Atlas Copco Stationary Air Compressors

GA250-125

Instruction Manual

Serial Number: S989444 01-02v00

Customer: COMPANIA DE SERVISIO CAMPECHE, MEXICO

This book is made for a specific non standard compressor execution.

It contains four parts:
1) The standard basic product instruction manual, in which pages or
part of pages that describe items which are no longer valid for this
specific compressor are marked with “NOT TO BE USED, SEE
ADDENDUM”. In the content table these pages are marked up.
2) The instruction manual addendum, containing adapted text,
Including the description of non standard options
3) The instruction manual for the Elektronikon module
4) The operating instructions (short form)

• Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium.

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 meets the requirements for instruction specified by the
machine directive 98/37/EC and is valid for CE as well as non-CE labeled
machines

www.atlascopco.com

2004-01
 Atlas Copco Stationary Air Compressors
GA90 - GA110 - GA132 - GA160 - GA200 - GA250 - GA315
GA90 W - GA110 W - GA132 W - GA160 W - GA200 W -
GA250 W - GA315 W

Instruction book

Important
1. For GA/GA W 90 up to 160, this book applies to compressors from serial number AIF-078 300 onwards.
2. For GA/GA W 200 up to 315, this book applies to compressors from serial number AIF-078 302 onwards.
3. This book must be used together with the "User manual for Elektronikon® regulator for GA-GR-ZA-ZE-
ZR-ZT compressors".

Note: The PED instructions for this machine are included at the end of the book.

· Copyright 2002, Atlas Copco Airpower n.v., Antwerp, Belgium.

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 meets the requirements for instructions specified by the machinery
directive 98/37/EC and is valid for CE as well as non-CE labelled machines.

No. 2920 1475 00

Registration code: APC G³90/'99 / 38 / 963

2002-10 www.atlascopco.com

This instruction book describes how to handle the machines to ensure safe operation, optimum efficiency and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the
beginning. The maintenance schedule comprises measures for keeping the machine in good condition.
Keep the book available for the operator and make sure that the machine is operated and that maintenance is carried out according
to the instructions. Record all operating data, maintenance performed, etc. in an operator's logbook available from Atlas Copco.
Follow all relevant safety precautions, including those mentioned on the cover of this book.
Repairs must be carried out by trained personnel from Atlas Copco who can be contacted for any further information.
In all correspondence mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal data".
The company reserves the right to make changes without prior notice.
Contents
Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Main options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Air flow / regulating system . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Condensate drain system . . . . . . . . . . . . . . . . . . 7
1.2.3 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.5 Regulating system . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Elektronikon® control system . . . . . . . . . . . . . . . . . . . . 10
1.3.1 Automatic control of the compressor . . . . . . . 10
1.3.2 Protecting the compressor . . . . . . . . . . . . . . . . 10
1.3.3 Service warning . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.4 Automatic restart after voltage failure . . . . . . . 11
1.3.5 Permissive start . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 LEDs/buttons/keys . . . . . . . . . . . . . . . . . . . . . . 11
1.4.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.3 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.4 Emergency stop button . . . . . . . . . . . . . . . . . . . 12
1.5 Menu-driven control programs . . . . . . . . . . . . . . . . . . . 12
1.5.1 Function of control programs . . . . . . . . . . . . . 12
1.5.2 Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.3 External compressor status indication . . . . . . . 14
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Installation proposals . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Electric cable size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.5 Cooling water requirements . . . . . . . . . . . . . . . . . . . . . 28
2.5.1 Type of the system . . . . . . . . . . . . . . . . . . . . . . 28
2.5.2 Cooling water parameters . . . . . . . . . . . . . . . . 29
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . 31
3.1.2 User manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.3 Outdoor/altitude operation . . . . . . . . . . . . . . . . 31
3.1.4 Moving/lifting . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.5 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5 Checking the display . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6 Manual unloading/loading . . . . . . . . . . . . . . . . . . . . . . 34
3.7 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.8 Taking out of operation . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Preventive maintenance schedule for the compressor . 37
2 2920 1475 00
Instruction book
Page
4.1.1 Regular service operations . . . . . . . . . . . . . . . . 37
4.1.2 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.3 Service agreements . . . . . . . . . . . . . . . . . . . . . . 37
4.1.4 Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Motor greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.1 Fan motors on GA . . . . . . . . . . . . . . . . . . . . . . 37
4.2.2 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.6 Storage after installation . . . . . . . . . . . . . . . . . . . . . . . . 38
4.7 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5 Adjustments and servicing procedures . . . . . . . . . . . . . . . 39
5.1 Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4 Oil/water separators . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1 Readings on display . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2 Programmable settings . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Settings of safety valve . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4 Settings of overload relay, circuit breakers and fuses . 42
7.4.1 Motor overload relay and fuses for 50 Hz
compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4.2 Motor overload relay and fuses for 60 Hz IEC
compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4.3 Motor overload relay and fuses for 60 Hz CSA/
UL compressors . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4.4 Fan motor circuit breakers . . . . . . . . . . . . . . . . 44
7.4.5 Circuit breakers for dryer motor
(GA Full-feature) . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.6 Circuit breakers for dryer cooling fan motor
(GA Full-feature) . . . . . . . . . . . . . . . . . . . . . . . 45
7.4.7 Circuit breaker for control circuit . . . . . . . . . . 45
7.5 Compressor specifications . . . . . . . . . . . . . . . . . . . . . . 46
7.5.1 Reference conditions . . . . . . . . . . . . . . . . . . . . 46
7.5.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.5.3 Specific data of 7.5 bar - 50 Hz compressors . 46
7.5.4 Specific data of 8.5 bar - 50 Hz compressors . 47
7.5.5 Specific data of 10 bar - 50 Hz compressors . . 47
7.5.6 Specific data of 13 bar - 50 Hz compressors . . 48
7.5.7 Specific data of 100 psi - 60 Hz compressors . 48
7.5.8 Specific data of 125 psi - 60 Hz compressors . 49
7.5.9 Specific data of 150 psi - 60 Hz compressors . 49
7.5.10 Specific data of 200 psi - 60 Hz compressors . 50
7.6 Conversion list of SI units into British/American units 50
Instruction book

1 LEADING PARTICULARS The compressors are available for a maximum working pressure
of:
- 7.5, 8.5, 10 or 13 bar(e) for 50 Hz versions
1.1 General description - 107, 132, 157 or 200 psig for 60 Hz versions
GA90 up to GA315 and GA90 W up to GA315 W are single- The compressors include mainly:
stage, oil-injected screw compressors, driven by an electric - Air filter(s)
motor and enclosed in a sound-insulated bodywork. - Compressor element 1)
- Air receiver/oil separator
GA90 up to GA315 are air-cooled, abbreviated as "GA". GA90 - Air cooler
W up to GA315 W are water-cooled, abbreviated as "GA W". - Oil cooler(s)
- Drive motor
GA Full-feature (FF) compressors are provided with an air - Gear casing
dryer integrated in the bodywork. The system includes dryer - Unloader 1)
by-pass valves. - Elektronikon® control system
- Safety devices
- Air dryer with by-pass valves (Full-feature compressors
only)

1 Oil coolers 7 Gear casing 12 Air receiver

2 Control panel 8 Compressor element 13 Minimum pressure valve
3 Electric cabinet 9 Oil stop valve 14 Cooling fan
4 Power supply inlet 10 Check valve M1 Drive motor
5 Vibration damper 11 Unloader M25 Fan motor
6 Vibration damper
Fig. 1.1 Front view, GA110 FF

2920 1475 00 3
 Instruction book

1 Oil coolers
2 Control panel
3 Electric cabinet
4 Power supply inlet
5 Vibration damper
6 Vibration damper
7 Gear casing
8 Oil stop valve
9 Check valve
10 Compressor element
11 Unloader
12 Air receiver
13 Safety valve
14 Minimum pressure
valve
15 Arrow, motor
rotation direction
16 Cooling fans
17 Air filters
M1 Drive motor
M25/26 Fan motors

Fig. 1.2 Front view, GA250 FF

1 By-pass valve
2 By-pass valve
3 By-pass valve 1 2 3 4 5 6 7 M25
4 Oil coolers
5 Vent plugs
6 Air cooler
7 Cooling fan 20
8 Unloader
9 Oil drain plug, air
receiver 19 8
10 Air receiver
11 Oil cooler by-pass
valve
12 Oil filters
13 Condensate trap
18
14 Oil drain plug
15 Oil drain plug
16 Air dryer
17 Condensate outlets
18 DD filter (option)
19 Compressed air 17
outlet
20 Air filter
M25 Fan motor

Fig. 1.3 Rear view, 51329F

GA110 FF 16 15 14 13 12 11 10 9

4 2920 1475 00
Instruction book

1.1.1 Main options Oil containing frame

Full-feature
A refrigerant dryer is fully integrated in the bodywork of the
compressor. This “all-in-one” feature reduces the required
space for installation and provides savings on piping installation
cost.
Integrated DD filter
Full-feature compressors can be provided with an integrated
filter of the DD type to limit carry-over of solid particles and
oil. By integrating a DD filter, the compressor delivers Quality
Air according to ISO 8573-1, Class 2.4.2.
Integrated OSD
The OSD (Oil Separating Device) separates the oil residues
from the condensate water. The clean water can be drained
into the sewer without any further treatment. The separated oil
is collected and must be disposed of according to prevailing
regulations.
Electronic drain
The EWD (Electronic Water Drain) assures proper draining of
condensate and prevents water from entering the compressed
air net. At any malfunction of the draining process, the EWD
generates a warning message on the display of the Elektronikon
regulator.
Energy recovery
The compressors can be provided with the Atlas Copco energy
recovery systems to recover the major part of the compression
heat in the form of hot water without any influence on the
compressor performance.
This frame is installed under the machine and will collect oil
from occasional leakage and avoid oil to spread over the floor.
Modulating control
The modulating control system is designed to maintain a narrow
net pressure band (0.2 bar) by throttling the air inlet, thus
reducing the air flow (50% - 100%).
Heavy-duty air intake filter
A two-stage heavy-duty air intake filter kit is available allowing
the compressor to operate in heavily contaminated surroundings
(e.g. cement or mining industry). The larger dust particles are
collected in the first stage of the filter. The filter efficiency
(SAE fine) is 99% at 1µm, 99.8% at 2µm and 99.9% at 3 µm.
Rain protection
If a GA compressor is installed outdoors, the rain protection
prevents rain from entering the machine. At the same time it
protects the display of the Elektronikon regulator against sun
and rain.
High ambient temperature version
The GA HAT (High Ambient Temperature) version is specially
designed for continuous operation in humid and high ambient
temperature environment up to 50 degrees Celsius. This option
is available for GA air and water-cooled compressors except
for 13 bar (200 psi) and GA Full-feature compressors.
Phase Sequence Relay
The phase sequence relay prevents the drive motor from rotating
in the wrong direction.

1 2 3

11

1 By-pass valve 10
2 Vent plugs
3 Air cooler
4 Air receiver 4
5 Oil filters
6 Condensate trap
7 Oil drain plugs
8 Air dryer
9 Electronic water drain
(option)
10 By-pass valves 12
11 DD filter (option)
12 Oil drain plug, air receiver
50837F
Fig. 1.4 Rear view, GA250 FF 9 8 7 6 5

2920 1475 00 5
 Instruction book

1 4 3 2 1 Pipe coupling
20 2 Oil coolers
3 Arrow, motor rotation direction
4 Air cooler
19 5 Bolts
6 Filler plug (only to be used at initial
M25 5 start-up)
7 Air inlet hose
Y1 8 Unloader
9 Arrow, rotation direction of drive motor
18 10 Compressor element
6 11 Check valve
17
7 12 Oil drain plug, air receiver
16 13 Air receiver
21 8 14 Oil separator element
15 Oil filters
15 9
16 Receiver cover
10 17 Bolt
14
18 Minimum pressure valve
13 19 Cooling fan
11
20 Pipe, air receiver to air cooler
12 21 Safety valve
M25 Fan motor
Y1 Loading solenoid valve
50852F
Fig. 1.5 Side view, GA110 FF

1 Pipe coupling
2 Air cooler
3 Oil coolers 4 1 M25 2 3 20 M26 4
4 Cooling fan
5 Air inlet hoses
6 Filler plugs (only to be used at initial 18
start-up) 17
7 Check valves 6
8 Compressor elements 16
9 Arrow, rotation direction of drive motor 15 Y1
10 Unloaders
11 Air receiver 14 6
12 Oil filters 10 10
13 Oil separator element
14 Receiver cover 13
5
15 Bolt 12
16 Minimum pressure valve 5
17 Safety valve 7
18 Pipe, air receiver to air cooler
11
19 Oil drain plug, air receiver
20 Bolts
M25/26 Fan motors
Y1 Loading solenoid valve
50835F
Fig. 1.6 Side view, GA250 FF 19 8 7 9 8

6 2920 1475 00
Instruction book
PT 1000 thermal protection
The PT 1000 thermal protection provides protection of the drive
motor. Five sensors are installed in the motor, two to measure
the temperature of the bearings and three to measure the
temperature of the windings. The readings can be called up on
the display of the Elektronikon regulator. A message will appear
on the display and the general alarm LED will light up if one of
the temperatures exceeds the shut-down warning setting. If
the temperature rises above the shut-down setting, the
compressor will shut down and the general alarm LED starts
blinking.
DIN/BSP or ANSI/NPT connections
For GA90 up to 160 a BSP or NPT connection can be chosen.
For GA200 up to 315 a DIN or ANSI connection can be chosen.
HD Roto-fluid
Special oil for Atlas Copco GA oil-injected screw compressors.
It provides better cooling and extends the oil change interval
to 8000 hours.
Cooling air outlet ducting
Diverts the cooling air in such a way that the hot air is not led
to the cooling air inlet. This option is only available for air-
cooled compressors.
Lifting device
The lifting device is a solid steel beam construction bolted to
the compressor. It allows the customer to lift the compressor
by means of e.g. a crane.
It is AIB and CE approved and complies with all applicable
safety standards.
1.2 Air flow / regulating system (Figs. 1.7
and 1.8)
1.2.1 Air flow 1)
Air drawn through filter (1) and unloader (2) is compressed in
compressor element (14). Compressed air and oil are
discharged through check valve (16) to air receiver/oil separator
(17) in which the oil is separated from the compressed air. The
air is blown through minimum pressure valve (19) to air cooler
(4). The cooled air is discharged through condensate trap (28)
and outlet valve (27) towards the air net.
Check valve (16) prevents blow-back of compressed air.
Minimum pressure valve (19) prevents the receiver pressure
from dropping below a minimum pressure. The valve has a
built-in check valve.
2920 1475 00
1.2.2 Condensate drain system
A condensate trap (28) is installed downstream of the air cooler
to prevent condensate from entering the air outlet pipe. The
trap is provided with a float valve for automatically draining
condensate and with a manual drain valve.
Full-feature compressors, which are provided with an air dryer,
have a second condensate trap downstream of the dryer. This
trap is also provided with a float valve for automatically draining
condensate and with a manual drain valve.
1.2.3 Oil system 1)
Air pressure forces the oil from receiver (17) through oil coolers
(6), filters (7) and oil stop valve (15) to compressor element
(14) and the lubrication points.
Oil stop valve (15) prevents the compressor element from
flooding with oil when the compressor is stopped.
Valve (26) by-passes oil coolers (6) when starting the
compressor from cold condition, to ensure rapid warming of
the oil to normal working temperature.
In air receiver (17) most of the oil is removed from the air
centrifugally. Almost all of the remaining oil is removed by
separator element (18).
1.2.4 Cooling system
On GA, the system includes air cooler (4) and oil coolers (6),
cooled by one or two fans (5) 2).
GA W are provided with a cooling water system, including a
combined oil and air cooler.
1.2.5 Regulating system
The system keeps the net pressure within programmable
pressure limits by automatically loading and unloading the
compressor depending on the air consumption. It is controlled
by Elektronikon® regulator (E1) which also protects the
compressor and monitors components subject to service. See
section 1.3.
1.2.5.1 GA/GA W 90/160
Unloading
If the air consumption is less than the air delivery of the
compressor, the net pressure increases. When the net pressure
reaches the upper limit of the working pressure (unloading
7
 Instruction book

Fig. 1.7 GA90/160 Full-feature

during unloading

1 Air filter 9 By-pass opening 17 Air receiver

2 Unloader 10 Blow-off channel 18 Oil separator element
3 Unloading valve 11 Chamber, receiver pressure 19 Minimum pressure valve
4 Air cooler 12 Valve 20 Check valve
5 Cooling fan 13 Shield 21 Oil scavenging line
6 Oil coolers 14 Compressor element 22 Safety valve
7 Oil filters 15 Oil stop valve 23 Oil filler plug
8 Chamber, control pressure 16 Check valve 24 Oil level indicator

8 2920 1475 00
Instruction book

Fig. 1.8 GA200/315 during loading

25 Oil drain plug 34 Thermostatic expansion valve 44 Refrigerant compressor

26 By-pass valve 35 Sight-glass 45 Liquid separator
27 Air outlet valve (customer’s 36 Filter/dryer 46 Low pressure switch
installation) 37 Capillary tube 47 Air/refrigerant heat exchanger
28 Condensate trap 38 Fan control switch 48 Air/air heat exchanger
29 Channel 39 High pressure switch 49 By-pass valves
30 Flexible, receiver pressure 40 Fan 50 By-pass valve
31 Insulating block 41 Fan motor E1 Elektronikon regulator
32 Condensate trap 42 Condenser M1 Drive motor
33 Liquid – gas mixer 43 Hot gas by-pass valve Y1 Loading solenoid valve

Figs. 1.7 and 1.8 Regulating system

2920 1475 00 9

pressure), solenoid valve (Y1) is de-energized. The plunger of
the valve moves downwards by spring force:
1. The plunger of solenoid valve (Y1) shuts off the supply of
receiver pressure towards chamber (8).
2. Control pressure present in chamber (8) is vented to
atmosphere through loading solenoid valve (Y1). Unloading
valve (3) closes by spring force.
3. Valve (12) is pushed downwards releasing receiver pressure
through flexible (30) and channels (10 and 29) towards the
air inlet.
4. A small flow of air remains drawn in through hole (9) and
channel (10), and is blown from receiver (17) via flexible
(30) to the air inlet.
5. Air delivery is stopped (0 %), the compressor runs unloaded.
Loading
When the net pressure decreases to the lower limit of the
working pressure (loading pressure), solenoid valve (Y1) is
energized. The plunger of solenoid valve (Y1) moves upwards
against spring force:
1. The plunger of solenoid valve (Y1) opens the supply of
receiver pressure towards chamber (8). Unloading valve
(3) opens against spring force.
2. Receiver pressure also pushes valve (12) upwards, shutting
off blow-off channels (10 and 29).
3. Air delivery is resumed (100 %), the compressor runs
loaded.
1.2.5.2 GA/GA W 200/315
The operation of the system is similar to that of GA90/160,
except that GA/GA W 200/315 are equipped with two
compressor elements, each provided with an unloader, check
valve and oil stop valve.
1.3 Elektronikon® control system
In general, the Elektronikon regulator has following functions:
- automatic control of the compressor
- protecting the compressor
- monitoring components - service warning
- automatic restart after voltage failure
10
Instruction book
1.3.1 Automatic control of the compressor
The regulator 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 are taken into account.
The regulator stops the compressor whenever possible to reduce
the power consumption and restarts it automatically when the
net pressure decreases. In case the expected unloading period
is too short, the compressor is kept running to prevent too-
short standstill periods.
Warning A number of time-based automatic start/stop
commands may be programmed. Take into
account that a start command will be executed (if
programmed and activated), even after manually
stopping the compressor.
1.3.2 Protecting the compressor
Shut-down and motor overload
If the temperature at the outlet of the compressor or at the outlet
of the compressor element exceeds the programmed shut-down
level, the compressor will be stopped. This will be indicated
on the control display.
The compressor will also be stopped in case of overload of the
drive motor or in case of overload of the fan motor(s).
Consult the safety precautions as mentioned in section 4 and
remedy the trouble. See also the User manual for Elektronikon
regulator, section Status data menu.
Shut-down warning
If the regulator detects a temperature just below the programmed
shut-down level, this will be indicated on the control panel to
warn the operator before the shut-down level is reached.
The message disappears as soon as the warning condition
disappears.
1.3.3 Service warning
A number of service operations are grouped (called Level A,
B, C, ...). Each level has a programmed time interval. If a time
interval is exceeded, a message will appear on display (2-Fig.
1.9) to warn the operator to carry out the service actions
belonging to that level. See section 4.
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1.4 Control panel

1.4.1 LEDs/buttons/keys

Ref. Designation Function

1 Start button Push button to start the

compressor. LED (8) lights up
indicating that the Elektronikon
regulator is operative.

