INSTRUCTION BOOK

API586589
GA 37
Atlas Copco

GA 37
API586589

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.

2019 - 02

www.atlascopco.com
 Instruction book

Table of contents

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

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

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

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

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

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

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

2.1 INTRODUCTION.................................................................................................................................12

2.2 AIR AND OIL CIRCUIT......................................................................................................................... 15

2.3 COOLING SYSTEM.............................................................................................................................17

2.4 CONDENSATE SYSTEM.......................................................................................................................17

2.5 REGULATING SYSTEM........................................................................................................................ 19

2.6 ELECTRICAL SYSTEM.........................................................................................................................20

2.7 AIR DRYER......................................................................................................................................21

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

3.1 ELEKTRONIKON™ CONTROLLER.......................................................................................................... 23

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

3.3 ICONS USED ON THE DISPLAY..............................................................................................................25

3.4 MAIN SCREEN..................................................................................................................................27

3.5 SHUT-DOWN WARNING.......................................................................................................................28

3.6 SHUT-DOWN....................................................................................................................................29

3.7 SERVICE WARNING............................................................................................................................31

3.8 SCROLLING THROUGH ALL SCREENS.....................................................................................................32

3.9 CALLING UP TEMPERATURES...............................................................................................................36

3.10 CALLING UP RUNNING HOURS..............................................................................................................37

3.11 CALLING UP MOTOR STARTS............................................................................................................... 38

2 API586589
Instruction book

3.12 CALLING UP MODULE HOURS...............................................................................................................38

3.13 CALLING UP LOADING HOURS.............................................................................................................. 39

3.14 CALLING UP LOAD RELAY................................................................................................................... 39

3.15 CALLING UP/RESETTING THE SERVICE TIMER ......................................................................................... 40

3.16 SELECTION BETWEEN LOCAL, REMOTE OR LAN CONTROL........................................................................ 41

3.17 CALLING UP/MODIFYING CAN ADDRESS............................................................................................... 41

3.18 CALLING UP/MODIFYING IP, GATEWAY AND SUBNETMASK........................................................................ 43

3.19 CALLING UP/MODIFYING PRESSURE BAND SETTINGS.................................................................................44

3.20 MODIFYING THE PRESSURE BAND SELECTION......................................................................................... 46

3.21 CALLING UP/MODIFYING SERVICE TIMER SETTINGS...................................................................................46

3.22 CALLING UP/MODIFYING THE UNIT OF TEMPERATURE................................................................................47

3.23 CALLING UP/MODIFYING UNIT OF PRESSURE........................................................................................... 47

3.24 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE...................................................................... 47

3.25 SELECTION BETWEEN Y-D OR DOL STARTING...................................................................................... 48

3.26 CALLING UP MODIFYING LOAD DELAY TIME............................................................................................. 49

3.27 CALLING UP MODIFYING MINIMUM STOP TIME.......................................................................................... 49

3.28 ACTIVATING PASSWORD PROTECTION................................................................................................... 50

3.29 ACTIVATE LOAD/UNLOAD REMOTE PRESSURE SENSING............................................................................. 50

3.30 CALLING UP/MODIFYING PROTECTION SETTINGS...................................................................................... 51

3.31 TEST SCREENS................................................................................................................................ 53

3.32 WEB SERVER.................................................................................................................................. 54

3.33 PROGRAMMABLE SETTINGS.................................................................................................................61

4 Installation.....................................................................................................................64

4.1 DIMENSION DRAWINGS.......................................................................................................................64

4.2 INSTALLATION PROPOSAL................................................................................................................... 64

4.3 ELECTRICAL CONNECTIONS.................................................................................................................68

4.4 PICTOGRAPHS................................................................................................................................. 69

API586589 3
 Instruction book

5 Operating instructions................................................................................................. 72

5.1 INITIAL START-UP..............................................................................................................................72

5.2 BEFORE STARTING............................................................................................................................75

5.3 STARTING ...................................................................................................................................... 77

5.4 DURING OPERATION.......................................................................................................................... 77

5.5 CHECKING THE DISPLAY.....................................................................................................................79

5.6 STOPPING ......................................................................................................................................80

5.7 TAKING OUT OF OPERATION................................................................................................................80

6 Maintenance.................................................................................................................. 82

6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................82

6.2 OIL SPECIFICATIONS..........................................................................................................................84

6.3 DRIVE MOTOR .................................................................................................................................85

6.4 AIR FILTER......................................................................................................................................85

6.5 OIL AND OIL FILTER CHANGE...............................................................................................................86

6.6 COOLERS....................................................................................................................................... 87

6.7 SAFETY VALVES............................................................................................................................... 89

6.8 DRYER MAINTENANCE INSTRUCTIONS....................................................................................................89

6.9 SERVICE KITS.................................................................................................................................. 90

6.10 STORAGE AFTER INSTALLATION........................................................................................................... 91

6.11 DISPOSAL OF USED MATERIAL............................................................................................................. 91

7 Problem solving............................................................................................................92

8 Technical data...............................................................................................................96

8.1 READINGS ON DISPLAY...................................................................................................................... 96

8.2 ELECTRIC CABLE SIZE AND FUSES........................................................................................................97

8.3 PROTECTION SETTINGS....................................................................................................................101

8.4 DRYER SWITCHES...........................................................................................................................101

8.5 REFERENCE CONDITIONS AND LIMITATIONS.......................................................................................... 101

4 API586589
Instruction book

8.6 COMPRESSOR DATA........................................................................................................................102

8.7 TECHNICAL DATA CONTROLLER..........................................................................................................102

9 Instructions for use.................................................................................................... 104

10 Guidelines for inspection...........................................................................................105

11 Pressure equipment directives................................................................................. 106

12 Declaration of conformity.......................................................................................... 107

API586589 5
 Instruction book

1 Safety precautions

1.1 Safety icons

Explanation

Danger to life

Warning

Important note

1.2 General safety precautions

1. The operator must employ safe working practices and observe all related work safety
requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter
of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel. The personnel should apply safe working practices by use of
personal protection equipment, appropriate tools and defined procedures.
4. The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to the
applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any
electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.

If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!

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.

6 API586589
Instruction book

9. If compressed air is used in the food industry and more specifically for direct food contact, it
is recommended, for optimal safety, to use certified Class 0 compressors in combination
with appropriate filtration depending on the application. Please contact your customer center
for advice on specific filtration.

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.

API586589 7
 Instruction book

12. The electrical connections must correspond to the applicable codes. The machines must be
earthed and protected against short circuits by fuses in all phases. A lockable power
isolating switch must be installed near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after
voltage failure is activated, a sign stating "This machine may start without warning" must be
affixed near the instrument panel.
14. In multiple compressor systems, manual valves must be installed to isolate each
compressor. Non-return valves (check valves) must not be relied upon for isolating pressure
systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure relieving device or devices as
required.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other
high temperature piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to
be protected by a safety device with set pressure according to the maximum cooling water
inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the
dryer, safety valves must be installed in the vessels of the dryer.

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

1.4 Safety precautions during operation

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

Precautions during operation

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

8 API586589
Instruction book

6. Keep all bodywork doors shut during operation. The doors may be opened for short periods
only, e.g. to carry out routine checks. Wear ear protectors when opening a door.
On machines without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or
exceeds 80 dB(A) shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not
rubbing
• No leaks occur
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in
good repair, free of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a
workroom, take precautions against air pollution and possible contamination of the breathing
air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must
be taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure shall be protected by a pressure relieving device or devices as
required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book
must be respected. Local regulations remain applicable if they are more strict.

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

1.5 Safety precautions during maintenance or repair

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

Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes,
etc.).
2. Use only the correct tools for maintenance and repair work.

API586589 9
 Instruction book

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

10 API586589
Instruction book

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

API586589 11
 Instruction book

2 General description

2.1 Introduction
GA 30+, GA 37 and GA 45 are single-stage, oil-injected screw compressors, driven by an electric
motor. The compressors are air cooled.
The compressors are controlled by an Elektronikon™ controller. GA 30+ has an Elektronikon
controller with graphical display, while the basic version of the GA 37 and GA 45 have a basic
version of the Elektronikon controller. For the GA37 and the GA 45, the Elektronikon controller
with graphical display is available as standard option.
The controller is fitted to the right hand door panel on the front side. An electric cabinet
comprising the motor starter is located behind this panel.
The compressors are enclosed in a sound-insulated bodywork.
There are 2 versions of the compressor: Workplace Pack (without integrated dryer) and
Workplace Full-Feature (with integrated dryer).
The dryer removes water from the compressed air by cooling the air to near freezing point.

Front view, GA 30+ up to GA 45

12 API586589
Instruction book

Motor side view, GA 30+ up to GA 45 Full-Feature

API586589 13
 Instruction book

Service side view, GA 30+ up to GA 45 Full-Feature

References

1 Electric cabinet
AV Outlet valve
Ca Air cooler
Co Oil cooler
E Compressor element
ER Elektronikon™ controller
FN Cooling fan
M1 Motor of the compressor
S3 Emergency stop button
UA Unloader
Da (Dm) Condensate outlets
AF Air filter
AR Air receiver (oil separator tank)
OF Oil filter
DR Dryer (only on units with integrated dryer)

14 API586589
Instruction book

2.2 Air and oil circuit

Air circuit

Flow diagram, air circuit (compressors with integrated dryer)

Reference Description
1 Intake air
2 Air/oil mixture
3 Oil
4 Wet compressed air
5 Condensate
6 Dried compressed air

Description
Air drawn through inlet filter (AF) and open inlet valve (IV) of the unloader is compressed in
compressor element (E). A mixture of compressed air and oil flows into the air receiver/oil
separator tank (AR). The air is discharged through outlet valve (AV) via minimum pressure valve
(Vp) and air cooler (Ca).

