infinite, the compressor will always restart after
a voltage failure, no matter how long it takes to
restore the voltage. A restart delay can also be
programmed, allowing e.g. two compressors to
be restarted one after the other.
1.3.2 Control panel (Figs. 1.1 and 1.7)
LEDs/b ttons/keys
Ref. Designation F nction
1 Scroll keys Keys to scroll through the display.
2 Tabulator key Key to select the parameter
indicated by a horizontal arrow.
Only the parameters ollowed by
an arrow pointing to the right are
accessible or modi ying.
1 Manual condensate drain, dryer condensate trap
2 Automatic condensate drain, dryer condensate trap
3 Condensate outlet, optional OSD
4 Manual condensate drain, air cooler condensate trap
5 Automatic condensate drain, air cooler condensate trap
Fig. 1.5 Condensate outlets

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Instruction book

2920 1454 00 9
Instruction book
COMPRESSOR
A1 Dryer (optional)
B1 Optional electronic
condensate drain
PDS11 Delta P switch, integrated
dryer (optional)
PDT1 Di erential pressure sensor,
oil separator
PT20 Pressure sensor, air outlet
R3,4,5 Freeze protection (optional)
R7 Heater cubicle (optional)
R96 Anti-condensation heater
(optional)
TSLL91 Thermostat, reeze
protection (optional)
TT11 Temperature sensor,
compressor element outlet
TT90 Temperature sensor,
dewpoint
TT91 Temperature sensor,
converter cubicle (optional)
Y1 Solenoid valve, blow-o
MOTORS
M1 Compressor motor
M2 Fan motor, compressor
coolers
ELECTRIC CABINET
E1 Elektronikon control module
F4/5/6 Fuses
K11 Contactor, dryer
K15 Contactor, an motor
S3 Emergency stop button
S5 Service switch
S10 Main power isolating switch
(optional)
T1/T2 Trans ormer
T3 Trans ormer
Q15 Circuit breaker, an motor
CONVERTER CABINET
F1/2 Fuses
F9 Circuit breaker
K21 Line contactor
U1 Frequency converter
Z1 EMC ilter
CONTROL MODULE (E1)
I Start button
K01 Auxiliary relay, an motor
K02 Auxiliary relay
K03 Auxiliary relay
K04 Auxiliary relay, solenoid
valve
K05 Auxiliary relay, converter
shut-down
K06 Auxiliary relay, dryer
K07 Auxiliary relay, manual/
automatic operation
K08 Auxiliary relay, general
warning
K09 Auxiliary relay, general
shut-down
O Stop button
Fig. 1.6 Electrical diagram
1 Scroll keys
2 Tabulator key
3 Function keys
4 LED, voltage on
5 Pictograph, voltage on
6 Pictograph, alarm
7 LED, general alarm
8 Pictograph, automatic operation
9 LED, automatic operation
10 Stop button
11 Start button
12 Display
Fig. 1.7 Control panel