2 Display Indicates messages concerning the

compressor operating condition, a
Fig. 1.9 Control panel
service need or a fault.

3 Scroll keys Keys to scroll upwards or

downwards through the display.

4 Tabulator key Key to select the parameter

indicated by a horizontal arrow.
Only the parameters followed by
an arrow pointing to the right are
accessible for modifying.

5 Function keys Keys to control and program the

1.3.4 Automatic restart after voltage failure compressor. See section 1.4.3.

The regulator has a built-in function to automatically restart 6 Voltage on LED Indicates that the voltage is
the compressor if the voltage is restored after voltage failure. switched on.
For compressors leaving the factory, this function is made
inactive. If desired, the function can be activated. Consult 7 General alarm Is alight if a shut-down warning
Atlas Copco. LED condition exists. See section 1.3.

Warning If activated and provided the module was in the 7 General alarm Blinks if a shut-down condition
automatic operation mode, the compressor will LED exists, if an important sensor is out
automatically restart if the supply voltage to the of order or after an emergency
module is restored within a programmed time stop. See section 1.3.
period.
8 Automatic Indicates that the regulator is
The power recovery time (the period within which operation LED automatically controlling the
the voltage must be restored to have an automatic compressor.
restart) can be set between 1 and 255 seconds or
to Infinite. If the power recovery time is set to 9 Stop button Push button to stop the
Infinite, the compressor will always restart after compressor. LED (8) goes out.
a voltage failure, no matter how long it takes to
restore the voltage. A restart delay can also be S2 Emergency Push button to stop the compressor
programmed, allowing e.g. two compressors to be immediately in case of emergency.
restarted one after the other. After remedying the trouble,
unlock the button by pulling it out.

1.3.5 Permissive start

After a start command (either automatic start by the electronic

regulator or manual start), the permissive start function is
operative: if the oil injection pressure at the compressor
elements exceeds the programmed level, the compressor will
not start (indicated as <<Start failure>>).

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1.4.2 Display
Designation Function
The following is a typical example of the main screen, showing
in short the status of the compressor: Return To return to a previously shown option or
menu
Compressor Outlet 7.0 bar Extra To find information regarding the installed
modules
Automatically loaded ¯
Menu Unload
F1 F2 F3
1.4.4 Emergency stop button (S2-Fig. 1.9)
Fig. 1.10 Example of the main screen
In case of emergency, press the button to stop the compressor
immediately.
1.4.3 Function keys (5-Fig. 1.9)
Pressing the button breaks the circuit to the drive motor. The
The keys are used: circuit to the control circuit and other electrical components
- to call up or program settings is not broken.
- to reset an active motor overload, shut-down or service
message, or an emergency stop Warning - Before starting any maintenance or repairs,
- to have access to all data collected by the regulator wait until the compressor has stopped and open
the isolating switch (customer's installation) to
The functions of the keys vary depending on the displayed menu. switch off the voltage to the compressor.
The actual function is indicated on the bottom line of the display - Close the air outlet valve and open condensate
just above the relevant key. drain valves (1 and 2-Fig. 3.7)
The most common functions are listed below: Apply all relevant safety precautions, including
those mentioned in this book.
Designation Function

1.5 Menu-driven control programs

Add To add compressor start/stop commands (day/
hour) To facilitate programming and controlling the compressor,
menu-driven programs are implemented in the electronic
Back To return to a previously shown option or module.
menu
A simplified menu flow is shown in Fig. 1.11.
Cancel To cancel a programmed setting when
programming parameters
1.5.1 Function of control programs
Delete To delete compressor start/stop commands
Program/ Description
Help To find the Atlas Copco internet address Function

Limits To show limits for a programmable setting

Main screen Shows in short the operation status of the
MainScreen To return from a menu to the main screen (Fig. compressor. It is the gateway to all functions.
1.12) See Fig. 1.12.
Status data Calling up the status of the compressor
Menu Starting from the main screen (Fig. 1.12), to protection functions:
have access to submenus - shut-down
- shut-down warning
Menu Starting from a submenu, to return to a - service warning
previous menu - warning
Resetting of a shut-down, motor overload and
Modify To modify programmable settings service condition.
Program To program modified settings Measured data Calling up:
- actually measured data
Reset To reset a timer or message - the status of a number of inputs

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-Motor Starts -Oil separator

-Module Hours -Dryer LAT
-Load Relay -Emergency Stop
Automatic Operation Maximum Pressure 8.3 bar ↑ -Compressor Outlet -Remote Start/Stop
Compressor Outlet 6.4 bar
-Dp oilseparator -Remote Load/Unload
Local Control Running Hours 1016 hrs -Remote pressure sensing
-Dp Air Filter
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Oil injection element -Overload Motor
-Compressor Outlet -Overload Fanmotor
Menu Unload Mainscreen Help Extra Mainscreen Help Extra -Starter Feedback Contact
-Element 1 Outlet
-Element 2 Outlet -PB 1 open/ PB2 closed
-Cooling medium -Overload dryerdryer fan

Status Data → All Conditions Are OK

Measured Data
Counters ↓ -Oil Injection Element -Remote Start/Stop
-Compressor Outlet -Remote LoadUnload
Mainscreen Menu Help -Element 1 Outlet -Remote pressure sensing
-Element 2 Outlet -Overload Motor
-Cooling Medium -Overload Fanmotor
-Oil Separator -Starter Feedback Contact
Status Data ↑ Compressor Outlet 5.4 bar -Dryer LAT -PB1 open/ PB2 closed
Measured Data → Dp Oil Separator 1.1 bar -Emergency Stop -Overload Dryer/Dryer Fan

Counters ↓ Dp Air Filter 0.02 bar ↓

Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1016 hrs

-Unloading Pressure 2
Counters → Loaded Hours 980 hrs Loading Pressure 6.4 bar -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Permisive Start Time
-Communication Time-out
Counters ↑ Display Test → -Oil Injection Element
Test → Parameters ↑ Compressor Outlet 5.4 bar -Compressor Outlet
Safety Valve Test
↓ Protections → Dp Oil Separator 1.1 bar -Element 1 Outlet
Modify Parameters ↓ -Element 2 Outlet
Mainscreen Service Plan ↓ Dp Air Filter - 0.011 bar ↓ -Cooling Medium
Menu
Menu Menu -Oil Separator
-Dryer LAT
-Emergency Stop
Test ↑ Parameters → Protections ↑ Service Timer -Remote Start/Stop
-Remote Load/Unload
Modify Parameters → Protections Service Plan → Running hours → -Remote Pressure Sensing
Service ↓ Service Plan ↓ Clock Function ↓ 130 hrs ↓ -Overload Motor
-Overload Fanmotor
Mainscreen Menu Menu Menu -Starter Feedback Contact
-PB1 open/ PB2 closed
-Overload Dryer/Dryer Fan
Service Plan ↑ Clock Function
Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 130 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52407PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Password
-Node ID
Saved Data → Last Shutdown 3 ↓
-Digital Presband Selec.
Mainscreen Menu

Fig. 1.11 Menu flow

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1.5.3 External compressor status indication

Program/ Description
Function
Terminal strip (1X7-Fig. 1.13) is provided with auxiliary
contacts for external indication of:
Counters Calling up the:
- running hours Indication Relay Terminals Max. load
- number of motor starts on strip 1X7
- regulator (module) hours

Test Allows a display test. Automatic operation K07 11-12 10 A / 230 V AC

Warning K08 13-14 10 A / 230 V AC
Modify Modifying the settings for: Shut-down K09 15-16 10 A / 230 V AC
parameters - parameters: loading and unloading Compressor loading K11 17-18 3 A / 230 V AC
pressures Motor running K21 19-20 6 A / 230 V AC
- protections: compressor outlet pressure,
air filter pressure drop, .... (see Fig. 1.11)
- service plans: timers for service plans Warning Stop the compressor and switch off the voltage
- clock functions: automatic compressor before connecting external equipment.
start/stop/pressure band commands
- configuration: time, date, display
language, …

Service Calling up service plans and resetting the

timers after carrying out the service actions
belonging to a plan. See section 4.

Saved data Calling up the saved data: last shut-down, last

emergency stop data

1.5.2 Main screen

When the voltage is switched on, the main screen is shown

automatically, showing in short the operation status of the
compressor.

Compressor Outlet 7.0 bar

Automatically loaded ¯
Menu
F1 F2 F3

Fig. 1.12 Main screen, typical example

If the function keys or arrow keys are not used for some minutes,
the display will automatically return to the Main screen.
Whenever displayed on a submenu screen, press the key F0/1 Circuit breakers K23 Delta contactor
Mainscreen to return to the Main screen. F3/4/5 Circuit breakers, Q25 Circuit breaker, fan
control circuit motor M25
Footnotes chapter 1 F21 Compressor motor (GA90/315)
overload relay Q26 Circuit breaker, fan
1) GA/GA W 90 up to 160 have one compressor element and one K11 Auxiliary relay, motor M26
unloader. GA/GA W 200 up to 315 have two compressor loading (GA132/315)
elements, each provided with an unloader, check valve and oil K21 Line contactor T1/T2 Transformers
stop valve. K22 Star contactor 1X3/7 Terminal strips
2) GA90 and GA110 are provided with one fan. GA132 up to GA315
are provided with two fans. Fig. 1.13 Electric cabinet, typical example

14 2920 1475 00
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2 INSTALLATION
2.1 Dimension drawings
NOT TO BE USED, SEE ADDENDUM

Fig. 2.1 Dimension drawing, GA90 and GA110

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NOT TO BE USED, SEE ADDENDUM

Fig. 2.2 Dimension drawing, GA90 W and GA110 W

16 2920 1475 00
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NOT TO BE USED, SEE ADDENDUM

Fig. 2.3 Dimension drawing, GA132 and GA160

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NOT TO BE USED, SEE ADDENDUM

Fig. 2.4 Dimension drawing, GA132 W and GA160 W

18 2920 1475 00
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NOT TO BE USED, SEE ADDENDUM

Fig. 2.5 Dimension drawing, GA200 up to GA315

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NOT TO BE USED, SEE ADDENDUM

Fig. 2.6 Dimension drawing, GA200 W up to GA315 W

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2.2 Installation proposals (Figs. 2.7 up to 2.10)

Fig. 2.7 Installation proposal, GA90 up to GA160

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Fig. 2.8 Installation proposal, GA90 W up to GA160 W

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Fig. 2.9 Installation proposal, GA200 up to GA315

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Ref. Description Ref. Description

1 Install the compressor on a level floor suitable for taking 3 The pressure drop over the air outlet pipe can be
the weight of the compressor. For ventilation proposal calculated as follows:
1, the minimum distance between the top of the
bodywork and the ceiling is 1200 mm. dp = (L x 450 x Qc1.85) / (d5 x p)

2 Remove the plastic plug (if provided) from the dp = pressure drop (recommended maximum =
compressor air outlet pipe (3-Fig. 3.5/7-Fig. 3.6) and 0.1 bar)
fit the air outlet valve 1) to the pipe. Close the valve L = length of outlet pipe in m
and connect it to the net. d = inner diameter of the outlet pipe in mm
p = absolute pressure at the compressor outlet in
bar(a)
Qc = free air delivery of the compressor in l/s

Fig. 2.10 Installation proposal, GA200 W up to GA315 W

24 2920 1475 00
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Ref. Description Ref. Description

It is recommended that the connection of the compressor collector. For draining of purified condensate water, an
air outlet pipe is made on top of the main air net pipe to oil/water separator (type OSD) can be integrated in the
minimize carry-over of possible remainder of bodywork. It is recommended to provide a funnel to
condensate. allow visual inspection of the condensate flow.
As a rule of thumb, following formula can be used to
calculate the recommended volume of the air net: 5-Fig. 2.8 - 8-Fig. 2.10
For GA W, fit a water shut-off valve and water drain
V = (30 x C x p x Q) / dp valve in the compressor water inlet pipe and outlet pipe.
Remove the plastic plugs (if provided) from the
V = recommended air net volume in l compressor water pipes and connect the pipes to the
dp = pressure difference between unloading and cooling water circuit.
loading pressures in bar (recommended
minimum = 0.6) 6-Fig. 2.7/2.9/2.10 - 7-Fig. 2.8
p = compressor inlet pressure in bar absolute Location of the Elektronikon regulator.
Q = free air delivery of compressor in l/s
C = correction factor, see below 7-Fig. 2.7/2.9/2.10 - 8-Fig. 2.8
See section 2.3 for the recommended size of the supply
Air consumption divided by Correction factor C cables. Check that the electrical connections correspond
compressor air delivery to the local codes. The installation must be earthed and
protected against short circuits by fuses in all phases.
0.9 0.10 An isolating switch must be installed near the
0.8 0.15 compressor.
0.7 0.20
0.5 0.25 8-Fig. 2.7 - 9-Fig. 2.8/2.10
0.3 0.20 Location of a pipe coupling 3).
0.2 0.15
0.1 0.10

4 The inlet grids and ventilation fan should be installed in

such a way that any recirculation of cooling air to the
compressor is avoided. The maximum air velocity
through the grids is 5 m/s.

The required ventilation to limit the compressor room

temperature can be calculated as follows:

Qv = 0.92 N/dT (GA) Qv = 0.1 N/dT (GA W)

Qv = required ventilation capacity in m3/s

N = shaft input of compressor in kW
dT = temperature increase in compressor room

If cooling air ducts are installed, the maximum allowable

pressure drop over the ducts is 30 Pa. The maximum
pressure drop depends on the ambient temperature. The
fan capacity should match the compressor fan capacity
at a pressure head equal to the pressure drop caused by
the cooling air outlet ducts. Consult Atlas Copco.

5-Fig. 2.7/2.9/2.10 - 6-Fig. 2.8

Remove the plastic plugs (if provided) from the
condensate outlets (Fig. 3.7) and fit the manual
condensate drain valves (1 and 2-Fig. 3.7). 2) Lay out
the drain piping towards the condensate collector. The
drain pipes must not dip into the water of the drain

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NOT TO BE USED, SEE ADDENDUM

F21 Compressor motor overload K41 Contactor, fan motor of dryer M42 Fan motor, air dryer (GA200/
relay (GA90/315 Full-feature) 315 Full-feature)
K21 Line contactor K42 Contactor, fan motor of dryer Q25 Circuit breaker, fan motor M25
K22 Star contactor (GA200/315 Full-feature) (GA90/315)
K23 Delta contactor M1 Drive motor Q26 Circuit breaker, fan motor M26
K25 Contactor, fan motor M25 M25 Fan motor, GA90/315 (GA132/315)
(GA90/315) M26 Fan motor, GA132/315 Q40 Circuit breaker, compressor
K26 Contactor, fan motor M26 M40 Compressor motor, air dryer motor of air dryer (Full-feature
(GA132/315) (Full-feature only) only)
K30 Phase sequence relay (option) M41 Fan motor, air dryer (GA90/ Q41 Circuit breaker, fan motor(s) of
K40 Contactor, compressor motor 315 Full-feature) air dryer (Full-feature only)
of air dryer (Full-feature only) 1X3 Earthing strip

Fig. 2.11 Electrical connections (typical example)

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2.3 Electric cable size

50 Hz compressors 6)

Type 230 V 400 V 500 V

GA90 2x (3x120mm²+70mm²) 3x95mm²+50mm² 3x70mm²+35mm²

GA110 2x (3x150mm²+95mm²) 3x120mm²+70mm² 3x95mm²+50mm²
GA132 2x (3x185mm²+95mm²) 2x (3x95mm²+50mm²) 3x120mm²+70mm²
GA160 2x (3x240mm²+120mm²) 2x (3x120mm²+70mm²) 2x (3x70mm²+35mm²)

Type 230 V 400 V 500 V

GA200 2x (3x150mm²+70mm²) 2x (3x120mm²+70mm²)

GA250 2x (3x185mm²+95mm²) 2x (3x150mm²+70mm²)

60 Hz IEC compressors 6)

Type 220/230 V 380 V 440/460 V

GA90 2x (3x120mm²+70mm²) 3x120mm²+70mm² 3x95mm²+50mm²

GA110 2x (3x150mm²+95mm²) 2x (3x70mm²+35mm²) 2x (3x50mm²+25mm²)
GA160 2x (3x95mm²+50mm²) 2x (3x95mm²+50mm²)

Type 220/230 V 380 V 440/460 V

GA200 2x (3x150mm²+70mm²) 2x (3x120mm²+70mm²)

GA250 2x (3x185mm²+95mm²) 2x (3x150mm²+70mm²)
GA315 2x (3x240mm²+120mm²) 4) or 2x (3x185mm²+95mm²)
4x (3x70mm²+35mm²) 5)

60 Hz CSA/UL compressors 7)

Type 440/460 V 575 V

GA90 3xAWG0000+AWG2 3xAWG00+AWG4

GA110 2x (3xAWG00+AWG4) 3xAWG000+AWG3
GA160 2x (3xAWG000+AWG3) 2x (3xAWG00+AWG4)

Type 440/460 V 575 V

GA200 2x (3xMCM400+AWG0) 4) or 2x (3xMCM250+AWG2) 4) or

4x (3xAWG00+AWG4) 5) 4x (3xAWG1+AWG6) 5)
GA250 2x (3xMCM500+AWG0) 4) or 2x (3xMCM300+AWG0) 4) or
4x (3xAWG000+AWG3) 5) 4x (3xAWG0+AWG4) 5)
GA315 4x (3xAWG000+AWG3) 5) 4x (3xAWG00+AWG4) 5)

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2.4 Pictographs 1 Start

2 Keys to scroll through display
3 Key to go to next field on display
4 Voltage on
5 Alarm
6 Automatic operation
7 Stop
8 Oil the gaskets, screw on the
filters and tighten by hand
(approx. one half turn)
9 Cooling water inlet
10 Cooling water outlet
11 Consult the Instruction book
before maintenance or repair
12 Condensate outlet
13 Automatic condensate drain
14 Automatic condensate drain for
optional oil/water separator (type
OSD)
15 Manual condensate drain
16 Stop the compressor before
cleaning the coolers
Fig. 2.12 Pictographs, control panel 17 Warning: under tension
18 Read Instruction book before
starting the compressor
19 Switch off the voltage and de-
pressurize the compressor before
maintenance or repair
20 Before connecting the compressor
electrically, consult the Instruction
book for the motor rotation
direction
21 Torques for steel (Fe) or brass
(CuZn) bolts
22 Consult the Instruction book
before greasing
23 Switch off the voltage before
removing the protecting cover
inside the electric cabinet

Figs. 2.12 and 2.13 Pictographs

Fig. 2.13 Pictographs, other locations (typical examples)

2.5 Cooling water requirements This recommendation is a general guide line for acceptable
coolant quality.
The cooling water quality must meet certain minimum
requirements.
2.5.1 Type of the system
No general recommendation can encompass the effects of all
combinations of the various compounds, solids and gases Closed system
typically found in cooling water in interaction with different In a closed system, the same cooling water is circulating through
materials. a system without contact with air.

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Open system The Rysnar Index is calculated as follows :

An open system is a pass-through system, or a circulating system
with a cooling tower. In the latter case, the composition of the RSI = 2*pH - pH
s
water that enters the cooler must be considered, and not the
composition of the make-up water. Due to the evaporative effect where pH = measured pH (at room temperature) of
in the cooling tower, much higher concentrations of ions can water sample
be obtained in the circulating water than in the make-up water. pH = pH at saturation
s

The pH is calculated by using :

s
2.5.2 Cooling water parameters
pH = (9.3 + A + B) - (C + D)
s
The Rysnar stability index (RSI)
A: depends on the total solids concentration
The Rysnar Index (RSI) is a parameter for predicting whether (mg/l).
water will tend to dissolve or precipitate calcium carbonate.
The adhesion of scaling depositions and their effect are different B: depends on the highest cooling water
on different materials, but the equilibrium of the water (scaling temperature (°C),
or corrosive) is only determined by its actual pH value and by For GA/GR units take T = 75°C
the saturation pH value (pH ).
s
C: depends on the calcium hardness
The saturation pH value is determined by the relationship (ppm CaCO ).
3
between the calcium hardness, the total alkalinity, the total solids
concentration and the temperature. D: depends on the HCO - concentration or
3
M-alkalinity (mval/l).

The values from A, B, C and D are found in the

table below.