API586589 15
 Instruction book

The air cooler is provided with a moisture trap (MT).

On compressors with integrated dryer, the air flows through air dryer (DR) before it is discharged
through outlet valve (AV). Also see section Air dryer.
Under all circumstances, the minimum pressure valve (Vp) keeps the pressure in the separator
tank (AR) above the minimum value that is required for lubrication of the compressor element. An
integrated check valve prevents the compressed air downstream the minimum pressure valve
from being vented to atmosphere during unloaded operation. When the compressor is stopped,
inlet valve (IV) closes, preventing compressed air (and oil) to be vented into the air filter.

Oil circuit

Flow diagram, oil circuit

Reference Description
1 Intake air
2 Air/oil mixture
3 Oil
4 Wet compressed air

Description
Air pressure in the separator tank forces the oil via oil filter (OF) to compressor element (E),
where it acts as sealant, coolant, lubricant and corrosion inhibitive (during stand still periods).
In air receiver/oil separator tank (AR), most of the oil is separated from the air/oil mixture by
gravity and inertia. The remaining oil is separated by oil separator (OS). The oil collects in the
lower part of air receiver/oil separator (AR).
The oil circuit is provided with a thermostatic bypass valve (BV). When the oil temperature is
below its setpoint, the oil cooler is bypassed. Bypass valve (BV) starts opening the supply to
cooler (Co) when the oil temperature has increased to the setpoint temperature. At approx. 15 ˚C
(27 ˚F) above the setpoint temperature, all the oil flows through the oil cooler.

16 API586589
Instruction book

A tropical thermostatic valve (available as an option) offers a higher opening temperature, it helps
avoiding condensate accumulation in the oil. This option is advised when the compressor
operates in high humidity conditions.

2.3 Cooling system

Diagram

Reference Description
1 Intake air
2 Air/oil mixture
3 Oil
4 Wet compressed air
5 Condensate

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

2.4 Condensate system

The condensate, collected in the moisture trap of the air cooler, is evacuated via an automatic
drain. A compressor with integrated dryer has an additional drain on the moisture trap of the
dryer. Each drain is connected to its outlet connection (Da) and a manual drain valve (Dm).

Mechanical drains
GA 37 and GA 45 have a mechanical condensate drain (MWD).

API586589 17
 Instruction book

Mechanical condensate drain

A float opens or closes the outlet dependant on the level of the condensate in the bowl.

Drain connections

Condensate drain connections

Reference Designation
Dm Manual drain valve
Dm1 Manual drain valve of the dryer (only on units with integrated dryer)

18 API586589
Instruction book

2.5 Regulating system

Load/unload regulating system

Regulating system (loaded condition)

Loading
When the net pressure is below the loading pressure, solenoid valve (Y1) is energised. Results:
• The space above unloading valve/blow-off valve (UV) is connected with the oil separator
tank pressure (1) via the solenoid valve.
• Unloading valve/blow-off valve (UV) moves downwards, closing off the connection to
channels (2) and (3).
• Underpressure from the compressor element causes loading plunger (LP) to move
downwards and inlet valve (IV) to open fully.
Air delivery is 100%, the compressor runs loaded.

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

API586589 19
 Instruction book

Air output is stopped, the compressor runs unloaded.

2.6 Electrical system

Electrical components
The electrical system comprises following components:

Typical example of electric cubicle

Reference Designation
F1 Fuse
F2 Fuse
F3 Fuse
F7/8/9 Fuses (only on units with integrated dryer)
F21 Overload relay, compressor motor

20 API586589
Instruction book

Reference Designation
Q15 Circuit breaker, fan motor (on air-cooled compressors)
K5 Auxiliary relay
K11 Auxiliary contactor (only on units with integrated dryer)
K12 Auxiliary contactor (only on units with integrated dryer)
K25 Phase sequence relay
E10 Smartbox
K21 Line contactor
K22 Star contactor
K23 Delta contactor
T1 Transformer
PE Earth terminal

Electrical diagram

9828 5102 00 Service diagram

The complete electrical diagram can be found in the electric cubicle and on the CD-ROM,
supplied with the machine.

2.7 Air dryer

(On compressors with integrated dryer only)

Flow diagram

Air dryer

API586589 21
 Instruction book

Reference Name
AI Air inlet
AO Air outlet
1 Air/air heat exchanger
2 Air/refrigerant heat exchanger/evaporator
3 Condensate separator
4 Automatic drain / condensate outlet
5 Refrigerant compressor
6 Refrigerant condenser
7 Liquid refrigerant dryer/filter
8 Capillary
9 Bypass valve
10 Condenser cooling fan
11 Pressure switch, fan control
12 Liquid separator

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 condensate drain (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 about evaporating pressure.
The refrigerant enters evaporator (2) where it withdraws heat from the compressed air by further
evaporation at about constant pressure. The heated refrigerant leaves the evaporator and is
sucked in by the compressor (5) through a liquid separator (12).
Bypass valve (9) regulates the refrigerant flow. Fan (10) is switched on or off by switch (11)
depending on the pressure degree of the condensate.

22 API586589
Instruction book

3 Elektronikon™ controller

3.1 Elektronikon™ controller

Control panel

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

The controller maintains the net pressure between programmable limits by automatically loading
and unloading the compressor. A number of programmable settings, e.g. the unloading and
loading pressures, the minimum stop time and the maximum number of motor starts within a
given period of time are taken into account.
The controller stops the compressor whenever possible to reduce the power consumption and
restarts it automatically when the net pressure decreases. If the expected unloading period is to
short, the compressor is kept running to prevent too short stand-still periods.

Protecting the compressor

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

Before remedying, consult the Safety precautions.

API586589 23
 Instruction book

Shutdown warning
A shutdown warning level is a programmable level below the shutdown level.
If one of the measurements exceeds the programmed shutdown warning level, this will also be
indicated to warn the operator before the shutdown level is reached.

Service warning
If the service timer exceeds a programmed value, this will be indicated on the display to warn the
operator to carry out some service actions.

Other warnings
On compressors equipped with an integrated dryer, a warning message will appear if the dew
point is too high or too low for the given ambient temperature.

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. The ARAVF label 1079 9932 74 (see section
Pictographs) shall be glued near to the controller. Consult your local supplier.

If activated, and if the controller was in the automatic operation mode, the compressor
will automatically restart when the supply voltage to the module is restored!

3.2 Control panel

Detailed description

Control panel of the Elektronikon controller

Reference Designation Function

1 Display Shows icons and operating conditions.
2 Automatic operation symbol

24 API586589
Instruction book

Reference Designation Function

3 LED, Automatic operation Indicates that the regulator is automatically controlling
the compressor: the compressor is loaded, unloaded,
stopped and restarted depending on the air
consumption and the limitations programmed in the
regulator.
4 Warning symbol
5 LED, Warning Is lit if a warning condition exists.
6 Voltage symbol
7 LED, Voltage on Indicates that the voltage is switched on.
8 Service symbol
9 LED, Service Is lit when service is needed.
10 Start button This button starts the compressor. Automatic operation
LED (3) lights up. The Elektronikon is operative.
11 Stop button This button is used to stop the compressor. Automatic
operation LED (3) goes out.
12 Scroll buttons Use these buttons to scroll through the menu.
13 Enter button Use this button to confirm the last action.
14 Escape button Use this button to go to previous screen or to end the
current action.

3.3 Icons used on the display

Function Icon Description
Compressor status When the compressor is stopped, the icon stands still.
When the compressor is running, the icon is rotating.

Motor stopped

Running unloaded

Running loaded

Machine control mode Remote start / stop

LAN control

API586589 25
 Instruction book

Function Icon Description

Automatic restart after Automatic restart after voltage failure is active
voltage failure

Timer

Active protection functions Emergency stop

Service Service required

Units Pressure unit (Mega Pascal)

Pressure unit (pounds per square inch)

Pressure unit (bar)

Temperature unit (degree Centigrade)

Temperature unit (degree Fahrenheit)

Hours

Percent

The value shown must be multiplied by 10 to get the actual

value

The value shown must be multiplied by 100 to get the actual

value

The value shown must be multiplied by 1000 to get the

actual value

Motor (overload)

Element outlet temperature.

26 API586589
Instruction book

Function Icon Description

Filter

Drain

Energy saving (dryer)

Ambient temperature

Dewpoint temperature

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

3.4 Main screen

When the voltage is switched on, the first screen is a test screen. The next screen is the Main
screen, shown automatically.

The Main screen shows:

• The compressor status by means of pictographs
• The air outlet pressure

Always consult Atlas Copco if the pressure on the display is preceded by a "t".

API586589 27
 Instruction book

3.5 Shut-down warning

Description
A shut-down warning will appear in the event of:
• Too high a temperature at the outlet of the compressor element
• Too fast increase of temperature at the outlet of the compressor element
• Too high a dewpoint temperature (Full-Feature compressors)

Compressor element outlet temperature

• If the outlet temperature of the compressor element exceeds the shut-down warning level
(see section Programmable settings), warning LED (5) starts blinking.

• Press Scroll down button (12). The screen shows the temperature at the compressor
element outlet:

It remains possible to scroll through other screens, using the Scroll buttons up and down (12) to
check the actual status of other parameters. Press button (11) to stop the compressor and wait
until the compressor has stopped. Switch off the voltage, inspect the compressor and remedy.
The warning message will disappear as soon if the warning condition disappears.

Dewpoint temperature
On compressors with integrated dryer, alarm LED (5) will light up and the related pictograph will
appear flashing if the dewpoint temperature exceeds the warning level (programmable).

28 API586589
Instruction book

Main screen with the dewpoint temperature warning

The related pictograph

will appear flashing

Press the Scroll button (12) until the actual dewpoint temperature appears.

Warning screen, dewpoint temperature

The screen shows that the dewpoint temperature is 9˚C.