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Instruction book
Ref. Designation F nction
3 Function keys Keys to control and program the
compressor. See below.
4 Voltage on LED Indicates that the voltage is
switched on.
5 Pictograph Voltage on
6 Pictograph Alarm
7 General alarm LED Is normally out. Is alight or
blinks in case o an abnormal
condition. See below
8 Pictograph Automatic operation
9 Automatic Indicates that the regulator is
operation LED automatically controlling the
compressor.
10 Stop button Push button to stop the
compressor. LED (9) goes out.
11 Start button Push button to start the
compressor. LED (9) lights up
indicating that the regulator is
operative (in automatic
operation).
12 Display Indicates messages concerning
the compressor operating
condition, a service need or a
ault.
S3- Emergency Push button to stop the
Fig. stop button compressor in case o
1.1 emergency. A ter remedying the
trouble, unlock the button by
pulling it out.
F nction keys
The keys are used:
- To call up or to program settings
- To reset a motor overload, shut-down or service message,
or an emergency stop
- To have access to all data collected by the regulator
The unctions o the keys vary depending on the displayed
menu. The actual unction is abbreviated and indicated on
the bottom line o the display just above the relevant key. The
most common abbreviations are listed below.
Abbre- Desig- F nction
viation nation
Add Add To add compressor start/stop commands
(day/hour)
Back Back To return to a previously shown option
or menu
Canc Cancel To cancel a programmed setting when
programming parameters
Del Delete To delete compressor start/stop
commands
Help Help To ind the Atlas Copco internet address
Lim Limits To show limits or a programmable
setting
Main Main To return rom a menu to the main screen
(Fig. 1.8)
Men Menu Starting rom the main screen (Fig. 1.8):
to have access to submenus
Men Menu Starting rom a submenu: to return to the
previous menu
Mod Modi y To modi y programmable settings
Prog Program To program modi ied settings
Rset Reset To reset a timer or message
Rtrn Return To return to a previously shown menu
Xtra Extra To ind in ormation regarding the
installed modules
General alarm LED (7-Fig. 1.7) 1)
- The LED blinks in case o a shut-down (due to too high a
compressor element outlet temperature, overload o the
an motor, etc.); at the same time the shut-down screen
appears. A ter eliminating the cause o the trouble and
when the abnormal condition has disappeared, press
unction key (3) below Rset.
- The LED blinks and the compressor is shut down i the
sensor o the compressor element is out o order; at the
same time the display will show a ault message.
Depressurize the compressor by pressing the emergency
stop button, close the air outlet valve and open the manual
drain valve. Check the sensor and its wiring.
- The LED is alight in case o a shut-down warning; at the
same time a warning message appears. Remedy; see
section 6.

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Instruction book
Compressor out
bar 7.0
rpm 5065 ¯
Menu
F1 F2 F3
Fig. 1.8 Example o the main screen
Status data ®
Measured data
Counters
Main ¯
F1 F2 F3
Fig. 1.9 Example o a main menu
Figs. 1.8 and 1.9 Displays
Calling p other men s
Starting rom the Main screen:
- Use the ¯ key (1-Fig. 1.7) or a quick look at the actual
compressor status
- Press the key Menu (F1), the option Status data will be
ollowed by a horizontal arrow:
- either press the tabulator key (2-Fig. 1.7) to select this
menu
- or use the ¯ key (1-Fig. 1.7) to scroll until the desired
submenu is ollowed by a horizontal arrow and then
press tabulator key to select this menu
1.4 Electric cabinet (Fig. 1.10
The electric cabinet mainly comprises trans ormers, uses, a
an motor contactor and circuit breaker, and or Full- eature
compressors also the dryer contactor.
The Elektronikon regulator and emergency stop button are
itted in the door o the cabinet.
The converter cabinet comprises the start and speed regulation
unit. The parameters o the start and speed regulation unit are
actory-set and need no adjustment. Changing the parameters
may damage the compressor; consult Atlas Copco.
F1 Circuit breaker
F4/F5/F6 Fuses
K11 Contactor, dryer
K15 Contactor, an motor
Q15 Circuit breaker, an
motor
T1 Trans ormer
T2 Trans ormer
Fig. 1.10 Electric cabinet (typical example)
F1/F2 Fuses
F9 Circuit breaker
K21 Line contactor
PE Earth terminal
U1 Frequency converter
Fig. 1.11 Converter cabinet

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Instruction book
1.5 Air dryer on GA Workplace Full-feature
(Figs. 1.2 and 3.5
GA Workplace Full- eature are provided with a dryer which
removes moisture rom the compressed air.
1.5.1 Compressed air circuit (Fig. 1.2)
Compressed air enters heat exchanger (13) and is cooled by
the outgoing, cold, dried air. Water in the incoming air starts
to condense. The air then lows through heat exchanger/
evaporator (15) where the re rigerant evaporates causing the
air to be urther cooled to close to the evaporating temperature
o the re rigerant. More water in the air condenses. The cold
air then lows through separator (3) where all the condensate
is separated rom the air. The condensate collects in
condensate trap (4) and is automatically drained. The cold,
dried air lows through heat exchanger (13), where it is warmed
up by the incoming air. Condensation in the air net cannot
occur unless the air is cooled to below the pressure dewpoint.
1.5.2 Refrigeration circuit (Fig. 1.2)
Compressor (M3) delivers hot, high-pressure re rigerant gas
which lows through condenser (2) where most o the
re rigerant condenses.
The liquid lows through liquid re rigerant dryer/ ilter (12) to
capillary tube (7). The re rigerant leaves the capillary tube at
evaporating pressure.
The re rigerant enters evaporator (15) where it withdraws heat
rom the compressed air by urther evaporation at constant
pressure. The heated re rigerant leaves the evaporator and is
sucked in by the compressor.
Footnote chapter 1
1) Consult the "User manual for Elektronikon regulator", section "Status data submenu".