Total dissolved solids   Temperature   Ca-hardness   M-Alkalinity  

(mg/l) A (°C) B (ppm CaCO ) C (mval/l) D
3

50 - 300 0.1 0-1 2.6 10 - 11 0.6 0.20 - 0.22 1.0

400 - 1000 0.2 2-6 2.5 12 - 13 0.7 0.24 - 0.26 1.1
    7-9 2.4 14 - 17 0.8 0.28 - 0.34 1.2
    10 - 13 2.3 18 - 22 0.9 0.36 - 0.44 1.3
    14 - 17 2.2 23 - 27 1.0 0.46 - 0.54 1.4
    18 - 21 2.1 28 - 34 1.1 0.56 - 0.70 1.5
    22 - 27 2.0 35 - 43 1.2 0.72 - 0.88 1.6
    28 - 31 1.9 44 - 55 1.3 0.90 - 1.10 1.7
    32 - 37 1.8 56 - 69 1.4 1.12 - 1.38 1.8
    38 - 44 1.7 70 - 87 1.5 1.40 - 1.76 1.9
    45 - 50 1.6 88 - 110 1.6 1.78 - 2.20 2.0
    51 - 56 1.5 111 - 138 1.7 2.22 - 2.78 2.1
    57 - 63 1.4 138 - 174 1.8 2.80 - 3.54 2.2
    64 - 71 1.3 175 - 220 1.9 3.54 - 4.40 2.3
    72 - 80 1.2 230 - 270 2.0 4.6 - 5.4 2.4
        280 - 340 2.1 5.6 - 7.0 2.5
        350 - 430 2.2 7.2 - 8.8 2.6
        440 - 550 2.3 9.0 - 11.0 2.7
        560 - 690 2.4 11.2 - 13.8 2.8
        700 - 870 2.5 14.0 - 17.6 2.9
        880 - 1000 2.6 17.8 - 20.0 3.0

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The interpretation of the values obtained is :

RSI < 6 boiler scale formation

RSI 6 - 7 neutral water
RSI > 7 corrosive water

A more detailed interpretation follows below :

RSI Tendency of the water Action

RSI < 3.9 Very high scale formation Water cannot be used

4.0 < RSI < 5.5 High boiler scale formation Regular control and descaling operation necessary

5.6 < RSI < 6.2 Slight boiler scale formation Water treatment not necessary
Occasional inspection recommended

6.3 < RSI < 6.8 Neutral water Water treatment not necessary
Occasional inspection recommended

6.9 < RSI < 7.5 Slight corrosion at higher temperature Water treatment not necessary
Occasional inspection recommended

7.6 < RSI < 9.0 Strong corrosion Regular control necessary, use of corrosion inhibitor
recommended

9.1 < RSI < 11 Very strong corrosion Regular control necessary, use of corrosion inhibitor required

RSI > 11 Very strong corrosion in complete

water system Water should not be used

This table indicates that distilled or demineralised water should In a closed system, the following limits apply: TDS < 3000
never be used, as their RSI is > 11. mg/l (< 3800 µS/cm)

The RSI only indicates the equilibrium of scaling – descaling. For an open system, the following limits apply: TDS < 450
A cooling water showing good RSI conditions can still be mg/l (< 580 µS/cm)
unsuitable due to other factors.
Chlorides (Cl-)
From the table above, the RSI index should be between 5.6
and 7.5, otherwise contact a specialist. Chloride ions will create pitting corrosion on stainless steel.
Their concentration should be limited :
pH
Closed cooling system : Chlorides < 500 ppm
The effect of pH is already calculated in the Rysnar index, but Open cooling system : Chlorides < 150 ppm
the pH itself has some additional limitations : 6.8 < pH
However, if the water is scaling, lower limits should be used.
Total dissolved solids (TDS) (See The Rysnar stability index (RSI)).

This is the sum of all ions in the water. It can be derived from Free chlorine (Cl )
2
the dry residue after evaporation (but not including suspended
solids), or it can be estimated from the electrical conductivity. Continuously, a level of 0.5 ppm should not be exceeded.
For shock treatments, a maximum limit of 2 ppm for maximum
30 minutes/day applies.

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Sulphates (SO4--) 3 OPERATING INSTRUCTIONS

Closed cooling system : Sulphates < 400 ppm
Open cooling system : Sulphates < 150 ppm
3.1 Initial start-up

Carbonate hardness
3.1.1 Safety precautions
Closed cooling system : 50-1000 ppm CaCO
Open cooling system : 50-500 ppm CaCO
3 The operator must apply all related safety precautions including
3 those mentioned in this book.
HCO - / SO 2-
should be >1
3 4

Ammonia
3.1.2 User manual
< 0.5 ppm
Read the "User manual for Elektronikon regulator " to
Copper familiarize yourself with all regulator functions.

< 1 ppm

Iron and Manganese 3.1.3 Outdoor/altitude operation

< 1 ppm If the compressor is installed outdoors or if the air inlet

temperature can be below 0 degrees Celsius, precautions must
Organics be taken. In this case, and also if operating at high altitude,
consult Atlas Copco.
No algae.
No oil.

Suspended solids 3.1.4 Moving/lifting

Non-soluble particles, size < 1mm. The compressor can be moved by a lift truck using the slots in
< 10 ppm the frame. 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 will be lifted
perpendicularly. Lift smoothly and avoid twisting.

3.1.5 Initial start-up

1. Consult section 2 for the electric cable size, installation

Footnotes chapter 2
1) To be provided by the customer.
2) GA Full-feature (provided with an integrated dryer) have two
condensate traps and two drain valves. Compressors without dryer
have one trap and one valve.
3) Available as an option.
4) Split up in 2 cables connected to line and delta contactor.
5) Split up in 2x 2 cables connected to line and delta contactor.
6) For PVC cable (70 degrees Celsius), at ambient of 40 degrees
Celsius.
7) For PVC cable (90 degrees Celsius), at ambient of 40 degrees
Celsius.
proposals and dimension drawings.
2. Read the "User manual for Elektronikon® regulator" to
familiarize yourself with all regulator functions.
3. A sticker dealing in short with the operation instructions is
delivered with the literature set. Affix the sticker next to
the control panel.
4. Stick labels near the control panel warning the operator that:
- the compressor may automatically restart after voltage
failure
- the compressor is automatically started and stopped
- the compressor may be remotely controlled
5. A number of VCI (Volatile Corrosion Inhibitor) plates are
provided inside the bodywork to protect the compressor
against corrosion. Remove the plates.

2920 1475 00 31

50542F
1 2
1 Bush (to be removed)
2 Vibration damper
Fig. 3.1 Transport fixations, gear casing of GA/GA W 90/160
50839F
1
1 Bush (to be removed)
2 Vibration damper
Fig. 3.3 Transport fixations, gear casing of GA/GA W 200/315
6. The gear casing supports, motor support and air receiver
supports are secured to the frame, immobilizing the vibration
dampers during transport.
For GA/GA W 90 up to GA/GA W 160, remove bushes (1-
Fig. 3.1) from both gear casing supports as well as bushes
(1-Fig. 3.2) from the motor support. Also remove the bushes
(or transport bolts) fitted next to the air receiver supports.
For GA/GA W 200 up to GA/GA W 315, remove bushes
(1-Fig. 3.3) from both gear casing supports as well as bushes
(1-Fig. 3.4) from the motor support. Also remove the bushes
fitted next to the air receiver supports.
7. Check the wires at transformer (T1-Fig. 1.13) for correct
32
Instruction book
50543F
1 2 1
1 Bush (to be removed)
2 Vibration damper
Fig. 3.2 Transport fixations, drive motor of GA/GA W 90/160
50843F
1 2
1 Bushes (to be removed)
2 Vibration damper
Fig. 3.4 Transport fixations, drive motor of GA/GA W 200/315
connection, the settings of overload relay (F21) and circuit
breakers (Q25/26/40/41) 1) 7), and that overload relay (F21)
is set for automatic resetting. See section 7.4.
8. Remove filler plugs (6-Figs. 1.5/1.6). Pour approx. 1 l of
oil into the compressor elements. Reinstall the plugs.
9. Close drain valves (1 and 2-Fig. 3.7). 2)
10. For GA W, check that the cooling water drain valves 6) in
the inlet and outlet lines are closed and that the water shut-
off valves 6) are open. Open the water regulating valve (4-
Fig. 3.10) and check for water flow.
11. Check that the compressor is filled with oil: the pointer of
oil level indicator (4-Fig. 3.11) should be in the green range.
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Instruction book

12. For GA Full-feature, check that valve (2-Figs. 1.3/3.6) is

closed and that valves (1 and 3-Figs. 1.3/3.6) are open. 4 5 1 6 7 2 3
13. For compressors provided with an OSD oil/water separator
5): fill the vessel with water to the level of the water outlet
and re-install the cover.
14. Switch on the voltage. Start the compressor and stop it
immediately. Check the rotation direction of the drive motor
(M1-Figs. 1.1 and 1.2) while the motor is coasting to a stop.
If the rotation direction is wrong, switch off the voltage and
reverse two incoming electric lines.
The correct direction of rotation is indicated for the drive
motor by arrow (9-Figs. 1.5/1.6) on the gear casing and for
the fan motors by arrows (15-Fig. 1.2) on the motor
housings.
50845F

3.2 Before starting 1 By-pass valve

2 By-pass valve
Attention 3 By-pass valve
- The operator must apply all relevant safety precautions, 4 Voltage supply inlet
including those mentioned in this instruction book. 5 Air inlet
- In case the water system was drained (see section 3.7), close 6 Data plate
the drain valves. 7 Location of air outlet valve

1. Switch on the voltage. Voltage on LED (6-Fig. 3.8) lights
up.
2. Close condensate drain valves (1 and 2-Fig. 3.7). 2)
3. Open air outlet valve (3-Fig. 3.5/7-Fig. 3.6).
4. Check oil level indicator (4-Fig. 3.11): the pointer should
be in the green or orange range 4).
Fig. 3.6 Air inlet/outlet and dryer by-pass valves, GA200/315
5. For GA Full-feature (provided with an integrated dryer),
check that valve (2-Fig. 1.3/3.6) is closed and that valves
(1 and 3-Fig. 1.3/3.6) are open.
6. On GA W open the water shut-off valves 6) and regulating
valve (4-Fig. 3.10).

1 2
51542F
3
1 2
3
3
5
4 5 6

6 1 2 4

1 Manual condensate drain

2 Manual condensate drain (Full-feature only)
50844F
3 Automatic condensate drain for optional oil/water
separator (type OSD)
1 Voltage supply inlet 4 Automatic condensate drain
2 Data plate 5 Automatic condensate drain (Full-feature only)
3 Location of air outlet valve 6 Automatic drain for optional DD filter

Fig. 3.5 Air outlet, GA90/160 Fig. 3.7 Location of condensate outlets

2920 1475 00 33
 Instruction book

3.3 Starting

1. Press start button (1-Fig. 3.8). The compressor starts

running in unloaded condition. Automatic operation LED
(8) lights up.
2. Approx. 10 seconds later (programmable), the compressor
starts running loaded. The message on display (2) changes
from <<Automatically unloaded>> to <<Automatically
loaded>>.
On GA W also:
3. Regulate the cooling water flow (using valve 4-Fig. 3.10)
with the compressor running loaded. Adjust the water
flow to obtain the most suitable air temperature at the outlet
of the compressor elements, i.e. between 2 and approx. 7
degrees Celsius above the relevant temperature in Fig. 3.9.
Fig. 3.8 Control panel
Attention
- For optimum operation, the cooling water outlet temperature
must never exceed the value specified in section 7.5.
- Consult Atlas Copco if condensate should be formed during
frequent unloading periods.

3.4 During operation

1. When automatic operation LED (8-Fig. 3.8) is alight,
starting and stopping of the motor is controlled
automatically.
2. Check the readings on display (2-Fig. 3.8). See section
3.5.
3. To unload the compressor manually, press key <<Unload>>
(5-Fig. 3.8) 8). To put the compressor back into automatic
operation, press key <<Load>> (5) 8).
4. For GA Full-feature provided with an OSD oil/water
separator: regularly check that the vessel is filled; if
necessary, gently top up with water to the level of the water
outlet and re-install the cover.
Important
- If the compressor is stopped, it may start automatically. See
also section 1.3.1.
3.5 Checking the display (2-Fig. 3.8)
1. Regularly check the display for readings and messages.
Normally, the main screen (Fig. 1.12) is shown, indicating
the compressor outlet pressure, the status of the compressor
and the functions of the keys below the display.
2. Always check the display and remedy the trouble if alarm
LED (7) is alight or blinks. See section 1.3. Also consult
the "User manual for Elektronikon regulator", section
"Submenu STATUS DATA".
3. The display 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. Consult your Atlas
Copco Customer Centre. See also section 4.1.
Warning Before carrying out any maintenance, repair or
adjustment, stop the compressor, press emergency
stop button (S2-Fig. 3.8) and switch off the
voltage. Close the air outlet valve and open the
manual condensate drain valve(s). 3)
4. Regularly check the actual compressor status by pressing
the ¯ key from the main screen.
3.6 Manual unloading/loading (Fig. 3.8) 8)
Normally, the compressor runs in automatic operation, i.e. the
electronic regulator loads, unloads, stops and restarts the
compressor automatically. LED (8) is then alight.
Manually unloading
Press key <<Unload>> (5). LED (8) goes out. The message
<<Manually Unloaded>> appears on the display. The
compressor remains running unloaded unless it is loaded again
manually.
Manually loading
Press key <<Load>> (5). LED (8) lights up. The command
<<Load>> does not force the compressor in loaded condition,
but it will switch the compressor to automatic operation again:
the compressor will be loaded if the air net pressure drops below
the programmed level.
3.7 Stopping
1. Press stop button (9-Fig. 3.8). LED (8) goes out. The
message <<Programmed stop>> appears. The compressor
runs unloaded for 30 seconds and then stops.

34 2920 1475 00
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SEE ALSO ADDENDUM

Example: ambient temperature 20 degrees Celsius, relative humidity 100 % and working pressure 10 bar(e). The minimum
allowable temperature at the outlet of the compressor elements is 68 degrees Celsius. Regulate the cooling water flow to obtain
a temperature between 70 and approx. 75 degrees Celsius at the outlet of the compressor elements.

Fig. 3.9 Minimum allowable air temperature at outlet of compressor elements (for water-cooled compressors)

2. To stop the compressor in case of emergency, press button

(S2-Fig. 3.8). Alarm LED (7) blinks. After remedying the
fault, unlock the button by pulling it out.
3. Close air outlet valve (3-Fig. 3.5/7-Fig. 3.6).
4. Open condensate drain valves (1 and 2-Fig. 3.7). 2)
5. On GA W, close the water shut-off valves 6).
6. On GA W, if the compressor is installed in a room where
freezing temperatures are expected, drain the cooling
system by opening the drain valves in the water inlet and
outlet pipes (customer's installation).
7. Switch off the voltage.

2 4

1 Water outlet
1
2 Water inlet
3 Combined oil and air coolers
4 Regulating valve, water flow

Fig. 3.10 Water system of GA W (typical example) 50847F

2920 1475 00 35
 Instruction book

Important
- After pressing stop button (9), the compressor will run
unloaded for 30 seconds. The compressor stops after this
period. A start command during this period is ignored.
- After stopping, the compressor is prevented from restarting
within a programmable time (20 seconds). A start command
given during this minimum stop time will be memorized;
automatic operation LED (8) lights up. The compressor
will start when the minimum stop time has run out.

3.8 Taking out of operation

At the end of the service life of the compressor, proceed as

follows:

1. Stop the compressor and close the air outlet valve. 50544F
2. Switch off the voltage and disconnect the compressor from 1 2 3 4 5 6
the mains.
3. Depressurize the compressor by opening valves (1 and 2-
Fig. 3.7) 2) 3) and loosening plug (5-Fig. 3.11) one turn.
4. Shut off and depressurize the part of the air net which is 1 Oil filters
connected to the outlet valve. Disconnect the compressor 2 Air receiver
air outlet pipe from the air net. 3 Oil separator element
5. Drain the water, oil and condensate circuits. 4 Oil level sight-glass
6. Disconnect the compressor condensate piping from the 5 Oil filler plug
condensate drain net. 6 Oil drain plug
7. Disconnect the cooling water pipes from the compressor.
Fig. 3.11 Air receiver

Footnotes chapter 3

1) GA90 and GA110 have one fan motor and circuit breaker, GA132 up to GA315 have two fan motors and circuit breakers.
2) GA Full-feature (provided with an integrated dryer) have two condensate traps and two drain valves. Compressors without dryer have
one trap and one valve.
3) On compressors with optional OSD separator, a valve is fitted underneath the condensate trap. Close the valve after repairing.
4) If the compressor has only just stopped, wait one minute before checking the level.
5) Available as an option.
6) Customer’s installation.
7) GA W are equipped with a ventilation fan in the roof. Check that it withdraws heat from the bodywork.
8) If the <<Load>> or <<Unload>> function is not indicated on the bottom line of display (2-Fig. 3.8), press key <<Menu>> (5) until
function <<Main Screen>> appears above key (F1), then press key <<Main Screen>>.

36 2920 1475 00
Instruction book

4 MAINTENANCE
Warning Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop button (S2-
Fig. 3.8) and switch off the voltage. Close the air outlet valve and open the manual condensate drain valve(s). 1)

Take precautions to avoid an accidental restart. Apply all relevant safety precautions, including those mentioned
in this book.

4.1 Preventive maintenance schedule for the compressor 2)

4.1.1 Regular service operations

To ensure safe operation and long service life carry out following operations at the interval (period or running hours) which
comes first. The "longer interval" checks must also include the "shorter interval" checks.

The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the environmental and working
conditions of the compressor.

Period Running hours Operation

Daily 8 Check readings on display

Daily 8 Check that condensate is discharged during loading

Daily -- Check oil level. Before starting, the level should be in the middle of the sight-glass

3-monthly -- Clean compressor

3-monthly -- Check for possible leaks

3-monthly 500 Check coolers; clean if necessary

4.1.2 Service kits 4.1.4 Service plan

Atlas Copco Customer Centres will be glad to provide you with
a wide range of service kits. Service kits comprise all parts
needed for servicing components and offer the benefits of
genuine Atlas Copco parts while keeping the maintenance
budget low. See also section 4.7.
4.1.3 Service agreements
A number of service operations are grouped (called Level A,
Level B, Level C, ...). Each level stands for a number of service
actions to be carried out at the time intervals programmed in
the Elektronikon regulator.
When reaching a level, a message will appear on the screen.
After carrying out all service actions, the interval timers are to
be reset using the key "Reset" in menu "Service". Consult your
Atlas Copco Customer Centre.

Atlas Copco Customer Centres have a range of service

agreements to suit your needs: 4.2 Motor greasing
- An Inspection plan NOT TO BE USED,
4.2.1 Fan motors on GA
- A Preventive maintenance plan
- A Total responsibility plan GA132 up to GA315 have two fan motors (M25/26-Fig. 1.6).
GA90 and GA110 have one fan motor (M25-Fig. 1.5). The
Contact your Customer Centre to agree on a tailor-made service SEE ADDENDUM
bearings of the fan motor(s) are greased for life. Contact your
agreement. It will ensure optimum operational efficiency, Customer Centre for the replacement interval of the motor
minimize downtime and reduce the total life cycle costs. bearings.

2920 1475 00 37
 Instruction book

4.2.2 Drive motor (M1-Figs. 1.1/1.2) 4.4 Oil change

NOT TO BE USED,
Contact your Customer Centre for the recommended grease
type, the greasing quantity and interval for the motor bearings.
Important
SEE ADDENDUM
Never mix greases of different brands or types.
4.3 Oil specifications
It is strongly recommended to use following oils:
Roto-Inject Fluid is a high-quality lubricant ensuring optimum
lubrication for a service life of up to 4000 running hours.
HD Roto-FluidPlus is a very cost-effective oil ensuring optimum
lubrication for a service life of up to 8000 running hours.
Important
Never mix oils of different brands or types.
1
1. Run the compressor until warm. Stop the compressor and
switch off the voltage. Wait a few minutes and depressurize
by unscrewing plug (5-Fig. 3.11) only one turn to permit
any pressure in the system to escape.
2. On GA, loosen vent plugs (5-Fig. 1.3/2-Fig. 1.4) on top of
the coolers.
3. Drain the oil by removing the drain plugs. Plugs are
provided on the air receiver (6-Fig. 3.11), oil stop valves
(3-Fig. 4.1), check valves (6-Fig. 4.1), oil coolers (on GA
only) (14 and 15-Fig. 1.3) and gearbox (2-Fig. 4.1). GA W
are additionally provided with a plug in the oil flexible
between the oil filter housing and the oil coolers. Tighten
the plugs after draining.
4. Remove filler plug (5-Fig. 3.11). Fill the air receiver with
oil until the level reaches the filler opening. Reinstall and
tighten plug (5-Fig. 3.11). Tighten the vent plugs (5-Fig.
1.3/2-Fig. 1.4).
5. Run the compressor loaded for a few minutes to allow the
oil cooler by-pass valve to open. Stop the compressor and
wait a few minutes.
6. Depressurize the system by unscrewing plug (5-Fig. 3.11)
only one turn to permit any pressure in the system to escape.
Remove the plug. Fill the air receiver with oil until the
level reaches the filler opening. Tighten plug (5-Fig. 3.11).
7. After carrying out the service actions of the related service
plan, the service warning must be reset. See also section
4.1.