• It remains possible to scroll through other screens (using Scroll buttons 12) to check the
actual status of other parameters.
• Press button (11) to stop the compressor and wait until the compressor has stopped.
• Switch off the voltage, inspect the compressor and remedy.
• The warning message will disappear as soon as the warning condition disappears.

3.6 Shut-down

Description
The compressor will be shut down:
• In case the temperature at the outlet of the compressor element exceeds the shut-down
level
• In case of error of the outlet pressure sensor
• In case of overload of the drive motor
• In case of overload of the fan motor on air-cooled compressors

API586589 29
 Instruction book

Compressor element outlet temperature

• If the outlet temperature of the compressor element exceeds the shut-down level (factory
setting 120 ˚C / 248 ˚F, programmable) the compressor will be shut-down, alarm LED (5) will
flash, automatic operation LED (3) will go out and the following screen will appear:

Main screen with shut-down indication, element outlet temperature

The related pictograph

will appear flashing.

• Press Scroll buttons (12) until the actual compressor element temperature appears.

Shut-down screen, element outlet temperature

The screen shows that the temperature at the outlet of the compressor element is 120 ˚C.
• Switch off the voltage and remedy the trouble.
• After remedying and when the shut-down condition has disappeared, switch on the voltage
and restart the compressor.

Motor overload
• In the event of motor overload, the compressor will be shut-down, alarm LED (5) will flash,
automatic operation LED (3) will go out and the following screen will appear:

30 API586589
Instruction book

Main screen with shut-down indication, motor overload

• Switch off the voltage and remedy the trouble.

• After remedying and when the shut-down condition has disappeared, switch on the voltage
and restart the compressor.

3.7 Service warning

Description
A service warning will appear when the service timer has reached the programmed time interval.

If the service timer exceeds the programmed time interval, service LED (9) will light up.
To display the service timer, press Scroll buttons (12) to scroll to <d.6>: the service symbol is
shown. Next, press the Enter button (13). The reading of the service timer is shown in <hrs> (or
<x1000 hrs> if the service timer value is higher than 9999).

Example of the service timer screen

The example screen shows that the service timer is at 4002 hours.
Actions to be taken:

API586589 31
 Instruction book

Stop the compressor, switch off the voltage and carry out the required service actions. See
section Preventive Maintenance.

• The longer interval service actions must also include the shorter interval actions.
In the example above, carry out all service operations belonging to the 8000
running hours interval as well as those belonging to the 4000 running hours
interval.
• The setting of the service timer can be changed in function of the operating
conditions. See section Preventive Maintenance schedule.

After servicing, reset the service timer. See section Calling up/resetting the service timer

3.8 Scrolling through all screens

Control panel

Control panel

Scroll buttons (12) can be used to scroll through all screens. The screens are divided into register
screens, measured data screens, digital input screens (numbered as <d. in>, <d. 1>, ...),
parameter screens (numbered as <P. 1>, <P. 2>, ...), protections screens (numbered as <Pr.
1>,...) and test screens (numbered as <t. 1>,...).
During scrolling, the numbers of the screens appear consecutively. For most screens, the unit of
measurement and the related pictograph are shown together with the screen number.

Example

The screen shows the screen number <d.1>, the unit used <hrs> and the related symbol for
running hours. Press Enter key (13) to call up the actual running hours.

32 API586589
Instruction book

Overview of the screens

Digital input Designation Related topic

screens
<d. in> Digital input status
<d. 1> Running hours (hrs or x 1000 hrs) See section Calling-up running hours
<d. 2> Motor starts (x 1 or x 1000) See section Calling up motor starts
<d. 3> Module hours (hrs or x 1000 hrs) See section Calling up module hours
<d. 4> Loading hours (hrs or x 1000 hrs) See section Calling up loading hours
<d. 5> Load relay (x 1 or x 1000) See section Calling up load relay
<d. 6> Service timer reading (hrs or x 1000 hrs) See section Calling up/resetting the service
timer
<d. 7> Actual program version

Parameter Designation Related topic

screens
<P .1> Selection between local, remote or LAN See section Selection between Local
control Remote and LAN control
<P. 2> Setting a node ID for LAN control and the See section Calling up/modifying CAN
channels for Mk 4 and Mk 5 address control
<P. 3> Settings for IP, gateway and Subnet mask See section Calling up/modifying IP,
Gateway and Subnetmask
<P. 4> Pressure band settings See section Calling up/modifying pressure
band settings
<P. 5> Pressure band selection See section Modifying pressure band
selection
<P. 6> Modifying a service timer See section Calling up/modifying service
timer settings
<P. 7> Setting of unit for temperature See section Calling up/modifying unit of
temperature
<P. 8> Setting of unit for pressure See section Calling up/modifying unit of
pressure
<P. 9> Selection for function: Automatic restart See section Activating automatic restart
after voltage failure (active or not, only for
Atlas Copco)
<P. 10> Selection between Y-D or DOL starting See section Selection between Y-D or DOL
starting
<P. 11> Setting of load delay time See section Calling up/modifying load
delay time
<P. 12> Setting of minimum stop time See section Calling up/Modifying minimum
stop time
<P. 13> Setting a password See section Activating password protection
<P. 14> Remote pressure sensing See section Activate Load/Unload remote
sensing

API586589 33
 Instruction book

Protections Designation Related topic

screens
<Pr. 1> Protections screens See section Calling up/modifying protection
<Pr. 2> settings
<Pr. 3>

Test screens Designation Related topic

<t. 1> Display test See sections Test screens
<t. 2> Safety valve test See sections Test screens
<t. 3> Production test See sections Test screens

34 API586589
Instruction book

Menu flow

Simplified menu flow

Ref. Description Ref. Description

(1) Compressor outlet pressure (16) Pressure band selection
(2) Compressor outlet temperature (17) Service timer settings
(3) Dewpoint temperature (18) Temperature unit
(4) Digital input status (19) Unit pressure

API586589 35
 Instruction book

Ref. Description Ref. Description

(5) Running hours (20) Auto restart
(6) Motor starts (21) Selection Y-D/DOL start (not modifiable)
(7) Module hours (22) Load delay time
(8) Loading hours (23) Minimum stop time
(9) Load relay (24) Password settings
(10) Service timer reading (25) Remote pressure sensing
(11) Actual program version (26) Protections
(12) LAN selection (27) Display test
(13) Settings node ID (28) Safety valve test
(14) IP settings (29) Production test
(15) Pressure band settings

3.9 Calling up temperatures

Control panel

Starting from the Main screen:

• Press Scroll button (12). The outlet temperature will be shown:

36 API586589
Instruction book

The screen shows that the outlet temperature is 82 ˚C.

• For Full-Feature compressors:
Press Scroll button (12). The dew point temperature will be shown:

The screen shows that the dew point temperature is 3 ˚C.

3.10 Calling up running hours

Control panel

Starting from the Main screen:

• Press Scroll button (12) until <d.1> is shown and then press Enter button (13):

The screen shows the unit used (x1000 hrs) and the value (11.25): the running hours of the
compressor are 11250 hours.

API586589 37
 Instruction book

3.11 Calling up motor starts

Control panel

Starting from the Main screen, press Scroll button (12) until <d. 2> is shown and then press Enter
button (13). A screen similar to the following appears:

This screen shows the number of motor starts (x 1 or - if <x1000> lights up - x 1000). In the
above example, the number of motor starts is 10100.

3.12 Calling up module hours

Control panel

Starting from the Main screen, press Scroll button (12) until <d. 3> is shown and then press Enter
button (13). A screen similar to the following appears:

38 API586589
Instruction book

In the example shown, the screen shows the unit used (hrs) and the value (5000): the regulator
module has been in service during 5000 hours.

3.13 Calling up loading hours

Starting from the Main screen:
• Press Scroll button (12) until <d.4> is shown and then press Enter button (13):

The screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1755>: the compressor
has been running loaded during 1755 hours.

3.14 Calling up load relay

Starting from the Main screen:

• Press Scroll button (12) until <d.5> is shown and then press Enter button (13):

This screen shows the number of unload to load actions (x 1 or - if <x1000> lights up - x 1000). In
the above example, the number of unload to load actions is 10100.

API586589 39
 Instruction book

3.15 Calling up/resetting the service timer

Calling up the service timer

Starting from the Main screen:

• Press Scroll button (12) until <d.6> is shown and then press Enter button (13):

This screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1191>. In the example
shown, the compressor has run 1191 hours since the previous service.

Resetting the service timer

After servicing, see section Service warning, the timer has to be reset:
• Scroll to register screen <d.6> and press Enter button (13).
• The reading (e.g. 4000) will appear.
• Press Enter button (13) and - if a password is set - enter the password.
The icon will flash (indicating that resetting is possible).
• Press Enter button (13) to reset the timer to <0.000> or press the Escape button (14) to
cancel the operation.

40 API586589
Instruction book

3.16 Selection between local, remote or LAN control

Starting from the Main screen, press Scroll button (12) until <P. 1> is shown and then press Enter
button (13). The actually selected control mode is shown: <LOC> for local control, <rE> for
remote control or <LAn> for LAN control.
To change: press Enter button (13) and - if necessary - enter the password (see section
Activating password protection). The actually selected control mode is blinking. Use Scroll button
(12) to change the control mode. Press Enter button (13) to program the new control mode or
press Escape button (14) to cancel.

3.17 Calling up/modifying CAN address

Calling up
Starting from the main screen, press the Scroll button (12) until <P. 2> is shown and then press
Enter button (13).
If necessary enter the password. The next screen shows that the function is ON or OFF. Press
the Enter button (13) to change this mode. Use the Scroll buttons (12) to select <On> or <OFF>
and press Enter to program.
When this function is ON, use the Scroll buttons up or down (12) to see the node ID.
If desired the user can change this ID. Press the Enter button (13): the node ID value starts
blinking. Use the Scroll buttons (12) to change the node ID. Press the Enter button (13) to
program the new node ID or press the Escape button (14) to leave this screen or to cancel this
operation.