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Instruction book
2 INSTALLATION
2.1 Dimension drawing (Fig. 2.1
Fig. 2.1 Dimension drawing

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Instruction book
2.2 Electric cable size
Attention
- Local regulations remain applicable i they are stricter than
the values proposed below.
- The voltage drop shall not exceed 5% o the nominal
voltage. It may be necessary to use cables with a larger
size than those stated to comply with this requirement.
- Use the original cable entrance ((2-Fig. 2.1).
- The voltage on the compressor terminals must not deviate
more than 10% o the nominal voltage.
50 Hz compressors
Compressor type GA18 VSD GA18 VSD GA18 VSD GA30 VSD GA30 VSD GA30 VSD
Voltage (V) . . . . . . . . . . . . . . . . . . . 400+N 400 500 400+N 400 500
Maximum line current
- Pack (A) . . . . . . . . . . . . . . . . . . . 51 51 36 68 68 56
- Full- eature (A) . . . . . . . . . . . . . . 56 59 40 73 77 60
Cable size (mm²) . . . . . . . . . . . . . . 25 25 25 50 50 50
Maximum use (A) . . . . . . . . . . . . . 63 63 63 80 80 80
60 Hz compressors
Compressor type GA18 VSD GA18 VSD GA30 VSD GA30 VSD
Voltage (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 460 380 460
Maximum line current
- Pack (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 37 71 60
- Full- eature (A) . . . . . . . . . . . . . . . . . . . . . . . 52 42 78 65
Cable size (mm²/AWG size). . . . . . . . . . . . . . . 25/4 25/4 50/1 50/1
Maximum use (A) IEC/CSA-UL . . . . . . . . . . 63/60 63/60 125/125 125/125
2.3 Installation proposal (Fig. 2.2
Ref. Description/recommendation
L = (dP x d5 x P) / (450 x Qc1.85)
L = pipe length in m
dP = maximum allowable pressure drop
(recommended 0.1 bar)
d = inner diameter o pipe in mm
P = compressor outlet pressure in bar absolute
Qc = ree air delivery o compressor in l/s
Ref. Description/recommendation
1 Install the compressor on a level loor suitable or taking
the weight o the compressor.
2 Compressed air outlet valve.
3 The maximum total pipe length (including
interconnecting piping between compressor and
receiver) can be calculated as ollows:

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Instruction book
Ref. Description/recommendation
4 Ventilation: the inlet grids and ventilation an should
be installed in such a way that any recirculation o
cooling air to the compressor is avoided. The air
velocity to the grids must be limited to 5 m/s. The
maximum allowable pressure drop over the cooling air
ducts depends on the ambient temperature; consult
Atlas Copco. The maximum air temperature at the
compressor intake opening is 40 degrees Celsius
(minimum 0 degrees Celsius).
For alternatives 1 and 3, the required ventilation to limit
the compressor room temperature can be calculated as
ollows:
Ref. Description/recommendation
Qv = 1.06 N/dT or GA VSD Workplace
Qv = (1.06 N + 1.3)/dT or GA VSD Workplace
Full- eature
Qv = required ventilation capacity in m3/s
N = nominal motor power input o compressor
in kW
dT = temperature increase in compressor room
Fig. 2.2 Installation proposal