8
4.5 Oil filter change

1. Stop the compressor, switch off the voltage and depressurize

by unscrewing plug (5-Fig. 3.11) only one turn to permit
any pressure in the system to escape.
2. Provide an oil pan to avoid possible oil spilling. Remove
oil filters (1-Fig. 3.11).
3. Clean the filter seats on the manifold. Oil the gaskets of the
new filters and screw them into place until the gaskets
contact their seats, then tighten by hand.
4. Tighten filler plug (5-Fig. 3.11).
50545F 5. After carrying out the maintenance operations of the related
7 6 5 4 3 2 service plan, the service warning must be reset. See also
section 4.1.

1 Unloader 4.6 Storage after installation

2 Oil drain plug
3 Oil drain plug Run the compressor, e.g. twice a week, until warm. Load and
4 Oil stop valve unload the compressor a few times to operate the components
5 Compressor element of the unloading/loading system.
6 Oil drain plug
7 Check valve If the compressor is going to be stored without running from
8 Air receiver time to time, protective measures must be taken. Consult Atlas
Copco.
Fig. 4.1 Compressor element

38 2920 1475 00
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4.7 Service kits 5 ADJUSTMENTS AND SERVICING

Service kits
PROCEDURES
Service kits comprise all parts needed for servicing components
and offer the benefits of genuine Atlas Copco parts while 5.1 Air filters (17-Fig. 1.2/20-Fig. 1.3)
keeping the maintenance budget low. All service kits are
mentioned in the relevant Parts Lists. 1. Stop the compressor and switch off the voltage. Remove
the filters.
Atlas Copco Roto-injectfluid 2. Fit the new filters.
Atlas Copco Roto-injectfluid (see section 4.3) can be ordered 3. After carrying out the service actions of the related service
in following quantities: plan, the service warning must be reset. See also section
4.1.
Quantity Ordering number
20-litre can 2901 0522 00
209-litre drum 2901 0045 01

5.2 Coolers

Keep the coolers clean to maintain the cooling efficiency.

Stop the compressor and switch off the voltage. On GA,

unscrew bolts (5-Fig. 1.5/20-Fig. 1.6) and rotate the fans away
from the cooler block. Blow air from the compressor elements
compartment through the coolers towards the drive motor
compartment. Remove any dirt. Reposition and fix the fans.
Make sure that the fans rotate freely.

Note
If it should be necessary to wash the coolers with a cleansing
agent, consult Atlas Copco.

On GA W, consult Atlas Copco for cleaning.

5.3 Safety valve (17-Fig. 1.6)

Operating
Operate the safety valve by unscrewing the cap one or two turns
and retightening it.

Testing
The valve can be tested on a separate compressed air line. If
the valve does not open at the pressure specified in section 7.3,
consult Atlas Copco.

Warning Never run the compressor without safety valves.

No adjustments are allowed.

Footnotes chapter 4 5.4 Oil/water separators (Fig. 5.1)

1) On compressors with optional OSD separator, a valve is fitted As an option, an oil/water separation system can be integrated
underneath the condensate trap. Close the valve after repairing.
inside the bodywork to separate the major part of the oil from
2) Use only authorized parts. Any damage or malfunction caused
by the use of unauthorized parts is not covered by Warranty or
the condensate. The condensate meets the requirements of the
Product Liability. environmental codes.

2920 1475 00 39
 Instruction book

2 3 6 PROBLEM SOLVING
1 1
Warning Before carrying out any maintenance, repair or
adjustment, stop the compressor, press emergency
2 7 stop button (S2-Fig. 3.8) and switch off the
3 voltage. Close the air outlet valve and open the
manual condensate drain valve(s). 1)
4
4
5 Take precautions to avoid an accidental restart.
5 8 Apply all relevant safety precautions, including
those mentioned in this book.
6
Faults and suggested remedies
51446F
6 1 A shut-down warning message appears on the display
LED (7-Fig. 3.8) will light up indicating that the temperature
at the outlet of the compressor elements is too high. See
1 Water outlet 5 Filter below. The message disappears as soon as the cause of the
2 Oil outlet 6 Oil collector trouble is remedied
3 Water vessel 7 Pre-filter
4 Condensate inlet 8 Pressure gauge 2 Unit is shut down
LED (7-Fig. 3.8) will blink indicating either that the outlet
Fig. 5.1 OSD90/315 oil separators (option) temperature is too high (see below) or that the motor
overload relay has tripped. Consult the "User manual for
Elektronikon regulator" to remedy the trouble and to reset
the message (section "Submenu STATUS DATA")

3 Condensate is not discharged from condensate trap(s)

during loading
a Discharge pipe of condensate trap clogged
a Check and correct as necessary
b Float valve of condensate trap(s) malfunctioning
b Remove float valve assembly, clean and check
The system includes an OSD315 oil/water separator (shown at
the left) connected to the condensate trap downstream of the 5 Compressor air delivery or pressure below normal
air cooler. The condensate is led from the condensate trap a Air consumption exceeds air delivery of compressor
through inlet (4) and filter (5) towards water vessel (3) where a Check equipment connected
the oil rises due to the difference in specific mass. The water b Choked air filters
flows through condensate outlet (1) to the outside of the b Replace filters
bodywork. The oil flows into collector (6), which must be c Air leakage
emptied regularly. c Check and correct

For Full-feature compressors, the system also includes an
OSD90 (shown at the right) connected to the dryer condensate
trap. OSD90 are additionally provided with a pre-filter (7)
and a pressure gauge (8).
Servicing procedure
1. Stop the compressor, press emergency stop button (S2-Fig.
3.8) and switch off the voltage.
2. Close the outlet valve and open the valve underneath the
air cooler condensate trap.
3. Oil the gaskets of the new filters, fill the filters with water
and fit them.
4. On OSD90, unscrew the pre-filter housing, fit a new pre-
filter and fit the housing using a new O-ring.
5. Inspect the strainer/restrictors at the inlet of the separator
vessels, clean and reinstall them. Close the valve underneath
the condensate trap.
6 Compressor element outlet temperature or delivery air
temperature above normal
a Insufficient cooling air
a Check for cooling air restriction. Improve ventilation of
compressor room. Avoid recirculation of cooling air
b On GA W, cooling water temperature too high or flow too
low
b See section 7.5. Increase water flow and check temperature
Footnote chapter 6
1) On compressors with optional OSD separator, a valve is fitted
underneath the condensate trap. Close the valve after repairing.

40 2920 1475 00
Instruction book

c Oil level too low

c Check and correct as necessary
d Oil coolers clogged
d Consult Atlas Copco
e Air cooler clogged
e Consult Atlas Copco
f On GA W, restriction in cooling water system due to dirt or
formation of scale
f Consult Atlas Copco

7 If an oil/water separator (OSD) is provided: turbulence

in separator vessel
a Air leakage through condensate flexible towards vessel
a Remove float valve assembly, clean and check

7 PRINCIPAL DATA
7.1 Readings on display

Normally the main screen (Fig. 1.12) is shown, indicating the actual air outlet pressure and the actual compressor status.
The ¯ key allows the operator to call up other information about the condition of the compressor (see section 3.5).

The readings below are valid when operating at reference conditions (section 7.5.1):

Maximum unloading pressure . . . . . . . . . . . . . . . . . . . . . . . . . See section 7.5

Compressor outlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . Depends on programmed unloading and loading pressures
Pressure drop over air filters . . . . . . . . . . . . . . . . . . . . . . . . . . Below 0.050 bar
Pressure difference over oil separator . . . . . . . . . . . . . . . . . . . Below 0.8 bar
Oil injection pressure at the compressor elements . . . . . . . . . . Depends on programmed unloading and loading pressures
Compressor outlet temperature:
-for GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 29°C
-for GA Full-feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 26°C
-for GA W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 25°C
-for GA W Full-feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. 22°C
Compressor element outlet temperature . . . . . . . . . . . . . . . . . . Between 55 and 100°C
Cooling air inlet temperature (on GA) . . . . . . . . . . . . . . . . . . Below 40°C 8)
Cooling water temperature (on GA W) . . . . . . . . . . . . . . . . . . Below 50°C
Pressure dewpoint (GA Full-feature) . . . . . . . . . . . . . . . . . . . Approx. 3°C 6)
Pressure drop over DD filter (option) . . . . . . . . . . . . . . . . . . . Below 0.35 bar

7.2 Programmable settings

NOT
A number TO BE parameters
of regulation USED,(e.g.SEE
loading ADDENDUM
and unloading pressures) and protection settings (e.g. shut-down level for the
compressor element temperature) are programmable. The "User manual for Elektronikon regulator" deals elaborately with this
matter (section "Submenu MODIFY PARAMETERS").

7.3 Settings of safety valve

11 bar(e) for 7.5 bar and 8.5 bar CE version

15 bar(e) for all other versions

Important
Some compressors with a specific approval may have valves with other settings. Always consult the data stamped on the valve
or consult Atlas Copco.

2920 1475 00 41
 Instruction book

7.4 Settings of overload relay, circuit breakers and fuses

7.4.1 Motor overload relay and fuses for 50 Hz compressors

GA / GA W Motor type, ABB Supply Max. setting of Max. fuse ratings

voltage overload relay F21 Class gL/gG Class gL/gG
(V) (A) Type 2 2) (A) Type 1 1) (A)

90 M2CA 280SMB-4 230 197 2x (3x250) 3x400

90 M2CA 280SMB-4 400 110 3x224 3x400
90 M2CA 280SMB-4 500 87 3x200 3x400
110 M2CA 280MLB-4 230 229 2x (3x300) 3x500
110 M2CA 280MLB-4 400 134 3x250 3x400
110 M2CA 280MLB-4 500 107 3x224 3x400
132 M2CA 315SMA-4 230 270 2x (3x400) 3x500
132 M2CA 315SMA-4 400 161 2x (3x250) 3x400
132 M2CA 315SMA-4 500 128 3x250 3x400
160 M2CA 315MB-4 230 345 2x (3x500) 3x800
160 M2CA 315MB-4 400 191 2x (3x250) 3x400
160 M2CA 315MB-4 500 154 2x (3x200) 3x400
200 M2CA 315LA-4 400 233 2x (3x400) 3x500
200 M2CA 315LA-4 500 186 2x (3x224) 3x355
250 M2CA 315LC-4 400 289 2x (3x315) 2x (3x500)
250 M2CA 315LC-4 500 234 2x (3x400) 3x500

7.4.2 Motor overload relay and fuses for 60 Hz IEC compressors

GA / GA W Motor type, ABB Supply Max. setting of Max. fuse ratings

voltage overload relay F21 Class gL/gG Class gL/gG
(V) (A) Type 2 2) (A) Type 1 1) (A)

90 M2CA 280MB-4 220-230 208 2x (3x250) 3x400

90 M2CA 280MB-4 380 122 3x224 3x400
90 M2CA 280MB-4 440-460 104 3x200 3x400
110 M2CA 315SMA-4 220-230 257 2x (3x300) 3x500
110 M2CA 315SMA-4 380 149 3x250 3x400
110 M2CA 315SMA-4 440-460 129 3x224 3x400
160 M2CA 315 MB-4 380 195 2x (3x250) 3x400
160 M2CA 315 MB-4 440-460 169 3x250 3x400
200 M2CA 315 LA-4 380 242 2x (3x400) 3x500
200 M2CA 315 LA-4 440-460 204 2x (3x400) 3x500
250 M2CA 315 LB-4 380 284 2x (3x400) 2x (3x500)
250 M2CA 315 LB-4 440-460 246 2x (3x400) 3x500
315 M2CA 315 LC-4 380 319 2x (3x500) 3x800
315 M2CA 315 LC-4 440-460 278 2x (3x400) 2x (3x500)

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7.4.3 Motor overload relay and fuses for 60 Hz CSA/UL compressors

With Siemens motor

GA / GA W Motor type, Siemens Supply Max. setting of Max. fuse ratings

voltage overload relay F21 CSA HRC UL Class K5
(V) (A) (A) (A)

90 1LA6 283-4 440-460 105 3x200 3x175

90 1LA6 283-4 575 80 3x200 3x175
110 1LA6 288-4 440-460 130 2x (3x175) 2x (3x175)
110 1LA6 288-4 575 100 3x200 3x175
160 1LA6 316-4 440-460 166 2x (3x200) 2x (3x200)
160 1LA6 316-4 575 128 2x (3x175) 2x (3x175)
200 1LA6 317-4 440-460 208 2x (3x300) 2x (3x300)
200 1LA6 317-4 575 159 2x (3x200) 2x (3x250)
250 1LA8 315-4 440-460 242 2x (3x300) 2x (3x300)
250 1LA8 315-4 575 184 2x (3x300) 2x (3x300)
315 1LA8 317-4 440-460 269 2x (3x300) 2x (3x300)
315 1LA8 317-4 575 206 2x (3x300) 2x (3x300)

With WEG motor

GA / GA W Motor type, Siemens Supply Max. setting of Max. fuse ratings

voltage overload relay F21 CSA HRC UL Class K5
(V) (A) (A) (A)

90 W21 125/4 444/5TSD 440-460 100 3x200 3x175

90 W21 125/4 444/5TSD 575 76 3x200 3x175
110 W21 150/4 444/5TSD 440-460 121 2x (3x175) 2x (3x175)
110 W21 150/4 444/5TSD 575 93 3x200 3x175
160 W21 200/4 504/5TSD 440-460 167 2x (3x200) 2x (3x200)
160 W21 200/4 504/5TSD 575 128 2x (3x175) 2x (3x175)
200 W21 250/4 449TCHZ 440-460 215 2x (3x300) 2x (3x300)
200 W21 250/4 449TCHZ 575 165 2x (3x200) 2x (3x250)
250 W21 300/4 5008TD 440-460 245 2x (3x300) 2x (3x300)
250 W21 300/4 5008TD 575 187 2x (3x300) 2x (3x300)
315 W21 350/4 5008TD 440-460 274 2x (3x300) 2x (3x300)
315 W21 350/4 5008TD 575 209 2x (3x300) 2x (3x300)

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7.4.4 Fan motor circuit breakers

Fan type Frequency Supply voltage Circuit breaker Max. setting of

(Hz) (V) circuit breaker (A)

Cooling fan for air and oil coolers (GA90/160) 50 230 Q25/26 12.4
Cooling fan for air and oil coolers (GA90/160) 50 400 Q25/26 7.2
Cooling fan for air and oil coolers (GA90/160) 50 500 Q25/26 5.7
Cooling fan for air and oil coolers (GA200/250) 50 230 Q25/26 17.1
Cooling fan for air and oil coolers (GA200/250) 50 400 Q25/26 9.9
Cooling fan for air and oil coolers (GA200/250) 50 500 Q25/26 7.7
Cooling fan for air and oil coolers (GA90/160) 60 220-230 Q25/26 14.3
Cooling fan for air and oil coolers (GA90/160) 60 380 Q25/26 8.6
Cooling fan for air and oil coolers (GA90/160) 60 440-460 Q25/26 7.2
Cooling fan for air and oil coolers (GA90/160) 60 575 Q25/26 5.7
Cooling fan for air and oil coolers (GA200/315) 60 220-230 Q25/26 20.2
Cooling fan for air and oil coolers (GA200/315) 60 380 Q25/26 11.7
Cooling fan for air and oil coolers (GA200/315) 60 440-460 Q25/26 9.9
Cooling fan for air and oil coolers (GA200/315) 60 575 Q25/26 7.7
Bodywork ventilation fan (GA90/250 W) 50 230 Q25 2.5
Bodywork ventilation fan (GA90/250 W) 50 400 Q25 1.4
Bodywork ventilation fan (GA90/250 W) 50 500 Q25 1.1
Bodywork ventilation fan (GA90/315 W) 60 220-230 Q25 2.1
Bodywork ventilation fan (GA90/315 W) 60 380 Q25 1.4
Bodywork ventilation fan (GA90/315 W) 60 440-460 Q25 1.1
Bodywork ventilation fan (GA90/315 W) 60 575 Q25 1.1

7.4.5 Circuit breakers for dryer motor (GA Full-feature)

Type Frequency Supply voltage Max. setting of circuit breaker Q40

(Hz) (V) (A)

GA90/110 dryer motor 50 230 19

GA90/110 dryer motor 50 400 11
GA90/110 dryer motor 50 500 9
GA132/160 dryer motor 50 230 28
GA132/160 dryer motor 50 400 16
GA132/160 dryer motor 50 500 13
GA200/250 dryer motor 50 400 27
GA200/250 dryer motor 50 500 22
GA90/110 dryer motor 60 220-230 25
GA90/110 dryer motor 60 380 15
GA90/110 dryer motor 60 440-460 13
GA90/110 dryer motor 60 575 10
GA160 dryer motor 60 380 22
GA160 dryer motor 60 440-460 19
GA160 dryer motor 60 575 15
GA200/315 dryer motor 60 380 38
GA200/315 dryer motor 60 440-460 33
GA200/315 dryer motor 60 575 25

44 2920 1475 00
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7.4.6 Circuit breakers for dryer cooling fan motor (GA Full-feature)

Type Frequency Supply voltage Max. setting of circuit breaker Q41

(Hz) (V) (A)

GA90/160 dryer cooling fan motor 50 230 2.5

GA90/160 dryer cooling fan motor 50 400 1.4
GA90/160 dryer cooling fan motor 50 500 1.1

GA200/250 dryer cooling fan motor 50 400 6.2

GA200/250 dryer cooling fan motor 50 500 5.1

GA90/160 dryer cooling fan motor 60 220-230 3.6

GA90/160 dryer cooling fan motor 60 380 2.2
GA90/160 dryer cooling fan motor 60 440-460 1.9
GA90/160 dryer cooling fan motor 60 575 1.4

GA200/315 dryer cooling fan motor 60 380 8.8

GA200/315 dryer cooling fan motor 60 440-460 7.7
GA200/315 dryer cooling fan motor 60 575 5.9

7.4.7 Circuit breaker for control circuit (Q1)

Type Frequency Supply Transformer Transformer Transformer Transformer

voltage T1 250 VA T1 400 VA T1 630 VA T1 800 VA
(Hz) (V) (A) (A) (A) (A)

GA90/160 50 230 1.5 2.4 3.6 4.5

GA90/160 50 400 0.9 1.4 2.2 2.8
GA90/160 50 500 0.7 1.1 1.8 2.2

GA200/250 50 400 0.9 1.4 2.2 2.8

GA200/250 50 500 0.7 1.1 1.8 2.2

GA90/160 60 220-230 1.6 2.4 3.7 4.7

GA90/160 60 380 0.9 1.4 2.2 2.8
GA90/160 60 440-460 0.8 1.2 1.9 2.4
GA90/160 60 575 0.6 0.92 1.4 1.8

GA200/315 60 380 0.9 1.4 2.2 2.8

GA200/315 60 440-460 0.8 1.2 1.9 2.4
GA200/315 60 575 0.6 0.92 1.4 1.8

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7.5 Compressor specifications

NOT TO BE USED, SEE ADDENDUM
7.5.1 Reference conditions

Absolute inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(a) 1

Relative air humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . % 0
Air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 20
Nominal effective working pressure . . . . . . . . . . . . . . . . . . . . bar(e) See sections below
Cooling water inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . °C 20

7.5.2 Limitations

Maximum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . °C 40 8)

Minimum air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . °C 0
Maximum effective working pressure . . . . . . . . . . . . . . . . . . . bar(e) See sections below
Maximum cooling water inlet temperature . . . . . . . . . . . . . . . °C 40
Maximum cooling water outlet temperature (open systems) . . °C 50
Maximum cooling water outlet temperature (recirculating
systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 60
Maximum cooling water inlet pressure . . . . . . . . . . . . . . . . . . bar(e) 10