API586589 41
 Instruction book

Modifying the node ID

The node ID can be changed; use a value between 1 and 31. When the function is ON, the
parameters cannot be modified. Change the function to OFF to change the node ID.

It is also possible to change the channels. The controller has 4 channels. When changing the
channels, the controller can act as a Mk IV controller (a previous version of the controller). To set
the channels, go to the screen where the node ID is visible. Press the Scroll button down (12).
The following screen appears:

Press the Enter button (13) to modify the setting. The utmost left value will blink. Change this
value by using the Scroll buttons (12). Press the Enter button (13) to confirm. Change the other
values in the same way, as required.
After modifying the settings, the screen may look as follows:

42 API586589
Instruction book

3.18 Calling up/modifying IP, Gateway and Subnetmask

Calling up
Starting from the Main screen, press the Scroll button (12) until <P. 3> is shown and then press
Enter button (13).
The next screen shows either <OFF> or <On>. If <On>, press the Enter button (13) to modify it to
<OFF>. Use the Scroll buttons Up or Down (12) to scroll between the items in this list (<IP> for IP
address, <Sub> for Subnetmask or <GAtE> for Gateway):

Modification
Press the Enter button (13) and if necessary enter the password. The first digits are blinking. Use
the Scroll buttons Up or Down (12) to modify the settings and press Enter (13) to confirm. Modify
the next digits the same way. The standard IP address is set as 192.168.100.100.

API586589 43
 Instruction book

3.19 Calling up/modifying pressure band settings

Calling up the settings

44 API586589
Instruction book

Starting from the Main screen:

• Press Scroll button (12) until <P.04> is shown and then press Enter button (13). Pressure
band 1 (<Pb.1>) is shown on the display. Button (12) can be used to scroll to pressure band
2 (<Pb.2>).
• Press Enter button (13) on the desired pressure band. The load level of the selected
pressure band appears. Button (12) can be used to scroll to the unload level.

Loading pressure

Unloading pressure

Modification
• Press Enter button (13) to modify the load level (value starts blinking). A password may be
required. Use Scroll buttons (12) to change the loading pressure.

API586589 45
 Instruction book

• Press Enter button (13) to program the new values or press the Escape button (14) to
cancel.

3.20 Modifying the pressure band selection

Control panel

Starting from the Main screen:

• Press Scroll button (12) until <P.05> is shown and then press Enter button (13). The active
pressure band 1 (<Pb.1>) is shown on the display.
• Press Enter button (13) to modify the pressure band selection (a password may be
required). The active pressure band <Pb.1> starts blinking.
• Press button (12) to modify the active pressure band. Press Enter button (13) to confirm or
the Escape button (14) to cancel.

3.21 Calling up/modifying service timer settings

Control panel

Starting from the Main screen:

• Press Scroll button (12) until <P. 6> is shown and then press Enter button (13): the setting of
the service timer is shown in <hrs> (hours) or <x1000 hrs> (hours x 1000). Example: <4000
hrs> means the timer is set at 4000 running hours.

46 API586589
Instruction book

• Press Enter button (13) to modify this value (a password may be required): the value blinks.
Use the Scroll buttons (12) to modify the setting.
• Press Enter button (13) to program the new value.

3.22 Calling up/modifying the unit of temperature

Control panel

Starting from the Main screen:

• Press Scroll button (12) until <P.07> is shown and then press Enter button (13). The actually
used unit is shown. Possible settings are <˚C> and <˚F>.
• Press Enter button (13) (unit blinks) and use the Scroll buttons (12) to select another unit of
temperature.
• Press Enter button (13) to program the new unit or press Escape button (14) to return to the
parameter screen without changes.

3.23 Calling up/modifying unit of pressure

Control panel

Starting from the Main screen:

• Press Scroll button (12) until <P.08> and the possible settings are shown (<Mpa>, <psi>,
and <bar>). Press Enter button (13) and the actually used unit is shown.
• Press Enter button (13) (unit starts blinking) and use the Scroll buttons (12) to select another
unit of pressure.
• Press Enter button (13) to program the new unit of pressure. Press the escape button (14) to
return to the parameter screens.

3.24 Activating automatic restart after voltage failure

Description
This function allows the compressor to restart automatically after a power failure.

API586589 47
 Instruction book

This parameter, accessible in screen <P. 9>, can only be modified after entering a code. Consult
your supplier if this function is to be activated.
For compressors leaving the factory, this function is made inactive. If desired, the function can be
activated. The ARAVF label 1079 9932 74( see section Pictographs ) shall be glued near to the
controller. Consult your local supplier.

3.25 Selection between Y-D or DOL starting

Control panel
Starting from the Main screen:
• Press Scroll button (12) until <P.10> and the motor pictograph is shown and then press
Enter button (13). The actually used starting mode is shown: <Y-D> (star-delta) or <doL>
(Direct-On-Line).
• For obvious reasons, this parameter must normally not be altered. Therefore it can only be
modified after entering a secure code. Consult Atlas Copco if the parameter is to be
changed.

Example of Y-D setting

48 API586589
Instruction book

3.26 Calling up modifying load delay time

Control panel

• Starting from the Main screen, press Scroll button (12) until <P.11> and the compressor load
pictograph is shown and press the Enter button (13).
Following screen appears:

• This screen shows the load delay time (10) and the unit (s= seconds). To modify this value
press the Enter button (13) (a password may be required).
• The value starts blinking and Scroll buttons (12) can be used to modify the value.
• Press the Enter button (13) to program the new value.
The minimum and maximum value depends on the parameters.

3.27 Calling up modifying minimum stop time

Starting from the Main screen:
• Press the Scroll button (12) until <P.12> and the motor pictograph is shown and press the
Enter button (13):

• This screen shows the minimum stop time (20) and the unit <s> (seconds).
• To modify this value press the Enter button (13). The value starts blinking and Scroll buttons
(12) can be used to modify this value.

API586589 49
 Instruction book

• Press Enter button (13) to program the new value.

The minimum and maximum values depend on the parameters.

3.28 Activating password protection

Important settings such as the setting of the service timer, pressure band setting, control mode
settings,... can be protected by a password.
Starting from the Main screen:
• Press Scroll buttons (12) until <P.13> is shown and press Enter button (13):

• Password (<PASS>) appears on the screen. Press the Enter button (13).
• The screen shows the password status (ON (<On>) or OFF (<OFF>). Press Enter button
(13) to modify.
• Change the value with Scroll buttons (12).
• Select <On> and press Enter button (13).
• Enter the new password and press Enter button (13) to confirm.
• Enter the password again and press Enter button (13) to confirm.
• <On> appears on the display. Press reset key to return to the parameter screen.

Lost passwords can not be recovered. Save the password carefully.

3.29 Activate load/unload remote pressure sensing

Starting from the Main screen:
• Press the Scroll button (12) until <P.14> appears
.
• Press the Enter button (13).

• The function of this screen is to activate the remote load/unload relay. To be able to activate
this remote Load/Unload functionality, a physical digital input with function Load/Unload is
required.

50 API586589
Instruction book

Once this parameter is activated, the physical digital input can be used to switch the
compressor between Load and Unload.

3.30 Calling up/modifying protection settings

Available protections

A number of protection settings are provided. The protection screens are labelled <Pr.>. The
pictograph shown with the protection screen indicates the purpose of the protection.
Possible combinations are <Pr.>, followed by a number and one of the next pictographs:

Pictograph Designation
<Pr.> combined with the pressure pictograph shows the pressure protections.

<Pr.> combined with the element outlet temperature pictograph shows the element
outlet temperature protections.

<Pr.> combined with the dew point temperature pictograph shows the dew point
temperature protections.

<Pr.> combined with the ambient temperature pictograph shows the ambient
temperature protections.

Following protection settings are available:

• A low warning level, shown on the display as <AL-L>.
• A high warning level, shown on the display as <AL-H>.
• A low shutdown level, shown on the display as <Sd-L>.
• A high shutdown level, shown on the display as <Sd-H>.
• A low service level shown on the display as <SE-L>.
• A high service level shown on the display as <SE-H>.

API586589 51
 Instruction book

Example of protection screens

In this menu the temperature protection settings can be checked and modified.

Changing the settings

Starting from the Main screen (the example given describes the protection of the element outlet
temperatures):
Press Scroll buttons (12) until <Pr.>, followed by a number and the element outlet temperature
pictograph is shown and press Enter button (13):
• The warning level for the high temperature warning level <AL-H> and the high temperature
shutdown level <Sd-H> become visible. Use Scroll keys (12) to move between the warning
level (<AL>) and the shutdown level (<Sd>), press the Enter button (13) to modify the value.
• An optional password may be required, the value starts blinking and Scroll buttons (12) can
be used to modify the value.
• Press the Enter button (13) to program the new value.

Programmable settings can only be modified within allowed limits.

52 API586589
Instruction book

3.31 Test screens

Display test
Starting from the Main screen, press Scroll buttons (12) until <t. 1> is shown and then press
Enter button (13).
The display now shows all icons that can be displayed:

Safety valve test

In the test screen <t. 2>, a safety valve test is provided. The safety valves can only be tested
after entering a code. Consult Atlas Copco if the safety valves are to be tested.

Production test
Test screen <t. 3> is only intended for production test. If the Main screen shows following screen,
the controller is in production test mode:

How to solve?
Use the Scroll buttons (12) and scroll to menu <t. 3>.
The screen shows:

API586589 53
 Instruction book

Press the Enter button (13): the text starts blinking. Press enter again and the menu disappears.

3.32 Web server

All controllers have a built-in web server that allows direct connection to the company network or
to a dedicated PC via a local area network (LAN). This allows to consult certain data and settings
via a PC instead of the display of the controller.