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Instruction book
Ref. Description/recommendation
5 The drain pipes to the drain collector must not dip into
the water o the drain collector. Atlas Copco has oil/
water separators (type OSD) to separate the major part
o the oil rom the condensate to ensure that the
condensate meets the requirements o the
environmental codes.
6 Control module with monitoring panel.
7 Mains cables entry.
8 Filter type DD (optional) or general purpose iltration
(particle removal down to 1 micron with a maximum
oil carry-over o 0.5 ppm). A high-e iciency ilter,
type PD (optional) may be installed downstream the
DD ilter (particle removal down to 0.01 micron with
max. oil carry-over o 0.01 ppm). I oil vapour and
odours are undesirable, a ilter o the QD type (optional)
should be installed downstream o the PD ilter.
It is recommended to install by-pass pipes over each
ilter together with ball valves, in order to isolate the
ilters during service operations, without disturbing the
compressed air delivery.
9 By-pass system to by-pass the dryer during service
operations (available as an option, consult Atlas
Copco).
10 High e iciency water separator, removes 90% o the
moisture in the compressed air when by-passing the
dryer.
Attention:
Working with machinery controlled by a requency converter
requires special sa ety precautions. These sa ety precautions
depend on the kind o network used (TN, TT or IT system).
Consult Atlas Copco.
2.4 Electrical connections (Fig. 1.11
- Check the uses and the setting o the circuit breaker. See
section 7.3.
- Connect the power supply to line contactor (K21). Connect
the earth conductor to connector (PE). Consult section
2.2.
3 OPERATING INSTRUCTIONS
Safety preca tions
The operator must apply all relevant sa ety precautions,
including those mentioned in this book.
Altit de operation
Consult Atlas Copco i operating above 1000 m.
Moving/lifting
The compressor can be moved by a li t truck using the slots in
the rame. Take care not to damage the bodywork during li ting
or transport. Be ore li ting, reinstall the transport securing
bolts (see section 3.1). Make sure that the orks protrude rom
the other side o the rame. The compressor can also be li ted
a ter inserting beams in the slots. Make sure that the beams
cannot slide and that they protrude rom the rame equally.
The chains must be held parallel to the bodywork by chain
spreaders in order not to damage the compressor. The li ting
equipment must be placed in such a way that the compressor
will be li ted perpendicularly. Li t smoothly and avoid
twisting.
3.1 Initial start-up
Remarks
1. Read the "User manual or Elektronikon regulator" to
amiliarize yoursel with all regulator unctions.
2. Consult section 2 or the dimension drawings, electric cable
size and installation proposal.
Start- p
1. The compressor element and motor are secured to the
rame, immobilizing the vibration dampers during
transport.
Remove the bolts and bushes (4-Fig. 3.2) immobilizing
the vibration dampers o the compressor element.
Remove bolts (2-Fig. 3.2) and support (3-Fig. 3.2).
2. 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 uses o the inert type in all phases.
3. Check the voltage selecting wires at the primary side o
trans ormers (T1 and T2-Fig. 1.10) and the setting o an
motor circuit breaker (Q15-Fig. 1.10). Check that the
switch on the circuit breaker is in position "I".
4. Fit the air outlet valve to the air outlet pipe. Close the
valve. Connect the air net to the valve.
5. Connect the manual and automatic condensate drain outlets
to a drain collector as described in section 2.3.