7.5.3 Specific data of 7.5 bar - 50 Hz compressors 3)

Compressor type 90 110 132 160 200 250

Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 7.5 7.5 7.5 7.5 7.5 7.5
Maximum working pressure, Full-feature . . . . . . . . bar(e) 7.25 7.25 7.25 7.25 7.25 7.25
Maximum working pressure, Full-feature
with DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.9 6.9 6.9 6.9 6.9 6.9
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 7 7 7 7 7 7
Nominal working pressure, Full-feature
with DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.9 6.9 6.9 6.9 6.9 6.9
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1490 1490 1490 1490 1490 1490
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . kW 103 124 147 178 224 272
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW 110 131 156 188 241 289
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW 100 121 142 173 216 264
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW 106 127 150 182 232 280
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 93 100 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 85 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . dB(A) 72 72 74 74 75 75
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71 71 71 71 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s 2.0 2.5 3.0 3.6 4.2 5.6
Minimum cooling water flow, GA W 10) . . . . . . . . l/s 0.7 0.8 0.9 1.1 1.3 1.6

46 2920 1475 00
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7.5.4 Specific data of 8.5 bar - 50 Hz compressors 3)

NOT TO BE USED, SEE ADDENDUM
Compressor type 90 110 132 160 200 250

Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 8.5 8.5 8.5 8.5 8.5 8.5
Maximum working pressure, Full-feature . . . . . . . . bar(e) 8.25 8.25 8.25 8.25 8.25 8.25
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7.9 7.9 7.9 7.9 7.9 7.9
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 8 8 8 8 8 8
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7.9 7.9 7.9 7.9 7.9 7.9
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1490 1490 1490 1490 1490 1490
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . kW 103 124 149 179 223 277
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW 110 131 158 189 239 294
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW 100 121 144 174 207 262
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW 106 127 152 183 222 277
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 93 100 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 85 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . dB(A) 72 72 74 74 75 75
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71 71 71 71 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s 2.0 2.5 3.0 3.6 4.2 5.6
Minimum cooling water flow, GA W 10) . . . . . . . . l/s 0.7 0.8 0.9 1.1 1.3 1.6

7.5.5 Specific data of 10 bar - 50 Hz compressors 3)

Compressor type 90 110 132 160 200 250

Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 10 10 10 10 10 10

Maximum working pressure, Full-feature . . . . . . . . bar(e) 9.75 9.75 9.75 9.75 9.75 9.75
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 9.4 9.4 9.4 9.4 9.4 9.4
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 9.5 9.5 9.5 9.5 9.5 9.5
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 9.4 9.4 9.4 9.4 9.4 9.4
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1490 1490 1490 1490 1490 1490
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . kW 102 124 146 178 224 273
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW 108 131 155 187 240 290
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW 99 121 141 173 216 265
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW 104 127 149 181 231 281
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 93 100 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 85 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . dB(A) 72 72 74 74 75 75
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71 71 71 71 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s 2.0 2.5 3.0 3.6 4.2 5.6
Minimum cooling water flow, GA W 10) . . . . . . . . l/s 0.7 0.8 0.9 1.1 1.3 1.6

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NOT TO BE USED, SEE ADDENDUM

7.5.6 Specific data of 13 bar - 50 Hz compressors 3)

Compressor type 90 110 132 160 200 250

Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 13 13 13 13 13 13

Maximum working pressure, Full-feature . . . . . . . . bar(e) 12.75 12.75 12.75 12.75 12.75 12.75
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 12.4 12.4 12.4 12.4 12.4 12.4
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 12.5 12.5 12.5 12.5 12.5 12.5
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 12.4 12.4 12.4 12.4 12.4 12.4
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1490 1490 1490 1490 1490 1490
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . kW 104 124 149 182 241 289
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW 110 130 158 191 258 306
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW 101 121 144 177 233 281
Power input, GA W Full-feature 7) . . . . . . . . . . . . . kW 106 126 152 185 250 298
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 93 100 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 85 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . dB(A) 72 72 74 74 75 75
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71 71 71 71 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s 2.0 2.5 3.0 3.6 4.2 5.6
Minimum cooling water flow, GA W 10) . . . . . . . . l/s 0.7 0.8 0.9 1.1 1.3 1.6

7.5.7 Specific data of 100 psi - 60 Hz compressors 3)

Compressor type 90 110 160 200 250 315

Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 7.4 7.4 7.4 7.4 7.4 7.4
Maximum working pressure, Full-feature . . . . . . . . bar(e) 7.15 7.15 7.15 7.15 7.15 7.15
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.8 6.8 6.8 6.8 6.8 6.8
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 6.9 6.9 6.9 6.9 6.9 6.9
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 6.8 6.8 6.8 6.8 6.8 6.8
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1790 1790 1790 1790 1790 1790
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . kW 109 133 178 217 254 291
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW 116 140 188 234 271 309
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW 105 128 171 208 245 282
Power input, GA Full-feature W 7) . . . . . . . . . . . . . kW 112 134 181 225 262 300
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 100 130 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 113 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . dB(A) 76 76 78 76 76 76
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71 71 71 72 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s 2.0 2.5 3.6 4.2 5.6 6.9
Minimum cooling water flow, GA W 10) . . . . . . . . l/s 0.7 0.8 1.1 1.3 1.6 1.8

48 2920 1475 00
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NOT TO BE USED, SEE ADDENDUM

7.5.8 Specific data of 125 psi - 60 Hz compressors 3)

Compressor type 90 110 160 200 250 315

Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 9.1 9.1 9.1 9.1 9.1 9.1
Maximum working pressure, Full-feature . . . . . . . . bar(e) 8.85 8.85 8.85 8.85 8.85 8.85
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 8.5 8.5 8.5 8.5 8.5 8.5
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 8.6 8.6 8.6 8.6 8.6 8.6
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 8.5 8.5 8.5 8.5 8.5 8.5
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1790 1790 1790 1790 1790 1790
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . kW 109 128 175 220 257 294
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW 116 136 184 236 273 312
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW 105 124 168 211 248 285
Power input, GA Full-feature W 7) . . . . . . . . . . . . . kW 112 131 176 227 264 303
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 100 130 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 113 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . dB(A) 76 76 78 76 76 76
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71 71 71 72 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s 2.0 2.5 3.6 4.2 5.6 6.9
Minimum cooling water flow, GA W 10) . . . . . . . . l/s 0.7 0.8 1.1 1.3 1.6 1.8

7.5.9 Specific data of 150 psi - 60 Hz compressors 3)

Compressor type 90 110 160 200 250 315

Maximum working pressure . . . . . . . . . . . . . . . . . . . bar(e) 10.8 10.8 10.8 10.8 10.8 10.8
Maximum working pressure, Full-feature . . . . . . . . bar(e) 10.55 10.55 10.55 10.55 10.55 10.55
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 10.2 10.2 10.2 10.2 10.2 10.2
Nominal working pressure . . . . . . . . . . . . . . . . . . . . bar(e) 10.3 10.3 10.3 10.3 10.3 10.3
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 10.2 10.2 10.2 10.2 10.2 10.2
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1790 1790 1790 1790 1790 1790
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . kW 110 132 178 222 260 303
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . kW 117 139 187 238 277 320
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . kW 106 127 171 211 248 285
Power input, GA Full-feature W 7) . . . . . . . . . . . . . kW 113 133 179 227 264 303
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 100 130 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 113 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . dB(A) 76 76 78 76 76 76
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . dB(A) 71 71 71 72 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . l/s 2.0 2.5 3.6 4.2 5.6 6.9
Minimum cooling water flow, GA W 10) . . . . . . . . l/s 0.7 0.8 1.1 1.3 1.6 1.8

2920 1475 00 49
 Instruction book

7.5.10 Specific data of 200 psi - 60 Hz compressors 3)

NOT TO BE USED, SEE ADDENDUM90

Compressor type 110 160 250 315

Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 13.8 13.8 13.8 13.8 13.8

Maximum working pressure, Full-feature . . . . . . . . . . . . . . . . bar(e) 13.55 13.55 13.55 13.55 13.55
Maximum working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 13.2 13.2 13.2 13.2 13.2
Nominal working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 13.3 13.3 13.3 13.3 13.3
Nominal working pressure, Full-feature with
DD filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 13.2 13.2 13.2 13.2 13.2
Motor shaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r/min 1790 1790 1790 1790 1790
Power input, GA 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW 111 134 178 269 307
Power input, GA Full-feature 7) . . . . . . . . . . . . . . . . . . . . . . . . kW 118 141 187 285 323
Power input, GA W 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW 107 129 171 260 298
Power input, GA Full-feature W 7) . . . . . . . . . . . . . . . . . . . . . kW 113 136 179 276 314
Oil capacity, GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 69 75 100 130 130
Oil capacity, GA W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 63 63 85 113 113
Sound pressure level, GA 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 76 76 78 76 76
Sound pressure level, GA W 4) . . . . . . . . . . . . . . . . . . . . . . . . dB(A) 71 71 71 72 72
Maximum cooling water flow, GA W 9) . . . . . . . . . . . . . . . . . l/s 2.0 2.5 3.6 5.6 6.9
Minimum cooling water flow, GA W 10) . . . . . . . . . . . . . . . . l/s 0.7 0.8 1.1 1.6 1.8

7.6 Conversion list of SI units into British/American units

1 bar = 14.504 psi

1 g = 0.035 oz
1 kg = 2.205 lb
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 l/s = 2.117 cfm
1 mm = 0.039 in
1 mbar = 0.401 in water column
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x degrees Celsius = (32 + 1.8 x) degrees Fahrenheit 5)

Footnotes chapter 7

1) Disturbance or destruction of the contactor and/or overload relay may occur (if damaged, the component must be replaced).
2) No damage will occur at the overload relay.
3) At reference conditions (see section 7.5.1).
4) According to PNEUROP PN8NTC2.2 at 1 m distance under free field conditions with a tolerance of 3 dB.
5) A temperature difference of 1 degree Celsius = a temperature difference of 1.8 degrees Fahrenheit.
6) At ambient of 20 degrees Celsius and 80% relative humidity.
7) At supply voltage of 400 V (50 Hz) or 440 V (60 Hz). Data may slightly differ at other voltages or for units with DD filter.
8) 50 degrees Celsius for HAT (High Ambient Temperature) versions.
9) At a temperature rise of 10 degrees Celsius.
10) At a temperature rise of 35 degrees Celsius.

50 2920 1475 00
Product : GA 90-315

This is a pressure assembly of cat III (GA 90-160) or cat. IV (GA 200-315) according to
97/23/EC.

Parts of article 3.3 of 97/23/EC are subject to good engineering practice.

Parts of category I according to 97/23/EC are integrated into the machine and fall under the
exclusion of article I, section 3.6.
Parts subject to the Simple Pressure Vessel Directive 87/404/EEC are excluded from 97/23/EC
according to article I, section 3.3.

The following pressure bearing parts are of category higher than I :

Oil separator vessel (GA 90-160) : Cat III

Design pressure 15 bar(e), content 275 l
Design standard : ASME section VIII div. 1.

Oil separator vessel (GA 200-315) : Cat IV

Design pressure 15 bar(e), content 292 l
Design standard : ASME section VIII div. 1.

Safety valve : Cat IV

Design code : AD-Merkblätter, A2
O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................

SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations 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.

In addition to normal safety rules which should be observed with stationary
air compressors and equipment, the following safety directions and
precautions are of special importance.
When operating this unit, the operator must employ safe working practices
and observe all related local work safety requirements and ordinances.
The owner is responsible for maintaining the unit in a safe operating
condition. Parts and accessories shall be replaced if unsuitable for safe
operation.
Installation, operation, maintenance and repair shall only be performed
by authorized, trained, competent personnel.
Normal ratings (pressures, temperatures, time settings, etc.) shall be
durably marked.
Any modification on the compressor or air dryer shall only be performed
in agreement with Atlas Copco and under supervision of authorized,
competent personnel.
If any statement in this book, especially with regard to safety, does not
comply with local legislation, the stricter of the two shall apply.
If necessary, install a suction duct. Never obstruct the air inlet. Care
shall be taken to minimize the entry of moisture with the inlet air.
4. The aspirated air shall be free from flammable fumes or vapours,
e.g. paint solvents, that can lead to internal fire or explosion.
5. Air-cooled units shall 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 inlet.
6. Arrange the air intake so that loose clothing of people cannot be
sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
air dryer or air net is free to expand under heat and that it is not in
contact with or close to flammable material.
8. No external force may be exerted on the air outlet valve; the connected
pipe must be free of strain.
9. If remote control is installed, the unit shall bear an obvious sign
reading:

These precautions are general and cover several machine types and
equipment; hence some statements may not apply to the unit(s) described
in this book.
Installation
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed:
1. A compressor or air dryer shall be lifted only with adequate equipment
in conformity with local safety rules.
Loose or pivoting parts shall be securely fastened before lifting. It is
strictly forbidden to dwell or stay in the risk zone under a lifted load.
Lifting acceleration and retardation shall be kept within safe limits.
W ear a safety helmet when working in the area of overhead or lifting
equipment.
2. Any blanking flanges, plugs, caps and desiccant bags shall be
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working
pressure.
3. Place the unit where the ambient air is as cool and clean as possible.
DANGER: This machine is remotely controlled and may start
without warning.
As a further safeguard, persons switching on remotely controlled
units 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.
10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
instrument panel.
11. In multiple compressor systems manual valves shall be installed to
isolate each compressor. Non-return valves (check valves) shall not
be relied upon for isolating pressure systems.
12. Never remove or tamper with the safety devices, guards or insulations
fitted on the unit. Every pressure vessel or auxiliary installed outside
the unit to contain air above atmospheric pressure shall be protected
by a pressure-relieving device or devices as required.
13. Pipework or other parts with a temperature in excess of 80 degrees
celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
pipework shall be clearly marked.

2920 1377 03 1/2 (continued on inside of cover)

 SAFETY PRECA UTIONS
14. If the ground is not level or can be subject to variable inclination,
consult Atlas Copco.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses.
Operation
1. Air hoses shall be of correct size and suitable for the working pressure.
Never use frayed, damaged or deteriorated hoses. 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.
Never play with compressed air. Do not apply it to your skin or
direct an air stream at people. Never use it to clean dirt from your
clothes. When using it to clean equipment, do so with extreme caution
and use eye protection.
2. The compressor is not considered as capable of producing air of
breathing quality. For breathing air quality, the compressed air must
be adequately purified according to local legislation and standards.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes.
4. Never operate the units at pressures below or in excess of their limit
ratings as indicated on the Principal Data sheet.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear
protectors when opening a door.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors.
7. Periodically check that:
a. All guards are in place and securely fastened
b. All hoses and/or pipes inside the unit are in good condition, secure
and not rubbing
c. There are no leaks
d. All fasteners are tight
e. All electrical leads are secure and in good order
.
f Safety valves and other pressure-relief devices are not obstructed
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds,
valves, hoses, etc. are in good repair, free of wear or abuse
8. 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.
9. Do not remove any of, or tamper with, the sound-damping material.
Maintenance
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job.
1. Use only the correct tools for maintenance and repair work.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped, the main power supply is
switched off and the machine has cooled down. Take positive
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in
progress; do not start" shall be attached to the starting equipment.
4. Before removing any pressurized component, effectively isolate the
unit from all sources of pressure and relieve the entire system of
pressure.
(continued)
5. Never use flammable solvents or carbon tetrachloride for cleaning
parts. Take safety precautions against toxic vapours of cleaning
liquids.
6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
clean cloth, paper or tape.
7. 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.
Whenever there is an indication or any suspicion that an internal
part of a machine is overheated, the machine shall be stopped but no
inspection covers shall be opened before sufficient cooling time
has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapour when air is admitted.
Never use a light source with open flame for inspecting the interior
of a machine, pressure vessel, etc.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
and that the control and shut-down devices function correctly. If
removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
10. 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.
11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
12. Make sure that all sound-damping material, e.g. on the bodywork
and in the air inlet and outlet systems of the compressor, is in good
condition. If damaged, replace it by genuine Atlas Copco material
to prevent the sound pressure level from increasing.
13. Never use caustic solvents which can damage materials of the air
net, e.g. polycarbonate bowls.
14. The following safety precautions are stressed when handling
refrigerant:
a. Never inhale refrigerant vapours. Check that the working area
is adequately ventilated; if required, use breathing protection.
b. Always wear special gloves. In case of refrigerant contact with
the skin, rinse the skin with water. If liquid refrigerant contacts
the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all
refrigerant is flushed away; then seek medical first aid.
c. Always wear safety glasses.
15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
Note: W ith stationary machine units driven by an internal combustion
engine, allowance has to be made for extra safety precautions, e.g. spark
arrestors, fuelling care, etc. Consult Atlas Copco.
All responsibility for any damage or injuryresulting from neglecting
these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
not expressly mentioned in this book, will be disclaimed by Atlas
Copco.
2920 1377 03 2/2
 Atlas Copco Stationary Air Compressors

GA250-125

Addendum to the Instruction Manual

Serial Number: S989444 01-02v00

Customer: COMPANIA DE SERVISIO CAMPECHE, MEXICO

• Copyright 2004, Atlas Copco Airpower n.v., Antwerp, Belgium.

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 meets the requirements for instruction specified by the
machine directive 98/37/EC and is valid for CE as well as non-CE labeled
machines

www.atlascopco.com

2004-03
 Addendum to the Instruction Manual

PREFACE

This is an addendum. This addendum describes how to handle and operate the subject machine, to
ensure safe operation, optimum working economy and long service life.

Please make this addendum available for the operator(s) and ensure that the machine is operated and
maintained in accordance with Atlas Copco instructions. Record all operating data, maintenance work
effected, etc. in an operator’s logbook which is available from Atlas Copco. Follow all applicable safety
precautions, as well as those mentioned in this addendum.

It is highly recommended that repairs are performed by trained personnel from Atlas Copco who can
be contacted for any further information.

This book only deals with the description and instructions applicable to the machine as it was shipped
ex-factory. If special devices or control systems are installed locally, complementary instructions must
be added. If the machine is used in a special process, the user should adapt the instructions, as
required.

The book is divided in three sections:

Part A - describing safety precautions – to be read before installing, operating or repairing the
unit.
Part B - giving general information about constructional adaptations.
Part C - concerning modifications.

Ownership data
Compressor type: Unit serial No. compressor:
Air dryer type: Unit serial No. dryer:
Motor type: Motor serial No.:
Delivery date: First start-up date:
Service Plan: Owner's machine No.:

Selected lubricants
Compressor: Capacity:
Bearing grease type, electric motor:
Dryer gearbox Capacity

Printed Matter Nos.

Atlas Copco compressor instruction book: Atlas Copco air dryer instruction book:

Atlas Copco compressor parts list: Atlas Copco air dryer parts list:
Atlas Copco logbook:

Local Atlas Copco Representative

Name:
Address:
Telephone: Contact persons: Service:
Telex: Parts:
E-mail

S989444 01-02v00 2
 Addendum to the Instruction Manual

A SAFETY PRECAUTIONS

To be read attentively and acted upon accordingly before installing, operating or repairing the
unit.

These recommendations 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.

In addition to normal safety rules, which should be observed with stationary air compressors and
equipment, the following safety directions and precautions are of special importance.

When operating this unit, the operator must employ safe working practices and observe all related
local work safety requirements and ordinances.

The owner is responsible for maintaining the unit in a safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.

Installation, operation, maintenance and repair shall only be performed by authorized, trained and
competent personnel.

Normal ratings (pressures, temperatures, time settings, etc.) shall be durably marked.

Any modification on the compressor shall only be performed in agreement with Atlas Copco and under
supervision of authorized and competent personnel.

If any statement in this book, especially with regard to safety, does not comply with local
legislation, the stricter of the two shall apply.

These precautions are general and cover several machine types and equipment; hence some
statements may not apply to the unit(s) described in this book.

Installation
Apart from general engineering practice in conformity with the local safety regulations, the following
directives are specially stressed:

1. A compressor shall be lifted only with adequate equipment in conformity with local safety rules.
Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or
stay in the risk zone under a lifted load. Lifting acceleration and retardation shall be kept within
safe limits.
Wear a safety helmet when working in the area of overhead or lifting equipment.
2. Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the
pipes. Distribution pipes and connections shall be of correct size and suitable for the working
pressure.
3. Place the unit where the ambient air is as cool and clean as possible. If necessary, install a
suction duct. Never obstruct the air inlet. Care shall be taken to minimize the entry of moisture
with the inlet air.
4. The aspirated air shall be free from flammable fumes or vapours, e.g. paint solvents, that can lead
to internal fire or explosion.
5. Air-cooled units shall 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 inlet.
6. Arrange the air intake so that loose clothing of people cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler, air dryer or air net is free to
expand under heat and that it is not in contact with or close to flammable material.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.