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

Configuration of the network card

• Go to Network and Sharing Center (1).

54 API586589
Instruction book

• Click on Change adapter settings (1).

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

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

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

• Use the following settings:

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

API586589 55
 Instruction book

Configure a company network (LAN) connection

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

• Adapt the network settings in the controller:

• Go to Main Menu

56 API586589
Instruction book

• Go to Settings (1)

• Go to Network (1)

• Go to Ethernet (1)

• Switch Off (1) the Ethernet communication to allow editing the settings

API586589 57
 Instruction book

• Adapt IP Address (1)

• Adapt Gateway IP (2)
• Adapt Subnet Mask (3)
• Switch On (4) the Ethernet communication

• Wait a few minutes so the LAN network can connect to the controller

Configuration of the web server

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

All screen shots are indicative. The number of displayed fields depends on the selected
options.

• Open your browser and type the IP address of the controller you want to view in your
browser (in this example http://192.168.100.100). The interface opens:

58 API586589
Instruction book

Screen shot (example!)

Navigation and options

• The banner shows the unit type and the language selector. In this example, three languages
are available on the controller.

• On the left side of the interface, you can find the navigation menu.
If a license for ESi is foreseen, the menu contains 3 buttons.
• Machine: shows all generator settings.
• ES: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure unit.

API586589 59
 Instruction book

Unit settings
All unit settings can be displayed or hidden. Put a check mark in front of each point of interest
and it will be displayed. Only the machine status is fixed and can not be removed from the main
screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference
button from the navigation menu.

Counters
Lists all current counter values from controller and unit.

Info status
Machine status is always shown on the web interface.

Digital inputs
Lists all digital inputs and their status.

Digital outputs
Lists all digital outputs and their status.

60 API586589
Instruction book

Special protections
Lists all special protections of the unit.

Service plan
Displays all levels of the service plan and their status. This screen shot underneath only shows
the running hours. It is also possible to show the current status of the service interval.

3.33 Programmable settings

Parameters: unloading/loading pressures for compressors with built-in refrigeration dryer

Minimum Factory Maximum

setting setting setting
Unloading pressures
Unloading pressure (8.5 bar compressors) bar(e) 4 8.0 8.3
Loading pressures
Loading pressure (8.5 bar compressors) bar(e) 4 7.4 8.2

Parameters

Minimum Factory Maximum

setting setting setting
Motor running time in star sec 5 10 10

API586589 61
 Instruction book

Minimum Factory Maximum

setting setting setting
Load delay time (star-delta) sec 0 0 10
Number of motor starts starts/day 0 240 240
Minimum stop time sec 10 20 30
Programmed stop time sec 0 3 20
Power recovery time (ARAVF) sec 10 10 3600
Restart delay sec 0 0 1200
Communication time-out sec 10 30 60

Protections

Minimum Factory Maximum

setting setting setting
Compressor element outlet temperature (shut- ˚C 50 110 119
down warning level)
Compressor element outlet temperature (shut- ˚C 111 120 120
down level)

Service plan
The built-in service timer will give a Service warning message after a preprogrammed time
interval has elapsed.
Also see section Preventive maintenance schedule.
Consult Atlas Copco if a timer setting has to be changed. See section Calling up/modifying
service timer settings. The intervals must not exceed the nominal intervals and must coincide
logically.

Terminology

Term Explanation
ARAVF Automatic restart after voltage failure. See section Elektronikon regulator and Activating
automatic restart.
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 regulator does not accept inconsistent settings, e.g. if the warning level is
element outlet 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 shut- Is the time for which the signal must exist before the compressor is shut down. If it is
down signal required to program this setting to another value, consult Atlas Copco.
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. Consult Atlas Copco if a setting
lower than 20 seconds is required.

62 API586589
Instruction book

Term Explanation
Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is
Loading pressure programmed at 7.0 bar(e) (101 psi(g)), the maximum limit for the loading pressure
changes to 6.9 bar(e) (100 psi(g)). The recommended minimum pressure difference
between loading and unloading is 0.6 bar (9 psi(g)).

API586589 63
 Instruction book

4 Installation

4.1 Dimension drawings

The dimension drawing can be found on the CD-ROM, DVD or USB, supplied with the unit.

Dimension drawing Model

9828 5102 34–01 GA 30+, GA 37, GA 45 Pack, metric units
9828 5102 34–02 GA 30+, GA 37, GA 45 Pack, imperial units
9828 5102 35–01 GA 30+, GA 37, GA 45 Full Feature, metric units
9828 5102 35–02 GA 30+, GA 37, GA 45 Full Feature, imperial units

Text on drawings Translation or Explanation

Cooling air outlet of compressor Cooling air outlet of compressor and motor
Air inlet of compressor Cooling air inlet of compressor and motor
Compressed air outlet Compressed air outlet connection
Electrical cable passage Electrical cable passage
Cooling air outlet of cubicle Cubicle cooling air outlet
Doors fully open Dimensions with doors fully open
Cooling air inlet of dryer Dryer cooling air inlet
Cooling air outlet of dryer Dryer cooling air outlet
Centre of gravity Centre of gravity
Approx. mass Approximate mass of the machine
Manual drain of after cooler Manual drain, aftercooler
Automatic drain of after cooler Connection of the automatic drain of the aftercooler
Manual drain of dryer Manual drain of the dryer
Automatic drain of dryer Connection of the automatic drain of the dryer
Only for energy recovery option Only for energy recovery option
Water inlet (energy recovery) Water inlet (energy recovery option)
Water outlet (energy recovery) Water outlet (energy recovery option)
Mounting holes of compressor Mounting holes to fixate the compressor

4.2 Installation proposal

Safety

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

64 API586589
Instruction book

Outdoor/altitude operation

The compressor is not designed for installation outdoors.

The compressors can be sold with option rain protection. With this option, this compressor
can be installed outside under a shelter, in frost free conditions. If frost might occur, the
appropriate measures must be taken to avoid damage to the machine and its ancillary
equipment. Consult Atlas Copco.

Moving/lifting

The compressor can be moved by a lift truck using the slots in the frame. Take care not to
damage the bodywork during lifting or transport. Make sure that the forks protrude from the
other side of the frame. The compressor can also be lifted after inserting beams in the
slots. Make sure that the beams cannot slide and that they protrude from the frame equally.
The chains must be held parallel to the bodywork by chain spreaders in order not to
damage the compressor. The lifting equipment must be placed in such a way that the
compressor is lifted perpendicularly. Lift gently and avoid twisting.

In case of units equipped with the Lifting Device Option, it is not allowed to lift the
compressor if the canopy parts or lifting supports are not completely installed. When the
compressor is being lifted, it is also forbidden to come under the load or to perform
maintenance activities to it.

API586589 65
 Instruction book

Compressor room example

Text on drawing

Reference Designation
(1) Ventilation proposals
(2) Minimum free area to be reserved for the compressor installation

All piping to be connected stress free to the compressor.

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

66 API586589
Instruction book

2. Position of the compressed air outlet valve.

3. The pressure drop over the air delivery pipe can be calculated from:

Δp = (L x 450 x Qc1.85) / (d5 x P), with

• Δp = pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi))

• L = length of the pipe in m
• Qc= Free air delivery of the compressor in l/s
• d = inner diameter of the pipe in mm
• P = absolute pressure at the compressor outlet in bar(a)
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 re-
circulation of cooling air is avoided.
The maximum 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), the minimum air
temperature is 0 °C (32 °F).
The required ventilation capacity to limit the compressor room temperature can be
calculated as follows:

Qv = 1.06 N/ΔT for versions without dryer

Qv = (1.06 N + 1.3)/ΔT for versions with dryer

• Qv = Required ventilation capacity in m3/s

• N = Shaft input of compressor in kW
• ΔT = Temperature increase in the compressor room in °C
5. The drain pipes to the drain collector must not dip into the water of the drain collector. Any
flow back must be avoided. 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 are available.
6. Control module with monitoring panel.
7. Position of the main cable entry. Power supply cable to be sized and installed by a qualified
electrician.

To preserve the protection degree of the electric cubicle and to protect its components from
dust from the environment, it is mandatory to use a proper cable gland when connecting the
supply cable to the compressor.

8. Provision for inlet and outlet of the energy recovery system (system is optional).
9. The air receiver (optional) should be installed in a frost-free room on a solid, level floor for
normal air consumption, the volume of the air net (receiver and piping) can be calculated as
follows:

V=(0.25 x Qc x P1 x To)/(fmax x ΔP xT1)

• V= Volume of the air net in l.

• Qc= Free air delivery of the compressor in l/s
• P1= Compressor air inlet pressure in bar absolute
• fmax= Cycle frequency =1 cycle/30s
• ΔP= P unload - P load in bar
• T1= Compressor air inlet temperature in K

API586589 67
 Instruction book

• To= Air receiver temperature K

10. To prevent feedback of exhaust air to the cooling inlet, sufficient space should be foreseen
above the unit to evacuate the exhaust air.

4.3 Electrical connections

Important remark

To preserve the protection degree of the electric cubicle and to protect its components from
dust from the environment, it is mandatory to use a proper cable gland when connecting the
supply cable to the compressor.

Electrical connections

Reference Designation
(1) Customer’s installation
(2) All voltages (50 and 60 Hz)

Instructions
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 and the setting of the overload relay. See section Electrical cable size.
4. Connect earth conductor bolt (PE).
5. Connect the power supply cables to their terminals L1, L2, L3.

68 API586589
Instruction book

Compressor status indication

On compressors equipped with an Elektronikon™ controller, the controller is provided with an
auxiliary relay (K05) for remote indication of a shutdown. This NO contact (NO = normally open)
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
your supplier.