2920 1454 00 17
Instruction book
6. Check the oil level. The pointer o the level gauge (5-Fig.
3.1) should register in the green or orange range. The
bottle delivered loose with the compressor is illed with
Atlas Copco Roto-inject luid and can be used or topping
up.
7. A sticker dealing in short with the operating instructions
and explaining the pictographs is delivered with the
literature set. A ix the sticker next to the control panel.
Make yoursel amiliar with the instructions and
pictographs explained.
Stick labels on an obvious place near the control panel,
warning the operator that:
- the compressor is automatically started and stopped
(see section 1.2)
- the compressor may automatically restart a ter voltage
ailure (see section 1.3.1)
- the compressor may be remotely controlled (see section
3.1.1)
8. Switch on the voltage. Start the compressor and check the
rotation direction o the an motor. Rotation arrows, visible
through the grating in the roo , are provided on the an
plate. I the rotation direction is wrong, reverse two
incoming connections on the terminals o circuit breaker
(Q15-Fig. 1.10). Check the rotation direction o the drive
motor, the correct direction is indicated by arrow (11-Fig.
1.4) on the gear casing. I the rotation direction is wrong,
reverse two incoming connections on the drive motor.
9. Check the programmed settings. 1)
10. Start the compressor and run it or a ew minutes. Check
that the compressor operates normally.
3.1.1 Remote control
Consult the User manual or Elektronikon II regulators
section Con iguration menu i it is desired to switch to the
remote control mode.
Attention
Consult Atlas Copco be ore connecting a remote start/
programmed stop button.
3.2 Before starting
- I the compressor has not run or the past 6 months, special
precautions must be taken. Improve the lubrication o the
compressor element at starting: remove the our bolts o
expander (4-Fig. 3.3) li t the expander and po r 3/4 l of
oil into the compressor element. Reinstall the expander.
- Check the oil level (5-Fig. 3.1). The pointer should be in
the upper ield o the green range or in the HIGH range. I
the pointer registers in the LOW range, depressurize the
oil system by p shing the emergency stop b tton, close
the air o tlet valve and open man al drain valves (1
and 4-Fig. 1.5). Wait until the compressor has
depressurized. Unscrew oil iller plug (3-Fig. 3.1) only
one turn to permit any pressure in the system to escape.
Remove the iller cap and add oil until the level reaches
the iller neck. Tighten the plug.
1 Oil ilter
2 By-pass valve, oil cooler
3 Oil iller plug
4 Oil drain plug, air receiver
5 Oil level gauge
6 Air receiver
Fig. 3.1 Oil system components
1 Compressor motor
2 Bolts (to be removed)
3 Support (to be removed)
4 Bolt and bush (to be removed)
5 By-pass valve, oil cooler
Fig. 3.2 Parts, transport protection

2920 1454 00
18
Instruction book
- I the coloured part o the service indicator (1-Fig. 3.3)
shows ull out, replace the air ilter element.
3.3 Starting (Fig. 1.7
1. Switch on the voltage. Check that voltage on LED (4)
lights up. The message compressor off appears.
2. Open the air outlet valve.
3. Close condensate drain valves (1 and 4-Fig. 1.5).
4. Press start button I (11). The compressor starts running
and automatic operation LED (9) lights up.
3.4 During operation (Fig. 1.7
In order to ensure su icient motor cooling, the doors must be
closed during operation and may be opened or short periods
only to carry out checks.
1. Check the oil level d ring operation: the pointer o the
level indicator (5-Fig. 3.1) must register in the green range;
i not, press stop button O (10), press the emergency stop
b tton (S3-Fig. 1.1), close the air o tlet valve, open
man al drain valves (1 and 4-Fig. 1.5) and wait ntil
the compressor has depress rized. Unscrew oil filler
pl g (3-Fig. 3.1) only one t rn to permit any press re
in the system to escape. Remove the iller plug and add
1 Air ilter service indicator
2 Nozzle
3 Palm grip
4 Expander
5 Hose clip, air inlet hose
6 Air inlet hose
Fig. 3.3 View o blow-o nozzle
1 Compressor element
2 Oil drain plug
3 Check valve/oil stop valve
4 Arrow, indicating the correct rotation direction o the
drive motor
Fig. 3.4 View o compressor element
oil until the level reaches the iller neck. Tighten the plug.
2. I the coloured part o air ilter service indicator (1-Fig.
3.3) shows ully out, stop the compressor, switch o the
voltage and replace the air ilter element. Reset the
indicator by pushing its knob.
3. I automatic operation LED (9) 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.
Warning When the motors are stopped and LED (9) is
alight, the motors may start automatically.
Checking the display 2) (Fig. 1.7)
1. Regularly check the display or readings and messages.
Normally the main screen (Fig. 1.8) is shown, indicating
the compressor outlet pressure, the motor speed and the
abbreviations o the unctions o the keys below the display.
See section 1.3.
2. Always check the display (12) and remedy the trouble i
alarm LED (7) is alight or blinks. See section 1.3.2.