S989444 01-02v00 3
 Addendum to the Instruction Manual

9. If remote control is installed, the unit shall bear an obvious sign reading:

DANGER: This machine is remotely controlled and may start without warning.

As a further safeguard, persons switching on remotely controlled units 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.

10. On units with automatic start-stop system, a sign stating "This machine may start without
warning" shall be attached near the instrument panel.
11. In multiple compressor systems manual valves shall be installed to isolate each compressor. Non-
return valves (check valves) shall not be relied upon for isolating pressure systems.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the unit. Every
pressure vessel or auxiliary installed outside the unit to contain air above atmospheric pressure
shall be protected by a pressure-relieving device or devices as required.
13. Pipework or other parts with a temperature in excess of 80 degrees Celsius and which may be
accidentally touched by personnel in normal operation shall be guarded or insulated. Other high-
temperature pipework shall be clearly marked.
14. If the ground is not level or can be subject to variable inclination, consult Atlas Copco.
15. The electrical connections shall correspond to the local codes. The units shall be grounded and
protected against short circuits by fuses.

Operation
1. Air hoses shall be of correct size and suitable for the working pressure. Never use frayed,
damaged or deteriorated hoses. 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.
Never play with compressed air. Do not apply it to your skin or direct an air stream at people.
Never use it to clean dirt from your clothes. When using it to clean equipment, do so with extreme
caution and use eye protection.
2. The compressor is not considered as capable of producing air of breathing quality. For breathing
air quality, the compressed air must be adequately purified according to local legislation and
standards.
3. Never operate the unit when there is a possibility of taking in flammable or toxic fumes.
4. Never operate the unit at pressures below or in excess of its limit ratings as indicated on the
Principal Data sheet.
5. Keep all bodywork doors shut during operation. The doors may be opened for short periods only,
e.g. to carry out checks. Wear ear protectors when opening a door.
6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90
dB(A) shall wear ear protectors.
7. Periodically check that:
a. All guards are in place and securely fastened
b. All hoses and/or pipes inside the unit are in good condition, secure and not rubbing
c. There are no leaks
d. All fasteners are tight
e. All electrical leads are secure and in good order
f. Safety valves and other pressure-relief devices are not obstructed by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
8. 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.
9. Do not remove any of, or tamper with, the sound-damping material.

S989444 01-02v00 4
 Addendum to the Instruction Manual

Maintenance
Maintenance and repair work shall only be carried out under supervision of someone qualified for the
job.

1. Use only the correct tools for maintenance and repair work.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be undertaken when the unit is
stopped, the main power supply is switched off and the machine has cooled down. Take positive
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in progress; do not start" shall be
attached to the starting equipment.
4. Before removing any pressurized component, effectively isolate the unit from all sources of
pressure and relieve the entire system of pressure.
5. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapours of cleaning liquids.
6. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
7. 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.
Whenever there is an indication or any suspicion that an internal part of a machine is overheated,
the machine shall be stopped but no inspection covers shall be opened before sufficient
cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air
is admitted.
Never use a light source with open flame for inspecting the interior of a machine, pressure vessel,
etc.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
9. Before clearing the unit for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct and that the control and shut-down devices function
correctly. If removed, check that the coupling guard of the compressor drive shaft has been
reinstalled.
10. 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.
11. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam-cleaning.
12. Make sure that all sound-damping material, e.g. on the bodywork and in the air inlet and outlet
systems of the compressor, is in good condition. If damaged, replace it by genuine Atlas Copco
material to prevent the sound pressure level from increasing.
13. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
14. The following safety precautions are stressed when handling refrigerant:
a. Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if
required, use breathing protection.
b. Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water.
If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek
medical first aid.
c. Always wear safety glasses.
15. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.

Note:
With stationary machine units driven by an internal combustion engine, allowance has to be made for
extra safety precautions, e.g. spark arrestors, fuelling care, etc. Consult Atlas Copco.

All responsibility for any damage or injury resulting from neglecting these precautions, or by
non-observance of ordinary caution and due care required in handling, operating, maintenance
or repair, even if not expressly mentioned in this book, will be disclaimed by Atlas Copco.

S989444 01-02v00 5
 Addendum to the Instruction Manual

B. General
This addendum refers to the GA250 machines with Serial Numbers S989444 01-02v00 only.
In the first section of this document, reference will be made to the constructional adaptations.

1.1 Additional
The following modifications have been made to the GA250 compressor version:

COMPRESSOR
Standard options:
• AIR cooled
• ANSI flange on air outlet only
• Electrical approval CSA-UL
• Fan voltage 440 - 460 V
• Frequency 60 Hz
• HD oil instead of Roto Inject Fluid Oil
• Maximum working pressure 8.6 bar
• Pack version
• Pressure vessel approval ASME
• Starter included
• Supply voltage 440 - 460 V
• WEG motor

Special mechanical items:

• Copper free version, including:
- CU-free safety-valve
- Stainless steel instrument and regulating piping / flexibles
- CU-free drain system with rubber flexibles “push on system” and stainless steel couplings and
valves
- Stainless steel solenoid valve
- Sundries (nipples, nozzles, plugs, etc.)
• CU-free safety valve
• 1.25 mm ZINCOR metal sheet plates for canopy and suitable for offshore painting
• Aluminium coolers Teflon coated (externally). (Cooler coating can influence cooler performance
data)
• Special paint system:
Offshore paint system for 1.25 mm canopy and 4 mm frame. Surface preparation: ETS
phosphating spray and drying and cleaning. 3 paint layers according to painting instruction 9821-
1644-63/62. Minimum TDFT = 200 µm, tolerance according to Atlas Copco standard. Colour for
canopy = RAL 7001

MOTOR
The installed motor meets the following specifications:
• Standard WEG type W21 300/4 5008TD
• Shaft power: 220.0 kW
• Service factor: 1.20
• Voltage (± 10.0 %): 480 V
• Frequency: 60 Hz
• Drive speed: 1785 rpm
• Max. cooling air temperature: 40 °C
• Connection of windings: DELTA
• Insulation class: F
• Enclosure: IP55
• Construction form: B5 + SUPPORT
• Full load efficiency: 96.20 %
• Power factor: 0.850
• Nominal current: 324.0 Amp.

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 Addendum to the Instruction Manual

Starting: 780.0 %
• Nominal torque: 1184 Nm
Starting: 230.0 %
• Weight: 1454 Kg
• Max. Altitude: 1000 masl

Additional motor characteristics/information

• Nema efficiency = 96.2 %

Standard / Special motor options

• Anti condensation heaters (115 V)

ELECTRICS
• Atlas Copco STAR/DELTA starter, 480 V - 60 Hz
• Elektronikon® regulation, 115 V - 60Hz
• Solenoid valve 24 V - 60 Hz
Auxiliary equipment / provisions:
• Auxiliary circuits for motor heaters
• NEMA 4X control cubicle
• Fan motor 480 V / 60 Hz with anti-condensation heater (115 V)
• Auxiliary circuit for fan motor heater

1.2 Attachments
The following drawings are an integral part of this addendum and must always accompany this
publication:

• Dimension drawing: 9821 2002 89 (v.0)

• Flow diagram: 9823 1991 01 (v.1)
• Service diagram: 9821 1437 51 (v.0)

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 Addendum to the Instruction Manual

C. Modifications
As explained in the introduction, the GA250 compressors supplied for this contract have been
modified.
The following modifications to the standard Instruction Book are cross-referenced by section, sub-
section and paragraph.

1 Leading particulars
1.1 General description
The figures are applicable as typical examples, also concerning the compressor in question. For
information about added and replaced accessories and specifications about the electric connections,
see Section B, Dimension drawing 9821 2002 89, Service diagram 9821 1437 51 and Flow diagram
9823 1991 01.

2 Installation
2.1 Dimension drawings
Consult Dimension drawing no. 9821 2002 89.

2.3 Electric cables

2.3.2 Connection
For specifications about the connections, see Service diagram no. 9821 1437 51.

3 Operating instructions
3.7 Stopping
Disconnection of the electrical system puts the anti condensation systems out of order.
As long as the compressor remains connected, the thermostats will keep the temperature in the
motors above the set temperature, so no condensation will occur.

4 Maintenance
4.2 Motor Greasing
General

Safety precautions
Stop the compressor and switch off the voltage.
The operator must apply all related safety precautions.

The data below are valid for an air intake temperature of maximum 40 ° C.
Consult your Atlas Copco Customer Centre for higher intake temperatures.
Reset the regreasing service warning after regreasing.
Also check the motor data plate.

DRIVE MOTOR
Make WEG
Type W21 350/4 5008TD

DRIVE MOTOR GREASING

Type Esso/Exxon Polyrex EM
Interval 4000 h
Quantity (per bearing) 60 g

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 Addendum to the Instruction Manual

FAN MOTOR GREASING

The bearings of the fan motors are greased for life, contact your Customer Centre for the replacement
interval of the motor bearings.

Never mix greases of different brands of types

7 Principal data
7.2 Regulation & Protection
7.2.1 Regulation settings & parameters
Minimum Factory Maximum
setting setting Setting
Loading pressure (1) bar 4.5 8.0 8.5
Unloading pressure (1) bar 8.1 8.6 9.105
Overpressure setting (2) bar 9.105
Overpressure Timeout (2) sec 240
Y-Time sec 10 10 20
Load Delay sec 0 0 20
Nr Of Starts/Day 0 72 72
Minimum Stop Time sec 20 20 99
Programmed Stop Time sec 30 30 30
Permissive Start Time sec 0 30 255
Communication Time-Out (3) sec 10 20 60
Power Recovery Time (ARAVF) (3) sec 15 15 3600
Start Delay Time (ARAVF) (3) sec 0 3 255

(1) Pressure band 2 set identical to Pressure band 1

The regulator does not accept illogical settings, e.g. If the Unloading pressure is programmed at 7.0 bar,
the maximum limit for Loading changes to 6.9 bar.
(2) Only active in Remote control mode. Will force the compressor into unload when reached
(3) In case of LAN control. See Elektronikon Manual section 1.4. Factory setting : inactive

7.2.2 Protection settings

Minimum Factory Maximum
setting setting Setting
Compressor Outlet Shutd.Warn.(1) bar 0 16.5 16.9
Compressor Outlet Shutdown (1) bar 16.6 17 17
Dp Oil Separator Service Warning bar 0 0.8 0.8
Delay At Signal, Dp Oil Separator sec 0 60 255
Dp Air Filter Service Warning bar -0.100 -0.050 -0.050
Delay At Signal, Dp Air Filter sec 0 60 255
Oil Injection Element Perm.Start Level bar 2.0 2.5 13.2
Compressor Outlet Shutd.Warn.(1) °C 0 66 79
Compressor Outlet Shutdown (1) °C 67 80 120
Delay At Signal, Compressor Outlet sec 5 5 5

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 Addendum to the Instruction Manual

Element 1 & 2 Outlet Shutd.Warn.(1) °C 80 100 109

Element 1 & 2 Outlet Shutdown (1) °C 101 110 110
Delay At Signal, Element 1 & 2 Outlet sec 5 5 5
Oil Separator Shutd.Warn. °C 0 119.9 119.9
Oil Separator Shutdown °C 0 120 120
Delay At Start, Overload Motor Shutdown sec 0 1 1
Delay At Signal, Overload Motor Shutdown sec 0 1 1
Delay At Start, Overload Fanmotor Shutdown sec 0 1 1
Delay At Signal, Overload Fanmotor Shutdown sec 0 1 1
Delay At Start, Starter Feedback Contact (2) sec 0 13 60
Delay At Signal, Starter Feedback Contact (3) sec 0 2 3

(1) The regulator does not accept illogical settings, e.g. If the warning level is programmed at 114°C,
the minimum limit for the shutdown level changes into 115°C. ( = logic for pressure, step = 0.1 bar)
(2) Contact = open, Check area : Unload & Load
(3) Contact = closed, Check area : Stop

7.5 Compressor specifications

General information
Compressed medium Air
Max. ambient temperature 40.0 °C
Max. working pressure 8.600 bar(g)
Pressure vessel approval ASME
Fan motor(s): 480 V 60 Hz

For data concerning the motor, see Section B - paragraph 1.1 of this addendum.

Performance data
CONDITION 1 – MAXIMUM TEMPERATURE
Air inlet pressure 1.013 bar(a)
Ambient pressure 1.013 bar(a)
Air outlet pressure 8.600 bar(g)
Air inlet temperature 38.0 °C
Relative humidity 95.0 %
Volume flow rate 586.0 l/s Tol. ± 4.0 %
Normal capacity 1811.0 Nm3/h
Shaft input 235.0 kW, EXCL. FAN
Spec. shaft input 401.0 J/l Tol. ± 5.0 %, EXCL. FAN
Drive speed 1788 RPM
MRS Stage HP 2005 RPM
Total Cooling Water Flow 7.97 l/s
Pressure drop cooling water circuit 0.56 bar
Temp. HP Outlet 90 °C
Air discharge temperature 61 °C

CONDITION 2 – AVERAGE TEMPERATURE

Air inlet pressure 1.013 bar(a)
Ambient pressure 1.013 bar(a)
Air outlet pressure 8.600 bar(g)
Air inlet temperature 33.0 °C
Relative humidity 80.0 %
Volume flow rate 597.0 l/s Tol. ± 4.0 %
Normal capacity 1892.0 Nm3/h

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 Addendum to the Instruction Manual

Shaft input 236.0 kW EXCL. FAN

Spec. shaft input 396.0 J/l Tol. ± 5.0 %, EXCL. FAN
Drive speed 1788 RPM
MRS Stage LP 2005 RPM
Temp. HP Outlet 85 °C
Air discharge temperature 51 °C

CONDITION 3 – MINIMUM TEMPERATURE

Air inlet pressure 1.013 bar(a)
Ambient pressure 1.013 bar(a)
Air outlet pressure 8.600 bar(g)
Air inlet temperature 25.0 °C
Relative humidity 80.0 %
Volume flow rate 6070.0 l/s Tol. ± 4.0 %
Normal capacity 1986.0 Nm3/h
Shaft input 239.0 kW
Spec. shaft input 393.0 J/l Tol. ± 5.0 %
Drive speed 1788 RPM
MRS Stage HP 2005 RPM
Temp. HP Outlet 77 °C
Air discharge temperature 40 °C

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Dimension drawing

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Addendum to the Instruction Manual

Flow diagram

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Addendum to the Instruction Manual

Service diagram, part 1 of 3

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Service diagram, part 2 of 3

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Addendum to the Instruction Manual

Service diagram, part 3 of 3

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Instruction book

Atlas Copco Stationary Air Compressors

AQ30/55 - GA90/500 (W) – GR110/200 (W) – ZA3/6 – ZE3/4 – ZT/ZR15/90 –

ZT110/275 – ZR110/750

User manual for Elektronikon® regulator

From following serial numbers onwards:

GA90-110-132-160 (W): AIF-078 300

GA200-250-315 (W): AIF-078 302
GR110-132-160-200 (W): AIF-078 406
ZA3-4-5-6: AIF-078 954
ZE3-4: AIF-078 954
ZT15-18-22-30-37-45: AII-702 000
ZR30-37-45: AII-702 000
ZT55-75-90: AIF-077 519
ZR55-75-90: AIF-077 519
ZT110-132-145-160-200-250-275: AIF-079 599
ZR110-132-145-160-200-250-275-300-315-355- AIF-079 599
400-425-450-500-630-750:

This manual must be used together with the relevant instruction books of the compressors.

Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium.

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 meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines

No. 2920 1478 02

Replaces 2920 1478 01

Registration code: APC AQ30-55+55VSD/38/998

APC G > 90/'99 / 38 / 956
APC Z55-90 / 38 / 992
APC Z<55 + VSD / 38 / 391
APC ZE/ZA3-6 / 38 / 992
APC ZR/ZT110-275 / 38 / 969
APC ZR300-750 / 38 / 982

2003-11 www.atlascopco.com

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Contents

Page
1 General description............................................................................................................................ 4
1.1 Controlling the compressor............................................................................................................ 4
1.2 Protecting the compressor............................................................................................................. 4
1.2.1 Shut-down and fan motor overload ......................................................................................... 4
1.2.2 Shut-down warning.................................................................................................................. 5
1.2.3 Warning ................................................................................................................................... 5
1.3 Service warning ............................................................................................................................. 5
1.4 Automatic restart after voltage failure ............................................................................................ 5
1.5 Permissive start ............................................................................................................................. 5
1.6 Start commands during programmed stop time and minimum stop time ...................................... 5
2 Control panel (Fig. 2.1)....................................................................................................................... 6
3 Display - keys...................................................................................................................................... 7
3.1 Display (3-Fig. 2.1)......................................................................................................................... 7
3.2 Scroll keys (4-Fig. 2.1) ................................................................................................................... 7
3.3 Tabulator key (5-Fig. 2.1) .............................................................................................................. 7
3.4 Function keys (9-Fig. 2.1) .............................................................................................................. 7
4 Menu-driven control programs ......................................................................................................... 9
4.1 Function of control programs ......................................................................................................... 9
4.2 Main screen ................................................................................................................................... 9
4.3 Calling up other menus ................................................................................................................ 10
5 Quick look at actual compressor status ........................................................................................ 21
6 Status data menu.............................................................................................................................. 22
6.1 No message exists....................................................................................................................... 22
6.2 A shut-down message exists ....................................................................................................... 22
6.3 A shut-down warning message exists ......................................................................................... 23
6.4 A service warning message exists............................................................................................... 24
6.5 A warning message exists ........................................................................................................... 24
7 Measured data menu........................................................................................................................ 25
8 Counters menu ................................................................................................................................. 25
9 Test menu.......................................................................................................................................... 26
10 Modify parameters.......................................................................................................................... 26
10.1 Modifying parameters ................................................................................................................ 26
11 Modifying protection settings ....................................................................................................... 28
11.1 Modifying settings for compressor element temperature........................................................... 28
12 Modifying service plans................................................................................................................. 29
13 Programming Clock function ........................................................................................................ 30
13.1 Programming start/stop/pressure band commands................................................................... 30
13.2 To activate/deactivate the timer................................................................................................. 31
13.3 To modify a command ............................................................................................................... 31
13.4 To add a command .................................................................................................................... 32
13.5 To delete a command ................................................................................................................ 33
14 Configuration menu ....................................................................................................................... 35
14.1 Programming compressor control modes.................................................................................. 35
15 Service menu .................................................................................................................................. 36
16 Saved data menu ............................................................................................................................ 37
17 Programmable settings.................................................................................................................. 38
17.1 GA90 (W) up to GA315 (W)....................................................................................................... 38
17.1.1 Parameters.......................................................................................................................... 38
17.1.2 Protections .......................................................................................................................... 41
17.1.3 Service settings ................................................................................................................... 43
17.2 GR110 (W) up to GR200 (W) .................................................................................................... 44
17.2.1 Parameters.......................................................................................................................... 44
17.2.2 Protections .......................................................................................................................... 45
17.2.3 Service settings ................................................................................................................... 46
17.3 ZE/ZA3-4.................................................................................................................................... 47
17.3.1 Parameters.......................................................................................................................... 47
17.3.2 Protections .......................................................................................................................... 49

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17.3.3 Service settings ................................................................................................................... 50

17.4 ZA5-6 ......................................................................................................................................... 51
17.4.1 Parameters.......................................................................................................................... 51
17.4.2 Protections .......................................................................................................................... 54
17.4.3 Service settings ................................................................................................................... 55
17.5 ZT15 up to ZT45 / ZR30 up to ZR45 ......................................................................................... 56
17.5.1 Parameters.......................................................................................................................... 56
17.5.2 Protections .......................................................................................................................... 56
17.5.3 Service settings ................................................................................................................... 57
17.6 ZT55 up to ZT90 / ZR55 up to ZR90 ......................................................................................... 58
17.6.1 Parameters.......................................................................................................................... 58
17.6.2 Protections .......................................................................................................................... 59
17.6.3 Service settings ................................................................................................................... 60
17.7 ZT110 up to ZT275 / ZR110 up to ZR750 ................................................................................. 61
17.7.1 Parameters.......................................................................................................................... 61
17.7.2 Protections .......................................................................................................................... 62
17.7.3 Service settings ................................................................................................................... 63
17.8 AQ30-55..................................................................................................................................... 64
17.8.1 Parameters.......................................................................................................................... 64
17.8.2 Protections .......................................................................................................................... 65
17.8.3 Service settings ................................................................................................................... 65
17.9 Notes chapter 17........................................................................................................................ 66

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1 General description
In general, the regulator has following functions:
- controlling the compressor
- protecting the compressor
- monitoring components subject to service
- automatic restart after voltage failure (made inactive)
- permissive start (GA/GR compressors)

1.1 Controlling the compressor

The regulator maintains the net pressure between programmable limits by automatically loading and
unloading the compressor depending on the air consumption. 1)

The regulator takes into account a number of programmable settings, such as:
- the unloading pressure
- the loading pressure
- the minimum stop time
- the maximum number of motor starts

The regulator stops the compressor whenever possible (when the expected unloading period exceeds a
programmed value) to reduce the power consumption and restarts it automatically when the net
pressure decreases. In case the expected unloading period is below a programmed value, the
regulator keeps the compressor running to prevent too-short standstill periods.