Compressor control mode

On compressors equipped with an Elektronikon™ controller, consult section Selection between
local, remote and LAN control if it is desired to switch to another control mode.
The following control modes can be selected:
• Local control: The compressor will react to commands entered by means of the buttons on
the control panel. Compressor start/stop commands via Clock function are active, if
programmed.
• Remote control: The compressor will react to commands from external switches.
Emergency stop remains active. Compressor start/stop commands via Clock function are
still possible.
Options:
• Remote starting and stopping (switch S1')
• Remote loading/unloading (switch S4')
• Remote pressure sensing (switch S' combined with pressure switch S4')

Have the modifications checked by your supplier.

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 your supplier.
See service diagram 9828 5102 00 to locate the connectors.

4.4 Pictographs

Description
Pictographs

1 2

API586589 69
 Instruction book

3 4

5 6

7 8

9 10

11 12

13 14

15

Reference Designation
1 Warning: Always read the manual, switch off the voltage, depressurise compressor and
lock out/ tag out before repairing.
2 Keep the doors closed during operation

70 API586589
Instruction book

Reference Designation
3 Switch off the voltage before removing protecting cover inside electric cubicle
4 Warning, voltage
5 Automatic condensate drain
6 Stop the compressor before cleaning the coolers
7 Lightly oil the gasket of the oil filter, screw it on and tighten by hand (approx. half a turn)
8 Before connecting the compressor electrically, consult the Instruction book for the motor
rotation direction
9 Compressor remains pressurized for 180 seconds after switching off the voltage
10 Torques for steel (Fe) or brass (CuZn) bolts
11 Switch off the voltage and wait at least 6 minutes before removing the screen
12 Oil outlet (option DD/PD filters)
13 Cooling water inlet
14 Cooling water outlet
15 Automatic Restart After Voltage Failure (ARAVF)

API586589 71
 Instruction book

5 Operating instructions

5.1 Initial start-up

The operator must apply all applicable Safety precautions.

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

Preparations
1. Consult the sections Electrical cable size, Installation proposal and Dimension drawings.
2. The following transport fixtures, painted red, must be removed:
• Bolt and bushes or support under the motor (1)
• Bolts and bushes under the gear casing (2)
• Bolts or bolts and bushes under the oil separator vessel (3)

3. Check that the electrical connections correspond to the applicable codes and that all wires
are clamped tight to their terminals.
The installation must be earthed and protected against short circuits by fuses of the inert
type in all phases. An isolating switch must be installed near the compressor.
4. Check transformer (T1) for correct connection.
Check the settings of drive motor overload relay (F21).
Check that the motor overload relay is set for manual resetting.

72 API586589
Instruction book

Electric cubicle

5. Check the setting of circuit breaker (Q15). Also check that the switch on the circuit breaker is
in position I.
6. Fit air outlet valve (AV). See section Introduction for the location of the valve.
Close the valve.
Connect the air net to the valve.
On compressors equipped with a dryer bypass, fit the air outlet valve to the dryer bypass
pipe.
7. Connect the condensate drain outlet(s) to a drain collector.
See section Condensate system.
The drain pipes to the drain collector must not dip into the water. If there is a risk for
freezing, the pipes must be insulated.
For draining of pure condensate water, install an oil/water separator which is available from
Atlas Copco as an option.
8. For compressors with a DD or a DD and PD filter: connect the automatic drain of the filters
to a suitable drain collector.
9. Provide labels, warning the operator that:

API586589 73
 Instruction book

• The compressor may automatically restart after voltage failure (if activated, consult
Atlas Copco).
• The compressor is automatically controlled and may be restarted automatically.

Initial start procedure

If the compressor has not run for the past 6 months, it is strongly recommended to
improve the lubrication of the compressor element before starting.
To do so:
1. Disconnect the inlet hose.
2. Remove the unloader (UA).
3. Pour approximately 0.75 l (0.20 US gal, 0.17 Imp gal) of compressor oil into the
compressor element inlet. For oil specifications, see section Oil specifications.
4. Reinstall the unloader and reconnect the inlet hose.
Make sure that all connections are tight.

Location of unloader

1. Check the oil level before starting.

The oil level should be between the oil filler neck (FC) and the bottom of the sight glass (Gl).

74 API586589
Instruction book

2. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation
direction of drive motor (M1) while the motor is coasting to a stop. The correct rotation
direction of the drive motor is indicated by an arrow shown on the motor fan cowl.
If the rotation direction of the drive motor is incorrect, open the isolating switch and reverse
two incoming electric lines.
Incorrect rotation direction of the drive motor may cause damage to the compressor.
3. Check also the rotation direction of the fan motor. Rotation arrows, visible through the
grating in the roof, are provided on the plate below the fan to indicate the correct rotation
direction of the fan motor.
If the rotation direction of the fan motor is incorrect, open the isolating switch and reverse
two incoming electric connections at the terminals of circuit breaker (Q15).
4. Check the programmed settings. For compressors equipped with an Elektronikon™
controller, consult section Programmable settings.
5. Start and run the compressor for a few minutes. Check that the compressor operates
normally.
6. Check that the outlet temperature doesn’t rise too much after start-up. The unit will
shutdown when the outlet temperature is 65°C (149°F) above the inlet temperature.

5.2 Before starting

Procedure
1. If the compressor has not run for the past 6 months, it is strongly recommended to improve
the lubrication of the compressor element before starting. See section Initial start.
2. Check oil level. Top up if necessary.

API586589 75
 Instruction book

Position of oil level sight glass

3. If necessary, empty the dust trap of the filter, see section Air filter.
If the red part of the air filter service indicator shows full out, replace the air filter element.
Reset the service indicator (VI) by pushing the knob in the extremity of the indicator.

Position of air filter and service indicator

76 API586589
Instruction book

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

Control panel Elektronikon™

Procedure
1. Open the air outlet valve.
2. Switch on the voltage. Check that voltage on LED (6) lights up.
3. Press start button (1) on the control panel. The compressor starts running and the automatic
operation LED (8) lights up. Ten seconds after starting, the drive motor switches over from
star to delta and the compressor starts running loaded.

5.4 During operation

Warnings

The operator must apply all relevant Safety precautions. Also consult section Problem
solving.

Keep the doors closed during operation. They may be opened for short periods only to
carry out checks.

When the motors are stopped and LED (8) (automatic operation) is alight, the motors
may start automatically.

API586589 77
 Instruction book

Checking the oil level

Control panel Elektronikon™

Regularly check the oil level. To do so:

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

78 API586589
Instruction book

Air filter

Position of the service indicator

Regularly check the service indicator. If the colored part of service indicator (VI) shows full out,
replace the air filter element. Reset the service indicator by pushing the knob in the extremity of
the indicator body.

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

5.5 Checking the display

Compressors with Elektronikon™ controller:

Control panel Elektronikon™

API586589 79
 Instruction book

Check the display (2) regularly for readings and messages. The display normally shows the
compressor outlet pressure, while the status of the compressor is indicated by pictographs.
Remedy the trouble if alarm LED (7) is lit or flashes, see section Shutdown warning, Shutdown
and Problem solving. The display (2) will show a service message if a service plan interval has
been exceeded or if a service level for a monitored component has been exceeded. Carry out the
service actions of the indicated plans or replace the component and reset the relevant timer, see
section Service warning.

5.6 Stopping

Control panel Elektronikon™

Procedure

Step Action
1 Press stop button (9). Automatic operation LED (8) goes out and the compressor stops after
30 seconds of unloaded operation.
2 To stop the compressor in the event of an emergency, press emergency stop button (10).
Alarm LED flashes (7).
On compressors equipped with an Elektronikon™ controller, remedy the problem cause,
unlock the button by pulling it out and press the Escape button (5) to reset.
Do not use emergency stop button (10) for normal stopping!
3 Close the air outlet valve.
4 Press the test button on top of the electronic water drain(s) (if supplied) to the depressurize the
piping between air receiver and outlet valve, next open the manual drain valve (Dm). See
section Condensate system.
Switch off the voltage.

5.7 Taking out of operation

Warning

The operator must apply all relevant Safety precautions.

80 API586589
Instruction book

Procedure

Step Action
- Stop the compressor and close the air outlet valve.
- Press the test button on top of the electronic water drain(s) until the air system between air
receiver and outlet valve is fully depressurized. Consult section Condensate system to locate
the drain valve.
- Switch off the voltage and disconnect the compressor from the mains.
- Open the condensate drain valve(s) (Dm).
- Unscrew the oil filler plug only one turn to permit any pressure in the system to escape.
Consult section Oil and oil filter change to locate the filler plug.
- Shut off and depressurise 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.

API586589 81
 Instruction book

6 Maintenance

6.1 Preventive maintenance schedule

Warning

Always apply all relevant Safety precautions.

Before carrying out any maintenance, repair work or adjustments, proceed as
follows:
• Stop the compressor.
• Close the air outlet valve and open the manual drain valve until the air system
between air receiver and outlet valve is fully depressurized.
• Press the emergency stop button.
• Switch off the voltage. Open and lock the isolating switch.
• Depressurize the compressor by opening the oil filler plug one turn.
Only pressing the emergency stop button is not sufficient to make the compressor
voltage free.
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted.

Warranty - Product Liability

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

Service kits
For overhauling or carrying out preventive maintenance, service kits are available. Consult the
Spare Parts list for part numbers.

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 O-rings and washers.

Intervals
The local 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.

Regular maintenance
Following actions have to be done on a regular basis:

82 API586589
Instruction book

Maintenance checklist

Period Operation
Daily Check oil level.
Check readings on the controller display.
Check the air filter service indicator.
Check that condensate is discharged during operation of the compressor.
Drain condensate.
Check the pressure dew point temperature (on compressors with integrated dryer).
3-monthly (1) Check coolers. Clean if necessary.
Check cooling fins of electric motor(s). Clean if necessary.
Remove the air filter element and inspect. If necessary, clean using an air jet. Replace
damaged or heavily contaminated elements.
Check the filter element of the electric cabinet. Replace if necessary.
On compressors with integrated dryer:
• Stop the compressor, close the air outlet valve and switch off the voltage.
• Remove any dirt from the condenser inlet with a vacuum cleaner.
• Next, clean with an air jet in the reverse direction of the normal flow. Use low
pressure air. Keep the compressed air nozzle more than 30 cm away from the
condenser to avoid damaging the condenser fins.
• Remove dust from inside the dryer, e.g. with a vacuum cleaner.
Do not use water or solvents to clean the condenser.
Yearly Check the condition of all hoses. Replace if necessary.