2920 1454 00 19
Instruction book
1 Hot gas by-pass valve
2 Cubicle
3 Accumulator
4 Re rigerant compressor
5 Condenser
6 Condenser an
7 Fan control switch
Fig. 3.5 Air dryer
3. The display (12) will show a service message i a service
plan interval has been exceeded or i a service level or a
monitored component has been exceeded. Carry out the
service actions o the indicated plans or replace the
component and reset the relevant timer.
Warning Before carrying out any maintenance, repair or
adjustment, stop the compressor, press the
emergency stop button (S3-Fig. 1.1), close the
air outlet valve and open valves (1 and 4-Fig.
1.5). Wait until the compressor is depressurized.
Switch off the voltage.
Notes:
- Whenever a shut-down, shut-down warning, service
request, sensor error or an motor overload message is
displayed, the ree spaces on the display between the
unction keys (3) are illed with blinking indicators (**).
- When more than one message needs to be displayed (e.g.
both warning and service), the messages are continuously
displayed or 3 seconds each.
4. Regularly press the ¯ key (1-Fig. 1.7) on the main screen
to call up in ormation about the actual compressor
condition:
- the maximum pressure
- the status o controlling the compressor (local or
remote)
- the status o the compressor start/stop timer (on or o )
3)
- the actual speed
- the loaded hours
- the motor starts
- the module hours
- the accumulated m³
- the outlet pressure
- the pressure di erence over the oil separator
- the compressor element outlet temperature
- the dewpoint temperature 4)
- the status o the an motor overload protection (normal
or not)
3.5 Stopping (Fig. 1.7
1. Press stop button O (10). LED (9) goes out. The
compressor stops and the message Programmed stop
appears on the screen. Five seconds later, the message
changes rom Programmed stop to Compressor stopped.
2. To stop the compressor in case o emergency, press the
emergency stop button (S3-Fig. 1.1).
3. Close the air outlet valve and switch o the voltage.
4. Open condensate drain valves (1 and 4-Fig. 1.5).
3.6 Taking out of operation
At the end o the li e cycle o the compressor, proceed as
ollows:
1. Stop the compressor and close the air outlet valve.
2. Switch o the voltage and disconnect the compressor
rom the mains.
3. Wait until the compressor has depressurized. Unscrew
plug (3-Fig. 3.1) only one turn to permit any pressure in
the system to escape. Open drain valves (1 and 4-Fig.
1.5).
4. Shut o and depressurize the part o the air net which is
connected to the outlet valve. Disconnect the
compressor air outlet pipe rom the air net.
5. Drain the oil and condensate circuits.
6. Disconnect the compressor condensate piping rom the
condensate drain net.

2920 1454 00
20
Instruction book
14 Switch o the voltage and depressurize the compressor
be ore starting maintenance or repairs
15 Consult Instruction book be ore greasing
16 Manual condensate drain
17 Automatic condensate drain
18 Torques or steel (Fe) or brass (CuZn) bolts
19 Compressor remains pressurized or 30 seconds a ter
switching o the voltage
20 Keep the doors closed during operation
21 Nozzle position, regreasing or automatic operation
22 Switch o voltage be ore removing protecting cover
inside electric cubicle
23 Lightly oil the gasket o the oil ilter, screw it on and
tighten by hand (approx. hal a turn)
24 Stop the compressor be ore cleaning the coolers
25 Switch o the voltage and wait or at least 6 minutes
be ore removing the screen
26 Be ore connecting compressor electrically, consult
the Instruction book or the motor rotation direction
27 Warning, voltage
Fig. 3.6 Pictographs
Footnotes chapter 3
1) Consult the "User manual for Elektronikon regulator", sections regarding the submenus "Measured data", "Service", "Modify settings",
"Timer" and "Programmable settings".
2) Consult the "User manual for Elektronikon regulator", sections "Status data submenu" and "Service submenu".
3) The com ressor is automatically started and sto ed if these start/sto commands are rogrammed and activated; consult the "User
manual for Elektronikon regulator", section "Timer submenu".
4) For Full-feature com ressors.