When the compressor has stopped automatically and the net pressure decreases, the regulator will
start the compressor before the net pressure has dropped to the loading pressure to prevent the net
pressure from falling under the programmed minimum level.

When stopping the compressor manually, the regulator will unload the compressor for a programmed
time and then stop the compressor. 2)

1.2 Protecting the compressor

1.2.1 Shut-down and fan motor overload
Several temperature and pressure sensors are provided on the compressor. If one of these
measurements exceeds the programmed shut-down level, the compressor will be stopped. This will be
indicated on the control display.

Depending on the compressor type, the compressor will also be shut down by the regulator in case of
overload of the dryer motor or fan motors.

1) For ZE and ZA without full-load/no-load regulator, the settings for unloading and loading the
compressor are not programmable; consequently, these parameters are not taken into account.
2) GA90/315 and GR110/200 have an unloading time of 30 seconds; for Z compressors this period
is 3 seconds.
If a compressor with 30 seconds unloading time was running at the moment of manually stopping
in automatic unloading condition for 10 seconds, it will remain running unloaded for 30 - 10 = 20
seconds before stopping.

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1.2.2 Shut-down warning

If the regulator detects a temperature or pressure just below the programmed shut-down level, this will
be indicated on the control panel to warn the operator before the shut-down level is reached. The
message disappears as soon as the warning condition disappears.

1.2.3 Warning
Depending on the compressor type, a warning message appears in case the dewpoint temperature
exceeds the warning level (Full-Feature compressors).

1.3 Service warning

A number of service operations are grouped in plans (called Service plans A, B, C…). Each Service
plan has a programmed time interval. If a time interval is exceeded, a message will appear on display
(3-Fig. 2.1) to warn the operator to carry out the service actions belonging to that plan.

1.4 Automatic restart after voltage failure

The regulator has a built-in function to automatically restart the compressor if the voltage is restored
after voltage failure. For compressors leaving the factory, this function is made inactive. If desired,
the function can be activated. Consult Atlas Copco.

Warning
If activated and provided the module was in the automatic operation mode, the compressor will
automatically restart if the supply voltage to the module is restored within a programmed time period.

The power recovery time (the period within which the voltage must be restored to have an automatic
restart) can be set between 15 and 3600 seconds or to Infinite. If the power recovery time is set to
Infinite, the compressor will always restart after a voltage failure, no matter how long it takes to restore
the voltage. A restart delay can also be programmed, allowing e.g. two compressors to be restarted
one after the other.

1.5 Permissive start

After a start command (either automatic start by the Elektronikon regulator or manual start), the start
conditions are checked; if the programmed start conditions are not fulfilled within a programmed time
interval, the compressor will not start (indicated as Start failure).

1.6 Start commands during programmed stop time and minimum stop time

Programmed stop time

After pressing stop button (1-Fig. 2.1), the compressor will run unloaded for a programmed time
period. The compressor then stops. A start command during this period is ignored.

Minimum stop time

After stopping, the module prevents the motor from restarting within a programmed time period. A
start command during this time will be memorized and executed after running out of this period.

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2 Control panel (Fig. 2.1)

Fig. 2.1 Control panel, typical example

Ref. Designation Function

1 Stop button
2 Start button
3 Display
4 Scroll keys
5 Tabulator key
6 Voltage on LED
7 General alarm LED
8 Automatic operation LED
9 Function keys
10 Pictograph
11 Pictograph
12 Pictograph
S2 Emergency stop button
Push button to stop the compressor. LED (8) goes out.
Push button to start the compressor. LED (8) lights up
indicating that the regulator is operative (in automatic
operation).
Indicates messages concerning the compressor operating
condition, a service need or a fault.
Keys to scroll through the display.
Key to select the parameter indicated by a horizontal
arrow.
Indicates that the voltage is switched on.
Is normally out. Is alight or blinks in case of an abnormal
condition. See below.
Indicates that the regulator is automatically controlling the
compressor.
Keys to control and program the compressor. See below.
Alarm.
Automatic operation.
Voltage on.
Push button to stop the compressor immediately in case
of emergency. After remedying the trouble, unlock the
button by pulling it out and press reset key 9.

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3 Display - keys

3.1 Display (3-Fig. 2.1)

The display has four lines of 40 characters. A typical display is shown in Fig. 4.1. It indicates:

1. On the first three lines:

- the name of the sensor of which the actual reading is displayed
- the unit of measurement and actual reading of the sensor
- messages regarding the compressor operating condition (compressor off, etc.), a
service need (e.g. for the oil filter and air filter) or a fault (e.g. shut-down)
2. On the fourth line, just above the three function keys (F1/F2/F3), the actual functions of these
keys.

3.2 Scroll keys (4-Fig. 2.1)

These keys, labelled with vertical arrows, allow scrolling through the display.

As long as a downward pointing arrow is shown at the utmost right position of the display, the key (4)
with the same symbol can be used to see the next item.

As long as an upward pointing arrow is shown at the utmost right position of the display, the key (4)
with the same symbol can be used to see the previous item.

3.3 Tabulator key (5-Fig. 2.1)

This key, labelled with two horizontal arrows, allows the operator to select the parameter indicated by
a horizontal arrow. Only the parameters followed by an arrow pointing to the right are accessible for
modifying.

3.4 Function keys (9-Fig. 2.1)

The keys are used:

- To call up or to program settings
- To reset a motor overload, shut-down or service message, or an emergency stop
- To have access to all data collected by the regulator

The functions of the keys vary depending on the displayed menu. The actual function is indicated on
the bottom line of the display just above the relevant key. The most common functions are listed
below.

Designation Function
Add To add compressor start/stop commands (day/hour)
Back To return to a previously shown option or menu
Cancel To cancel a programmed setting when programming parameters
Delete To delete compressor start/stop commands
Extra To find information regarding the installed modules
Help To find the Atlas Copco internet address
Limits To show limits for a programmable setting
Load To load the compressor manually
Mainscreen To return from a menu to the main screen (Fig. 4.1)
Menu Starting from the main screen (Fig. 4.1): to have access to submenus
Menu Starting from a submenu, to return to the previous menu

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Designation Function
Modify To modify programmable settings
Program To program modified settings
Reset To reset a timer or message
Return To return to a previously shown menu
Unload To unload the compressor manually

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Instruction book

4 Menu-driven control programs

To facilitate programming and controlling the compressor, menu-driven programs are implemented in
the electronic module.

4.1 Function of control programs

Program/Function Description
Main screen Shows in short the operation status of the compressor. It is the gateway to
all functions.
Status data Calling up the status of the compressor protection functions: shut-down -
shut-down warning - service warning - warning.
Resetting of a shut-down, motor overload and service condition.
Measured data Calling up the actually measured data and the status of a number of
inputs.
Counters Calling up the number of running hours, loaded hours, motor starts, …
Test Allows a display test.
Modify parameters Modifying the parameters for:
- parameters (e.g. loading pressure)
- protections (e.g. air temperature shut-down level)
- service plans
- clock functions (automatic compressor start/stop/pressure band
commands)
- configuration (time, date, display language, …)
Service Calling up service plans and resetting the timers.
Saved data Calling up the saved data: last shut-down, last emergency stop data

4.2 Main screen

When the voltage is switched on, the Main screen is shown automatically, showing in short the
operation status of the compressor.

Compressor Outlet 7.0 bar

Automatically Loaded ↓
Menu Unload
F1 F2 F3

Fig. 4.1 Main screen, typical example

If the function keys or arrow keys are not used for some minutes, the display will automatically return
to the Main screen.

Whenever displayed on a submenu screen, press the key Mainscreen to return to the Main screen.

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4.3 Calling up other menus

Starting from the Main screen:

- Use the ↓ key (Fig. 2.1) for a quick look at the actual compressor status (see section 5).
- Press the key Menu (F1); the option Status data will be followed by a horizontal arrow:
- either press the tabulator key (5-Fig. 2.1) to select this menu
- or use the ↓ key (Fig. 2.1) to scroll until the desired submenu is followed by a
horizontal arrow and then press tabulator key (5-Fig. 2.1) to select this menu.

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-Motor Starts -Oil Separator

-Module Hours -Dryer LAT
-Load Relay -Emergency Stop
Automatic Operation Maximum Pressure 8.3 bar ↑ -Compressor Outlet -Remote Start/Stop
Compressor Outlet 6.4 bar
-Dp Oil Sseparator -Remote Load/Unload
Local Control Running Hours 1016 hrs -Remote Pressure Sensing
-Dp Air Filter
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Oil Injection Element -Overload Motor
-Compressor Outlet -Overload Fanmotor
Menu Unload Mainscreen Help Extra Mainscreen Help Extra -Starter Feedback Contact
-Element 1 Outlet
-Element 2 Outlet -PB 1 open/ PB2 closed
-Cooling Medium -Overload Dryer/Dryer Fan

Status Data → All Conditions Are OK

Measured Data
Counters ↓ -Oil Injection Element -Remote Start/Stop
-Compressor Outlet -Remote LoadUnload
Mainscreen Menu Help -Element 1 Outlet -Remote Pressure Sensing
-Element 2 Outlet -Overload Motor
-Cooling Medium -Overload Fanmotor
-Oil Separator -Starter Feedback Contact
Status Data ↑ Compressor Outlet 6.4 bar -I -Dryer LAT -PB1 open/ PB2 closed
Measured Data → Dp Oil Separator 0.4 bar -Emergency Stop -Overload Dryer/Dryer Fan

Counters ↓ Dp Air Filter 0.02 bar ↓

Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1016 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Permisive Start Time
-Communication Time-out
Counters ↑ Display Test → -Oil Injection Element
Test → Parameters ↑ Compressor Outlet 6.4 bar -Compressor Outlet
Safety Valve Test
Protections → Dp Oil Separator 0.4 bar -Element 1 Outlet
Modify Parameters ↓ ↓ -Element 2 Outlet
Mainscreen Service Plan ↓ Dp Air Filter - 0.02 bar ↓ -Cooling Medium
Menu
Menu Menu -Oil Separator
-Dryer LAT
-Emergency Stop
Test ↑ Parameters → Protections ↑ Service Timer -Remote Start/Stop
-Remote Load/Unload
Modify Parameters → Protections Service Plan → Running hours → -Remote Pressure Sensing
Service ↓ Service Plan ↓ Clock Function ↓ 130 hrs ↓ -Overload Motor
-Overload Fanmotor
Mainscreen Menu Menu Menu -Starter Feedback Contact
-PB1 open/ PB2 closed
-Overload Dryer/Dryer Fan
Service Plan ↑ Clock Function
Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 130 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52762PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Password
-Node ID
Saved Data → Last Shutdown 3 ↓
-Digital Presband Selec.
Mainscreen Menu

Fig. 4.2 Menu flow, GA90/315 (60 Hz) air-cooled (typical example)

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Instruction book

-Motor Starts -Condensing Temperature

-Module Hours -Dryer Ambient
-Load Relay -Cool Water In
Compressor Outlet 6.4 bar Automatic Operation Maximum Pressure 8.3 bar ↑ -Compressor Outlet -Cool Water Out
-Dp oilseparator -Emergency Stop
Local Control Running Hours 1016 hrs -Remote Start/Stop
-Dp Air Filter
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Oil injection element -Remote Load/Unload
-Compressor Outlet -Remote pressure sensing
Menu Unload Mainscreen Help Extra Mainscreen Help Extra -Element 1 Outlet -Overload Motor
-Element 2 Outlet -Starter Feedback Contact
-Cooling medium -PB 1 open/ PB2 closed
-Oil separator -High Pressure Dryer
-Dryer LAT -Overload Dryer

Status Data → All Conditions Are OK

Measured Data -Oil Injection Element -Cool Water Out
Counters ↓ -Compressor Outlet -Emergency Stop
-Element 1 Outlet -Remote Start/Stop
Mainscreen Menu Help -Element 2 Outlet -Remote LoadUnload
-Cooling Medium -Remote Pressure Sensing
-Oil Separator -Overload Motor
-Dryer LAT -Starter Feedback Contact
Status Data ↑ Compressor Outlet 6.4 bar -I -Condensing Temperature -PB1 open/ PB2 closed
Measured Data → Dp Oil Separator 0.4 bar -Dryer Ambient -High Pressure Dryer
-Cool Water In -Overload Dryer
Counters ↓ Dp Air Filter 0.02 bar ↓
Mainscreen Menu
-Module Hours
-Load Relay

Measured Data ↑ Running Hours 1016 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Permisive Start Time
-Communication Time-out
Counters ↑ Display Test → -Oil Injection Element
Test → Parameters ↑ Compressor Outlet 6.4 bar -Compressor Outlet
Safety Valve Test
Protections → Dp Oil Separator 0.4 bar -Element 1 Outlet
Modify Parameters ↓ ↓ -Element 2 Outlet
Mainscreen Service Plan ↓ Dp Air Filter - 0.02bar ↓ -Cooling Medium
Menu
Menu Menu -Oil Separator
-Dryer LAT
-Condensing Temperature
Test ↑ Parameters → Protections ↑ Service Timer -Cool Water In
-Cool Water Out
Modify Parameters → Protections Service Plan → Running hours → -Dryer Ambient
Service ↓ Service Plan ↓ Clock Function ↓ 130 hrs ↓ -Emergency Stop
-Remote Start/Stop
Mainscreen Menu Menu Menu -Remote Load/Unload
-Remote Pressure Sensing
-Overload Motor
Service Plan ↑ Clock Function -Starter Feedback Contact
-PB1 open/ PB2 closed
Clock Function → Not Activated → -High Pressure Dryer
Configuration ↓ -Overload Dryer

Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 130 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52763PEN -Setpoint selection
Modify Parameters ↑ Last Shutdown 1 →
-CCM (control mode)
Service Last Shutdown 2 -Automatic Restart
-Password
Saved Data → Last Shutdown 3 ↓
-Node ID
Mainscreen Menu -Digital Presband Selec.

Fig. 4.3a Menu flow, GA90/315 (60 Hz) water-cooled (typical example)

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Instruction book

-Loaded Hours -Oil Separator 1

-Motor Starts -Oil Separator 2
-Module Hours -Oil Injection Element 1
Compressor Outlet 6.4 bar Automatic Operation Maximum Pressure 8.3 bar ↑ -Load Relay -Oil Injection Element 2
-Compressor Outlet -Emergency Stop
Local Control Pressure Band Used Press. Band 1 -Remote Start/Stop
-Dp Oilseparator 1
Automatically Loaded ↓ Week Timer Active ↓ Running Hours 1016 hrs ↓ -Dp Oilseparator 2 -Remote Load/Unload
-Dp Air Filter -Remote pressure sensing
Menu Unload Mainscreen Help Extra Mainscreen Help Extra -Compressor Outlet -Overload Motor
-Element 1 Outlet -Starter Feedback Contact
-Element 2 Outlet -PB 1 open/ PB2 closed
-Cooling Water Out

Status Data → All Conditions Are OK

Measured Data -Dp Air Filter -Oil Injection Element 2
Counters ↓ -Compressor Outlet -Emergency Stop
-Element 1 Outlet -Remote Start/Stop
Mainscreen Menu Help -Element 2 Outlet -Remote Load/Unload
-Cooling Water Out -Remote Pressure Sensing
-Oil Separator 1 -Overload Motor
-Oil Separator 2 -Starter Feedback Contact
Status Data ↑ Compressor Outlet 6.4 bar -I -Oil Injection Element 1 -PB1 open/ PB2 closed
Measured Data → Dp Oil Separator 1 0.4 bar
Counters ↓ Dp Oil Separator 2 0.4bar ↓
Mainscreen Menu
-Module Hours
-Load Relay

Measured Data ↑ Running Hours 1016 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Permisive Start Time
-Communication Time-out
Counters ↑ Display Test → -Dp Air Filter
Test → Parameters ↑ Compressor Outlet 6.4 bar -Compressor Outlet
Safety Valve Test
Protections → Dp Oil Separator 1 0.4 bar -Element 1 Outlet
Modify Parameters ↓ Outputs ↓ -Element 2 Outlet
Mainscreen Service Plan ↓ Dp Oil Separator 2 0.4bar ↓ -Cooling Water Out
Menu
Menu Menu -Oil Separator 1
-Oil Separator 2
-Oil Injection Element 1
Test ↑ Parameters → Protections ↑ Service Timer -Oil Injection Element 2
-Emergency Stop
Modify Parameters → Protections Service Plan → Running hours → -Remote Start/Stop
Service ↓ Service Plan ↓ Clock Function ↓ 130 hrs ↓ -Remote Load/Unload
-Remote Pressure Sensing
Mainscreen Menu Menu Menu -Overload Motor
-Starter Feedback Contact
-PB1 open/ PB2 closed
Service Plan ↑ Clock Function
Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ C.C.M. Local Control -Language In Use
Service → Running Hours →
Clock Function Pressure Band Used Press. Band 1 -Time
Saved Data ↓ 130 hrs ↓ -Date
Configuration → Note ID 31 ↓ -Date Format
Mainscreen Menu
Menu -Pressure Unit
Menu Modify -Temperature Unit
-Vibration Unit
55283PEN -Level Unit
Modify Parameters ↑ Last Shutdown 1 →
-Start Mode
Service Last Shutdown 2 -Automatic Restart
-Password
Saved Data → Last Shutdown 3 ↓
-M.C.C.
Mainscreen Menu -Digital Presband Selec.