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

Programmed service interventions

Apart from the above mentioned actions, a number of service interventions (see the table below)
are programmed in the controller. Each plan has a programmed time interval at which all service
actions belonging to that plan are to be carried out. When reaching the interval, a message will
appear on the screen indicating which service plans are to be carried out.
See section Service warning for compressors with an Elektronikon™ controller.
After servicing, the intervals must be reset.
See section Calling up/resetting the service timer for compressors with an Elektronikon™
controller.
Preventive Maintenance schedule programmed in the Elektronikon™

A-service B-service D-Service

Every 4000 running Every 8000 running Every 24000 running
hours (1) hours (2) hours
Change the air filter x x x
Change the electric cabinet filter mats x x x
Change the oil x (3) x x
Change the oil filter x (3) x x
Change the oil separator element x x
Overhaul non return valve of the x x
scavenge line
Overhaul the unloader x x

API586589 83
 Instruction book

Overhaul the minimum pressure valve x x

Change the thermostatic valve x x
Overhaul the condensate drain(s) x x
Overhaul the main drive motor x
Overhaul the compressor element x (4)

(1): or yearly (indicated by real time counter), whichever comes first.

(2): or every 2 years (indicated by real time counter), whichever comes first.
(3): If Roto-Xtend Duty Fluid and the corresponding oil filter is used, the oil and oil filter change
are part of the B service. See also section Oil specifications.
(4): For compressor elements used on operating pressures below or equal to 10 bar (145 psi),
the overhaul can be postponed to 32000 running hours.

• Consult your supplier before modifying a timer setting.

• For the change interval of oil and oil filter in extreme conditions consult your
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 lubricants from your manufacturer. 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 or on the compressor frame.

Roto-Inject Fluid Ndurance

Atlas Copco's Roto-Inject Fluid Ndurance is a specially developed lubricant for use in single
stage oil injected screw compressors. Its specific composition keeps the compressor in excellent
condition.
See the table below for oil exchange intervals:

Ambient temperature Element outlet Exchange interval Maximum time interval

temperature
up to 30°C (95°F) up to 95°C (203°F) 4000 1 year
from 30°C (86°F) up to from 95°C (203°F) up to 3000 1 year
35°C (95°F) 100°C (212°F)
from 35°C (95°F) up to from 100°C (212°F) up to 2000 1 year
40°C (104°F) 105°C (221°F)
above 40°C (104°F) above 105°C (221°F) use ROTO-Xtend Duty use ROTO-Xtend Duty
Fluid Fluid

84 API586589
Instruction book

6.3 Drive motor

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

6.4 Air filter

Location of 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.

Procedure
1. Stop the compressor. Switch off the voltage.
2. Release the snap clips of air filter (AF) and remove the cover and the air filter element.
Discard the filter element.
3. Fit the new element and the cover.
4. Reset service indicator (VI) by pushing the knob in the extremity of the body.
5. Reset the air filter service warning.
For compressors equipped with a standard controller, see section Service warning.

API586589 85
 Instruction book

6.5 Oil and oil filter change

Warning

The operator must apply all relevant Safety precautions.

Always drain the compressor oil at all drain points. Used oil left in the compressor can
contaminate the oil system and can shorten the lifetime of the new oil.
Never mix lubricants of different brands or types as they may not be compatible and the
oil mix will have inferior properties. A label, indicating the type of oil filled ex-factory, is
stuck on the air receiver/oil tank.

Procedure

Oil drain and filler plug on the oil separator vessel

Vent plug, oil cooler

86 API586589
Instruction book

Step Description
1 Run the compressor until warm. Stop the compressor after 3 minutes of unloaded operation.
Close the air outlet valve and switch off the voltage. Wait a few minutes and depressurise by
unscrewing oil filler plug (FC) just one turn to permit any pressure in the system to escape.
2 Air cooled units: loosen the vent plug (VP) of the oil cooler and wait for 5 minutes.
3 Remove drain plug (DP1) and open drain valve (Dm).
4 Collect the oil in a collector and deliver it to the local collection service. Refit and tighten the drain
and vent plugs after draining.
Close the drain valve (Dm).
5 Remove the oil filter (OF). Be aware that this filter has a left thread connection. Clean the seat
on the manifold. Oil the gasket of the new filter and screw it into place. Tighten firmly by hand.
6 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).
7 Run the compressor loaded for a few minutes. Stop the compressor and wait a few minutes to
allow the oil to settle.
8 Depressurise the system by unscrewing filler plug (FC) just one turn to permit any pressure in the
system to escape. Remove the plug.
Fill the air receiver with oil until the level reaches the filler neck.
Tighten the filler plug.
9 Reset the service warning after carrying out all service actions in the relevant Service Plan:
For compressors with a standard controller, see section Calling up/resetting the service timer.

6.6 Coolers

General
Keep the coolers clean to maintain their efficiency.

Instructions for air-cooled compressors

• Stop the compressor, close the air outlet valve and switch off the voltage.
• Cover all parts under the coolers.
• Remove the service plates. (1)

API586589 87
 Instruction book

• Remove any dirt from the coolers with a fibre brush. Brush in the direction of the cooling fins.
Also remove any dirt from the fan with a fibre brush.
• Next, clean with an air jet in the reverse direction to normal flow. Use low pressure air. If
necessary, the pressure may be increased up to 6 bar(e) (87 psig).
• If it is necessary to wash the coolers with a cleaning agent, consult your supplier.
• Remove the cover used during cleaning.
• Mount the service plates. (1)

88 API586589
Instruction book

6.7 Safety valves

Location of safety valve

Position of safety valve

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

Testing
Before removing the valve, depressurize the compressor. See also section Problem solving.
The safety valve (SV) can be tested on a separate air line. If the valve does not open at the set
pressure stamped on the valve, it needs to be replaced.

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

6.8 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:

API586589 89
 Instruction book

• 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.
• Stop the compressor, close the air outlet valve and switch off the voltage.
• Remove any dirt on the condenser inlet with a vacuum cleaner.
• Next, clean with an air jet in the reverse direction to normal flow. Use low pressure air. If
necessary, the pressure may be increased up to 6 bar(e) (87 psig).
• Clean the condenser area with a vacuum cleaner.
• Inspect and clean the electronic condensate drain monthly.

6.9 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
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.

90 API586589
Instruction book

6.10 Storage after installation

Procedure
Run the compressor regularly, e.g. twice a week, until warm. Load and unload the compressor a
few times.

If the compressor is going to be stored without running from time to time, protective
measures must be taken. Consult your supplier.

6.11 Disposal of used material

Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts,
etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the
local recommendations and environmental legislation.

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

API586589 91
 Instruction book

7 Problem solving

Warning

Always apply all relevant Safety precautions.

Before carrying out any maintenance, repair work or adjustment, press the stop button,
wait until the compressor has stopped and close the air outlet valve.
Open the manual drain valve(s).
Press the emergency stop button and switch off the voltage. Open and lock the isolating
switch.
Depressurise the oil separator vessel by opening the oil filler plug one turn.
For location of components: see sections Introduction, Condensate system and Initial
start.
The air outlet valve can be locked during maintenance or repair as follows:
• Close the valve.
• Remove the screw fixing the handle with the wrench delivered with the
compressor.
• Lift the handle and turn it until the slot of the handle fits over the blocking edge on
the valve body.
• Fit the screw.
• Always switch off the voltage. Only pressing the emergency stop button is not
sufficient to make the compressor voltage free.
• If the machine is equipped with an automatic restart after voltage failure function
and if this function is active, be aware that the machine will restart automatically
when the power is restored if it was running when the power was interrupted.

Faults and remedies, compressor

On compressors equipped with a standard controller, if the alarm LED is lit or flashes, consult
sections Shutdown warning , Shutdown and Service warning.

Condition Fault Remedy

Compressor does not start or Motor overload relay (F21) open Find cause and remedy. Replace
stops during operation. Controller if necessary.
shows motor overload problem.
Circuit breaker (Q15) or fan motor Find cause and remedy. Replace
overload (F15) open if necessary.
Too high temperature in oil Find cause and remedy. Replace
separator vessel or temperature if necessary.
switch (TSHH1) defective

92 API586589
Instruction book

Condition Fault Remedy

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

API586589 93
 Instruction book

Condition Fault Remedy

Insufficient cooling air or cooling air Check for cooling air restriction or
temperature too high improve ventilation of the
compressor room. Avoid
recirculation of cooling air. If
installed, check capacity of
compressor room fan
Oil cooler clogged Clean cooler
Bypass valve malfunctioning Have valve tested
Air cooler clogged Clean cooler
Compressor element out of order Consult your supplier
Cooling air fan does not deliver Unit shuts down due to Fan rotates in the wrong direction
enough air. overtemperature, fan overload, too due to wrong electrical
high oil consumption or less FAD. connection.

Faults and remedies, dryer

For all references hereafter, consult section Air dryer.

Condition Fault Remedy

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

94 API586589
Instruction book

Condition Fault Remedy

Condensate drain remains Drain system clogged Have system inspected
inoperative Clean the filter of the drain by opening the
manual drain valve.
On units with an electronic drain, check
functioning of the drain by pushing the test
button.
Condensate trap continuously Drain out of order Have system checked. If necessary,
discharges air and water replace the drain.
Evaporator pressure is too Hot gas bypass valve Have hot gas bypass valve adjusted
high or too low at unload incorrectly set or out of order
Condenser pressure too high See above
or too low
Shortage of refrigerant Have circuit checked for leaks and
recharged if necessary

API586589 95
 Instruction book

8 Technical data

8.1 Readings on display

Elektronikon™ Controller

Important

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

Reference Reading
Air outlet pressure Modulates between programmed unloading and loading pressures.
Compressor element Approx. 60 ˚C (108 ˚F) above cooling air inlet temperature.
outlet temperature
Dewpoint temperature See section Compressor data.

96 API586589
Instruction book

8.2 Electric cable size and fuses

Important

• The voltage on the compressor terminals must not deviate more than 10% of the
nominal voltage.
It is however highly recommended to keep the voltage drop over the supply cables
at nominal current below 5% of the nominal voltage (IEC 60204-1).
• If cables are grouped together with other power cables, it may be necessary to use
cables of a larger size than those calculated for the standard operating conditions.
• Use the original cable entry. See section Dimension drawings.
To preserve the protection degree of the electric cubicle and to protect its
components from dust from the environment, it is mandatory to use a fitting
cable gland when connecting the supply cable to the compressor.
• Local regulations remain applicable if they are stricter than the values proposed
below.
• Currents are calculated with the full service factor but we suggest to add 10% due
to over- and under-voltage.
Fuses are maximum allowed values calculated for full service factor and 10%
over- and under-voltage.
• Caution:
• Always double-check the fuse size versus the calculated cable size. If
required, reduce fuse size or enlarge cable size.
• Cable length should not exceed the maximum length according to IEC60204
table 10

Currents and fuses

IEC approval

Compressor type I (1) Max. fuse (1) I (2) Max. fuse (2)
gL/gG gL/gG
V Hz A A A A
GA 37 400 50 80.9 100 84.8 100

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

(1): compressors without integrated dryer
(2): compressors with integrated dryer
Fuse calculations for IEC are done according to 60364-4-43 Low-voltage electrical installations
- Part 4-43: protection against overcurrent. Fuse sizes are calculated in order to protect the cable
against short circuit.

Possible configurations
There are 3 possible cabling layouts:

API586589 97
 Instruction book

• (1): Single supply cables.

• (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 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.
See tables for maximum conductor temperature 70 °C and for maximum conductor temperature
90°C.

Installation method B2 according table B.52.1.

Multi-core cable in conduit on a wooden wall

Maximum allowed current in function of the ambient temperature for installation method B2

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

98 API586589
Instruction book

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
Cable section 30 °C 40 °C 45 °C 50 °C 55 °C
4 mm² < 32 A < 28 A < 25 A < 23 A < 20 A
6 mm² < 41 A < 36 A < 32 A < 29 A < 25 A
10 mm² < 57 A < 50 A < 45 A < 40 A < 35 A
16 mm² < 76 A < 66 A < 60 A < 54 A < 46 A
25 mm² < 96 A < 84 A < 76 A < 68 A < 59 A
35 mm² < 119 A < 104 A < 94 A < 84 A < 73 A
50 mm² < 144 A < 125 A < 114 A < 102 A < 88 A
70 mm² < 184 A < 160 A < 145 A < 131 A < 112 A
95 mm² < 223 A < 194 A < 176 A < 158 A < 136 A
120 mm² < 259 A < 225 A < 205 A < 184 A < 158 A

Installation method F according table B.52.1.

Single core cables, touching in free air
Clearance to wall not less than one cable diameter

Maximum allowed current in function of the ambient temperature for installation method F,
conductor temperature 70°C

Ambient temperature
Cable section 30 °C 40 °C 45 °C 50 °C 55 °C
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
150 mm² < 356 A < 310 A < 281 A < 253 A < 217 A
185 mm² < 409 A < 356 A < 323 A < 290 A < 249 A
240 mm² < 485 A < 422 A < 383 A < 344 A < 296 A
300 mm² < 561 A < 488 A < 443 A < 398 A < 342 A
400 mm² < 659 A < 573 A < 518 A < 467 A < 402 A

API586589 99
 Instruction book

Maximum allowed current in function of the ambient temperature for installation method F,
conductor temperature 90°C

Ambient temperature
Cable section 30 °C 40 °C 45 °C 50 °C 55 °C
25 mm² < 135 A < 123 A < 117 A < 110 A < 103 A
35 mm² < 169 A < 154 A < 147 A < 139 A < 128 A
50 mm² < 207 A < 188 A < 180 A < 170 A < 157 A
70 mm² < 268 A < 244 A < 233 A < 220 A < 204 A
95 mm² < 328 A < 298 A < 285 A < 269 A < 249 A
120 mm² < 383 A < 349 A < 333 A < 314 A < 291 A
150 mm² < 444 A < 404 A < 386 A < 364 A < 337 A
185 mm² < 510 A < 464 A < 443 A < 418 A < 388 A
240 mm² < 607 A < 552 A < 528 A < 498 A < 461 A
300 mm² < 703 A < 639 A < 611 A < 576 A < 534 A
400 mm² < 823 A < 749 A < 716 A < 674 A < 625 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 = 234 A, maximum ambient temperature is 45 °C, recommended fuse = 315 A
• Single supply cables (3 phases + PE - configuration (1)):
• I = 234 A + 10 % = 234 x 1.1 = 257.4 A
• The table for method F, 70 °C cable temperature and ambient temperature of 45
°C allows a maximum current of 323 A for a 185 mm² cable. So use a 3 x 185 mm²
+ 95 mm² cable.
• If the table for method F, 90 °C cable temperature and ambient temperature of 45
°C is used, 120 mm² is sufficient. So a single cable 3 x 120 mm² + 70 mm² is
sufficient .
• Parallel supply cable (2 x 3 phases + PE - configuration (2)):
• I = (234 A + 10 %)/2 = (234 x 1.1)/2 = 128.7 A

100 API586589
Instruction book

• Install 160 A fuses on each cable instead of 315 A.

• For a cable of 95 mm², method F, 70 °C cable temperature and ambient
temperature of 45 °C, the maximum current is 209 A x 0.8 = 167.2 A. So 2 parallel
cables of 3 x 95 mm² + 50 mm² are sufficient.
• For a cable of 95 mm², method F, 90 °C cable temperature and ambient
temperature of 45 °C, the maximum current is 233 A x 0.8 = 186.4 A. So 2 parallel
cables of 3 x 70 mm² + 35 mm² are sufficient.

8.3 Protection settings

Setting motor overload relay (F21)

Frequency (Hz) Voltage (V) 30kW F21 (A) 37kW F21 (A) 45kW F21 (A)
IEC
50 400 42 50 60

Settings for fan motor overload protection (Q15)

Frequency (Hz) Voltage (V) 30kW Q15 (A) 37kW Q15 (A) 45kW Q15 (A)
IEC
50 400 2.7 2.7 2.7

8.4 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.

8.5 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.

API586589 101
 Instruction book

Limits

Maximum working pressure See section Compressor data.

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

8.6 Compressor data

Reference conditions

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

GA 37

8.5 bar
Frequency Hz 50
Maximum (unloading) pressure, units with integrated dryer bar(e) 8.3
Reference working pressure bar(e) 8
Pressure drop over dryer, units with integrated dryer bar(e) 0.25
Set point of thermostatic valve ˚C 40
Motor shaft speed r/min 2956
Nominal motor power kW 37
Pressure dew point, units with integrated dryer ˚C 3
Temperature of air leaving outlet valve, units with integrated dryer ˚C 23
Dryer power at full load, units with integrated dryer kW 1.4
Dryer power at no load, units with integrated dryer kW 1.2
Refrigerant type, units with integrated dryer R410A
Refrigerant quantity, units with integrated dryer kg 0.8
Oil capacity l 17.7
Sound pressure level (according to ISO 2151 (2004)) dB(A) 67

8.7 Technical data 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)

102 API586589
Instruction book

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 6 (Elektronikon™ controller - p.n. 1900 5200 00 …. 1900 5200 09)
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 4 (Elektronikon™ controller - p.n. 1900 5200 00 …. 1900 5200 09)
Supply by controller 24 V DC
Supply protection Short circuit protected to ground
Input protection Not isolated

Analog inputs

Number of pressure inputs 1 (Elektronikon™ controller - p.n. 1900 5200 00 …. 1900 5200 09)
Number of temperature inputs 3 (Elektronikon™ controller - p.n. 1900 5200 00 …. 1900 5200 09)

API586589 103
 Instruction book

9 Instructions for use

Oil separator vessel

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

104 API586589
Instruction book

10 Guidelines for inspection

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

API586589 105
 Instruction book

11 Pressure equipment directives

Components subject to 2014/68/EU 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 2014/68/EU
and all pressure equipment according to the Simple Pressure Vessel Directive 2014/29/EU.

Compressor Component Description Volume Design Minimum and PED

type pressure maximum Class
design
temperature
GA 30+ up to GA 1625 430224 Vessel 30l 15 bar(e) -10 ˚C/ 120 ˚C II
45
0830 101068 Safety valve - - - IV
0830 101069 Safety valve - - - IV

Compressor type Component Description Number Minimum Inspection

of cycles wall frequency (2)
(1) thickness
GA 30+ up to GA 45 1625 5641 99 Vessel 2 x 106 8 mm 10 years
0830 1010 68 Safety valve - - -
0830 1010 69 Safety valve - - -

The compressors conform to PED smaller than category II.

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

106 API586589
Instruction book

12 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
(2): Applicable directives
(3): Standards used
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that
is supplied with this device.

API586589 107
 Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.
COMMITED TO SUSTAINABLE PRODUCTIVITY
We stand by our responsibilities towards our customers, towards the
environment and the people around us. We make performance stand
the test of time. This is what we call — Sustainable Productivity.

www.atlascopco.com