Fig. 4.3b Menu flow, GA315 (50 Hz)/500 water-cooled (typical example)

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Instruction book

-Motor Starts -Oil separator

-Module Hours -Dryer LAT
-Load Relay -Emergency Stop
Automatic Operation Maximum Pressure bar ↑ -Compressor Outlet -Remote Start/Stop
Compressor Outlet 19 bar
-Dp oilseparator -Remote Load/Unload
Interstage 5.5 bar Local Control Running Hours 1016 hrs -Remote pressure sensing
-Dp Air Filter
Week Timer Active ↓ -Oil injection element -Overload Motor
Automatically Loaded ↓ Loaded Hours 980 hrs ↓
-Compressor Outlet -Overload Fanmotor
Mainscreen Help Extra Mainscreen Help Extra -Starter Feedback Contact
Menu Unload -Element 1 Outlet
-Element 2 Outlet -PB 1 open/ PB2 closed
-Cooling medium -Overload dryerdryer fan

Status Data → All Conditions Are OK

Measured Data
Counters ↓ -Oil Injection Element -Remote Start/Stop
-Compressor Outlet -Remote LoadUnload
Mainscreen Menu Help -Element 1 Outlet -Remote Pressure Sensing
-Element 2 Outlet -Overload Motor
-Cooling Medium -Overload Fanmotor
-Oil Separator -Starter Feedback Contact
Status Data ↑ Compressor Outlet 19 bar -I -Dryer LAT -PB1 open/ PB2 closed
Measured Data → Dp Oil Separator 0.4 bar -Emergency Stop -Overload Dryer/Dryer Fan

Counters ↓ Dp Air Filter 0.02 bar ↓

Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1016 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 18.0 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 19.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 17.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Permisive Start Time
-Communication Time-out
Counters ↑ Display Test → -Oil Injection Element
Test → Parameters ↑ Compressor Outlet 19 bar -Compressor Outlet
Safety Valve Test
Protections → Dp Oil Separator 0.4 bar -Element 1 Outlet
Modify Parameters ↓ ↓ -Element 2 Outlet
Mainscreen Service Plan ↓ Dp Air Filter - 0.02 bar ↓ -Cooling Medium
Menu
Menu Menu -Oil Separator
-Dryer LAT
-Emergency Stop
Test ↑ Parameters → Protections ↑ Service Timer -Remote Start/Stop
-Remote Load/Unload
Modify Parameters → Protections Service Plan → Running hours → -Remote Pressure Sensing
Service ↓ Service Plan ↓ Clock Function ↓ 130 hrs ↓ -Overload Motor
-Overload Fanmotor
Mainscreen Menu Menu Menu -Starter Feedback Contact
-PB1 open/ PB2 closed
-Overload Dryer/Dryer Fan
Service Plan ↑ Clock Function
Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 130 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52764PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Password
-Node ID
Saved Data → Last Shutdown 3 ↓
-Digital Presband Selec.
Mainscreen Menu

Fig. 4.4 Menu flow, GR110/200 (typical example)

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Instruction book

-Motor Starts -Oil Temperature

Compressor Outlet 2.5 bar Automatic Operation Maximum Pressure 3 bar ↑ -Module Hours -Emergency Stop
-Load relay -Remote Start/Stop
Local Control Running Hours 1075 hrs
-Compressor Outlet -Remote Load/Unload
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Dp Air Filter -Remote Pressure Sensing
-Oil Pressure -Overload Motor
Menu Unload Mainscreen Help Extra Mainscreen Help Extra
-Compressor Outlet -Starter Feedback Contact
-Element 1 Outlet -PB1 Open/PB2 Closed
-Cooling Water In -Electr. Condensate Drain
-Cooling Water Out -Overload Dryer

Status Data → All Conditions Are OK

Measured Data
-Compressor Outlet -Remote Load/Unload
Counters ↓ -Remote Pressure Sensing
-Element 1 Outlet
Mainscreen Menu Help -Cooling Water In -Overload Motor
-Cooling Water Out -Starter Feedback Contact
-Oil Temperature -PB1 Open/PB2 Closed
-Emergency Stop -Electr. Condensate Drain
Status Data ↑ Compressor Outlet 2.5 bar -I -Remote Start/Stop -Overload Dryer

Measured Data → Dp Air Filter -0.026 bar

Counters ↓ Oil Pressure 2.2 bar ↓
Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1075 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 2.0 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 2.5 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 1.8 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Communication Time-out

Counters ↑ Display Test → -Compressor Outlet

Test → Parameters ↑ Compressor Outlet 2.5 bar -Element 1 Outlet
Safety Valve Test
Protections → Dp Air Filter -0.026 bar -Cooling Water In
Modify Parameters ↓ ↓ -Cooling Water Out
Mainscreen Service Plan ↓ Oil Pressure 2.2 bar ↓ -Oil Temperature
Menu
Menu Menu -Emergency Stop
-Remote Start/Stop
-Remote Load/Unload
Test ↑ Parameters → Protections ↑ Service Timer -Remote Pressure Sensing
-Overload Motor
Modify Parameters → Protections Service Plan → Running hours → -Starter Feedback Contact
Service ↓ Service Plan ↓ Clock Function ↓ 175 hrs ↓ -PB1 Open/PB2 Closed
-Electr. Condensate Drain
Mainscreen Menu Menu Menu -Overload Dryer

Service Plan ↑ Clock Function

Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 175 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52766PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Node ID
-MCC
Saved Data → Last Shutdown 3 ↓
-Digital Presband Selection
Mainscreen Menu

Fig. 4.5 Menu flow, ZE/ZA (typical example)

2920 1478 02 15
Instruction book

-Motor Starts -Emergency Stop

Compressor Outlet 6.4 bar Automatic Operation Maximum Pressure bar ↑ -Module Hours -Remote Start/Stop
-Load Relay -Remote Load/Unload
Local Control Running Hours 1075 hrs
-Compressor Outlet -Remote Pressure Sensing
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Dp Air Filter -Overload Motor
-Oil Pressure -Overload Fan motor
Menu Unload Mainscreen Help Extra Mainscreen Help Extra
-Intercooler -Starter Feedback Contact
-Compressor Outlet -PB1 Open/PB2 Closed
-Element 1 Outlet -Electr. Condensate Drain
-Element 2 Inlet
-Element 2 Outlet

Status Data → All Conditions Are OK

Measured Data
-Intercooler -Remote Load/Unload
Counters ↓ -Remote Pressure Sensing
-Compressor Outlet
Mainscreen Menu Help -Element 1 Outlet -Overload Motor
-Element 2 Inlet -Overload Fan Motor
-Element 2 Outlet -Starter Feedback Contact
-Emergency Stop -PB1 Open/PB2 Closed
Status Data ↑ Compressor Outlet 6.4 bar -I -Remote Start/Stop -Electr. Condensate Drain

Measured Data → Dp Air Filter -0.026 bar

Counters ↓ Oil Pressure 2.4 bar ↓
Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1075 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Communication Time-out

Counters ↑ Display Test → -Intercooler

Parameters ↑ Compressor Outlet 6.4 bar
Test → Safety Valve Test -Compressor Outlet
Protections → Dp Air Filter -0.026 bar -Element 1 Outlet
Modify Parameters ↓ ↓ -Element 2 Inlet
Service Plan ↓ Oil Pressure 2.4 bar ↓
Mainscreen Menu -Element 2 Outlet
Menu Menu -Emergency Stop
-Remote Start/Stop
-Remote Load/Unload
Test ↑ Parameters → Protections ↑ Service Timer -Remote Pressure Sensing
-Overload Motor
Modify Parameters → Protections Service Plan → Running hours → -Overload Fan Motor
Service ↓ Service Plan ↓ Clock Function ↓ 175 hrs ↓ -Starter Feedback Contact
-PB1 Open/PB2 Closed
Mainscreen Menu Menu Menu -Electr. Condensate Drain

Service Plan ↑ Clock Function

Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 175 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52760PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Node ID
-MCC
Saved Data → Last Shutdown 3 ↓
-Digital Presband Selection
Mainscreen Menu

Fig. 4.6 Menu flow, ZT15/45 (typical example)

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Instruction book

-Motor Starts -Emergency Stop

Compressor Outlet 6.4 bar Automatic Operation Maximum Pressure bar ↑ -Module Hours -Remote Start/Stop
-Load Relay -Remote Load/Unload
Local Control Running Hours 1075 hrs
-Compressor Outlet -Remote Pressure Sensing
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Dp Air Filter -Overload Motor
-Oil Pressure -Overload Fan motor
Menu Unload Mainscreen Help Extra Mainscreen Help Extra
-Intercooler -Starter Feedback Contact
-Compressor Outlet -PB1 Open/PB2 Closed
-Element 1 Outlet -Electr. Condensate Drain
-Element 2 Inlet
-Element 2 Outlet

Status Data → All Conditions Are OK

Measured Data
-Intercooler -Remote Load/Unload
Counters ↓ -Remote Pressure Sensing
-Compressor Outlet
Mainscreen Menu Help -Element 1 Outlet -Overload Motor
-Element 2 Inlet -Overload Fan Motor
-Element 2 Outlet -Starter Feedback Contact
-Emergency Stop -PB1 Open/PB2 Closed
Status Data ↑ Compressor Outlet 6.4 bar -I -Remote Start/Stop -Electr. Condensate Drain

Measured Data → Dp Air Filter -0.026 bar

Counters ↓ Oil Pressure bar ↓
Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1075 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Communication Time-out

Counters ↑ Display Test → -Intercooler

Parameters ↑ Compressor Outlet 6.4 bar
Test → Safety Valve Test -Compressor Outlet
Protections → Dp Air Filter -0.026 bar -Element 1 Outlet
Modify Parameters ↓ ↓ -Element 2 Inlet
Service Plan ↓ Oil Pressure bar ↓
Mainscreen Menu -Element 2 Outlet
Menu Menu -Emergency Stop
-Remote Start/Stop
-Remote Load/Unload
Test ↑ Parameters → Protections ↑ Service Timer -Remote Pressure Sensing
-Overload Motor
Modify Parameters → Protections Service Plan → Running hours → -Overload Fan Motor
Service ↓ Service Plan ↓ Clock Function ↓ 175 hrs ↓ -Starter Feedback Contact
-PB1 Open/PB2 Closed
Mainscreen Menu Menu Menu -Electr. Condensate Drain

Service Plan ↑ Clock Function

Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 175 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52761PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Node ID
-MCC
Saved Data → Last Shutdown 3 ↓
-Digital Presband Selection
Mainscreen Menu

Fig. 4.7 Menu flow, ZT55/90 (typical example)

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Instruction book

-Motor Starts -Oil Temperature

Compressor Outlet 6.4 bar Automatic Operation Maximum Pressure bar ↑ -Module Hours -Emergency Stop
-Load relay -Remote Start/Stop
Local Control Running Hours 1075 hrs
-Compressor Outlet -Remote Load/Unload
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Dp Air Filter -Remote Pressure Sensing
-Oil Pressure -Overload Motor
Menu Unload Mainscreen Help Extra Mainscreen Help Extra
-Intercooler -Starter Feedback Contact
-Compressor Outlet -PB1 Open/PB2 Closed
-Element 1 Outlet -Electr. Condensate Drain
-Element 2 Inlet -Overload Dryer
-Element 2 Outlet

Status Data → All Conditions Are OK

Measured Data
-Intercooler -Remote Load/Unload
Counters ↓ -Remote Pressure Sensing
-Compressor Outlet
Mainscreen Menu Help -Element 1 Outlet -Overload Motor
-Element 2 Inlet -Starter Feedback Contact
-Element 2 Outlet -PB1 Open/PB2 Closed
-Oil Temperature -Electr. Condensate Drain
Status Data ↑ Compressor Outlet 6.4 bar -I -Emergency Stop -Overload Dryer
-Remote Start/Stop
Measured Data → Dp Air Filter -0.026 bar
Counters ↓ Oil Pressure 2.5 bar ↓
Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1075 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Communication Time-out

Counters ↑ Display Test → -Intercooler

Test → Parameters ↑ Compressor Outlet 6.4 bar -Compressor Outlet
Safety Valve Test
Protections → Dp Air Filter -0.026 bar -Element 1 Outlet
Modify Parameters ↓ ↓ -Element 2 Inlet
Mainscreen Service Plan ↓ Oil Pressure 2.5 bar ↓ -Element 2 Outlet
Menu
Menu Menu -Oil Temperature
-Emergency Stop
-Remote Start/Stop
Test ↑ Parameters → Protections ↑ Service Timer -Remote Load/Unload
-Remote Pressure Sensing
Modify Parameters → Protections Service Plan → Running hours → -Overload Motor
Service ↓ Service Plan ↓ Clock Function ↓ 175 hrs ↓ -Starter Feedback Contact
-PB1 Open/PB2 Closed
Mainscreen Menu Menu Menu -Electr. Condensate Drain
-Overload Dryer

Service Plan ↑ Clock Function

Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 175 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52767PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Node ID
-MCC
Saved Data → Last Shutdown 3 ↓
-Digital Presband Selection
Mainscreen Menu

Fig. 4.8 Menu flow, ZT110/750 (typical example)

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Instruction book

-Motor Starts -Element 2 Outlet

Compressor Outlet 6.4 bar Automatic Operation Maximum Pressure 7 bar ↑ -Module Hours -Element 2 Inlet
Local Control -Compressor Outlet -Cooling Water In
Running Hours 1075 hrs
-Dp Air Filter -LP Cooling Water Out
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Oil Pressure -Cooling Water Out
Menu Unload Mainscreen Help Extra -Intercooler -Oil Temperature
Mainscreen Help Extra
-Compressor Outlet -Emergency Stop
-Element 1 Outlet -Remote Start/Stop

Status Data → All Conditions Are OK

Measured Data
-Intercooler -LP Cooling Water Out
Counters ↓ -Cooling Water Out
-Compressor Outlet
Mainscreen Menu Help -Element 1 Outlet -Oil Temperature
-Element 2 Outlet -Emergency Stop
-Element 2 Inlet -Remote Start/Stop
-Cooling Water In
Status Data ↑ Compressor Outlet 6.4 bar -I
Measured Data → Dp Air Filter -0.026 bar
Counters ↓ Oil Pressure 2.5 bar ↓
Mainscreen Menu -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1075 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar -I -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Communication Time-out

Counters ↑ Display Test → -Intercooler

Test → Parameters ↑ Compressor Outlet 6.4 bar -Compressor Outlet
Safety Valve Test
Protections → Dp Air Filter -0.026 bar -Element 1 Outlet
Modify Parameters ↓ ↓ -Element 2 Outlet
Mainscreen Service Plan ↓ Oil Pressure 2.5 bar ↓ -Element 2 Inlet
Menu
Menu Menu -Cooling Water In
-LP Cooling Water Out
-Cooling Water Out
Test ↑ Parameters → Protections ↑ Service Timer -Oil Temperature
-Emergency Stop
Modify Parameters → Protections Service Plan → Running hours → -Remote StartStop
Service ↓ Service Plan ↓ Clock Function ↓ 175 hrs ↓
Mainscreen Menu Menu Menu

Service Plan ↑ Clock Function

Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 175 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Setpoint Selection
-CCM (control mode)
52765PEN -Node ID
Modify Parameters ↑ Last Shutdown 1 →
Service Last Shutdown 2
Saved Data → Last Shutdown 3 ↓
Mainscreen Menu

Fig. 4.9 Menu flow ZR110/750 (typical example)

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Instruction book

-Motor Starts -P Water Injec/Separator

-Module Hours -Emergency Stop
-Load Relay -Remote Start/Stop
Compressor Outlet 7.0 bar Automatic Operation Maximum Pressure 7.5 bar ↑ -Compressor Outlet -Remote Load/Unload
-Separator -Remote Pressure Sensing
Local Control Running Hours 1016 hrs -Overload Motor
-Water Injection
Automatically Loaded ↓ Week Timer Active ↓ Loaded Hours 980 hrs ↓ -Blocking Air -Pump Overload
-Element Outlet -Water Level High Switch
Menu Unload Mainscreen Help Extra Mainscreen Help Extra -T Injection -Water Level Low Switch
-Delta T Element -Phase Sequence
-PB 1 open/ PB2 closed

Status Data → All Conditions Are OK

Measured Data
Counters ↓ -Blocking Air -Remote Pressure Sensing
-Element Outlet -Overload Motor
Mainscreen Menu Help -T Injection -Pump Overload
-Delta T Element -Water Level High Switch
-P Water Injec/Separator -Water Level Low Switch
-Emergency Stop -Phase Sequence
Status Data ↑ Compressor Outlet 7.0 bar → -Remote Start/Stop -PB 1 open/ PB2 closed
Measured Data → Separator 2.2 bar -Remote Load/Unload

Counters ↓ Water Injection 5.7 bar ↓

Mainscreen Menu Extra -Module Hours
-Load Relay

Measured Data ↑ Running Hours 1016 hrs

Loaded Hours 980 hrs -Unloading Pressure 2
Counters → Loading Pressure 6.4 bar ? -Y-Time
Test ↓ Motor Starts 945 number ↓ Unloading Pressure 7.0 bar -Load Delay
Menu -Nr Of Starts/ Day
Mainscreen Loading Pressure 2 6.0 bar ↓ -Minimum Stop Time
Menu Modify -Programmed Stop Time
-Permissive Start Time
-Communication Time-out
Counters ↑ Display Test → -Blocking Air
Test → Parameters ↑ Compressor Outlet 7.0 bar -Element Outlet
Safety Valve Test
Protections → Separator 2.2 bar -T Injection
Modify Parameters ↓ Outputs ↓ -Delta T Element
Mainscreen Service Plan ↓ Water Injection 5.7 bar ↓ -P Water Injec/Separator
Menu
Menu Menu -Emergency Stop
-Remote Start/Stop
-Remote Load/Unload
Test ↑ Parameters → Protections ↑ Service Timer -Remote Pressure Sensing
-Overload Motor
Modify Parameters → Protections Service Plan → Running hours → -Pump Overload
Service ↓ Service Plan ↓ Clock Function ↓ 130 hrs ↓ -Water Level High Switch
-Water Level Low Switch
Mainscreen Menu Menu Menu -Phase Sequence
-PB 1 open/ PB2 closed

Service Plan ↑ Clock Function

Clock Function → Not Activated →
Configuration ↓
Menu Menu Modify Delete

Modify Parameters ↑ Service Timer

Service Plan ↑ Time 10:54 -Language In Use
Service → Running Hours →
Clock Function Date 03/05/01 -Pressure Unit
Saved Data ↓ 130 hrs ↓ -Temperature Unit
Configuration → Date Format DD/MM/YY ↓ -Vibration Unit
Mainscreen Menu
Menu Menu Modify -Level Unit
-Pressure Band Used
-Start Mode
52974PEN -CCM (control mode)
Modify Parameters ↑ Last Shutdown 1 →
-Automatic Restart
Service Last Shutdown 2 -Password
-Node ID
Saved Data → Last Shutdown 3 ↓
-MCC
Mainscreen Menu -Digital Presband Selec.

Fig. 4.10 Menu flow AQ 30/55 (typical example)

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5 Quick look at actual compressor status

Procedure
1. Starting from the Main screen (see section 4.2), press the ↓ key: A screen similar to the one
below appears:

Automatic Operation
Local Control
Week Timer Active ↓
Mainscreen Help Extra
F1 F2 F3

Fig. 5.1 Example of an actual compressor status display

Line 1 indicates the automatic or manual operation status of the regulator:

<<Automatic operation>> means that the regulator automatically adapts the operation of the
compressor, i.e. matching the compressor output to the air consumption.

Line 2 indicates whether the regulator operates in local control or remote control mode:

<<Local control>> means that the start/stop buttons on the keyboard are activated.
<<Remote control>> means that these functions are controlled remotely. Consult Atlas Copco.

Line 3 indicates whether the timer, which generates time-based start and stop commands, is activated
or not. See section 13.

See section 3.4 for the functions of keys Mainscreen, Help and Extra.

2. Press the ↓ key to get other data (actual compressor conditions of the compressor) as shown
in Figs. 4.2 up to 4.10.

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6 Status data menu

Function
The status data submenu gives information regarding the status of the compressor protection
functions (shut-down, shut-down warning, service warning and warning) and allows resetting of a shut-
down, motor overload and service condition.

Procedure
Starting from the Main screen (see section 4.2):
- Press the key Menu (F1): the option Status data will be followed by a horizontal arrow.
- Press the tabulator key (5-Fig. 2.1).

6.1 No message exists

In this case, LED (7-Fig. 2.1) is out and the message on the display indicates that all conditions are
normal (Fig. 6.1):

All conditions Are OK

Menu Help
F1 F2 F3

Fig. 6.1 Example of a status data screen

6.2 A shut-down message exists

In case the compressor is shut down, LED (7-Fig. 2.1) will blink.

In case of a shut-down due to too high a temperature at the compressor element outlet, a screen
similar to the one below will appear:

Element Outlet 123 °C

Shutdown Maximum 110 °C

Menu *** Help *** Reset
F1 F2 F3

Fig. 6.2 Example of a status data screen

1. The indicators (***) are blinking. The screen shows the sensor (Element outlet), the actual
reading (123 °C), that the compressor is shut down (Shutdown), and the shutdown setting
(110 °C).
2. It remains possible to scroll through other menus, e.g. to check the values of other
parameters.

When returning to the Status data menu, the option Shutdowns will blink. This option can be
selected by pressing the tabulator key (5-Fig. 2.1) to return to the shut-down screen (Fig. 6.2).

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Shut-down reset

1. Switch off the voltage and remedy the trouble. After remedying and when the shut-down
condition has disappeared, switch on the voltage and press the key Reset.
2. Press the keys Menu and Mainscreen to return to the Main screen and restart the compressor
by means of button I.

Reset of fan motor overload

1. Switch off the voltage and remedy the trouble. Reset the overload relay after cooling off.
When the shut-down condition has disappeared, switch on the voltage and press the key
Reset.
2. Press the keys Menu and Mainscreen to return to the Main screen and restart the compressor
by means of button I.

6.3 A shut-down warning message exists

A shut-down warning level is a programmable level below the shut-down level.

1. If a shut-down warning exists, LED (7-Fig. 2.1) is alight. The Main screen will change into a
screen similar to the one below:

Compressor Outlet 7.0 bar

***** Shutdown Warning ***** ↓

Menu *** ***
F1 F2 F3

Fig. 6.3 Example of a shut-down warning screen

2. The message *Shutdown Warning* appears.

3. Press the key Menu (F1) and the tabulator key (5-Fig. 2.1) to select the Status data menu, the
option Protection is blinking.
4. Scroll to this option and select it by pressing the tabulator key (5-Fig. 2.1): option Warnings
blinks; scroll to this option and select it by pressing the tabulator key. A screen similar to the
one in Fig. 6.4 appears:

Element 2 Inlet 67 °C

Shutd. Warn. Maximum 65 °C ↓

Menu *** ***
F1 F2 F3

Fig. 6.4 Example of a shut-down warning screen

The screen shows that the temperature at the inlet of the HP compressor element (67 °C) is too high.
5. If necessary, stop the compressor by means of button O and wait until the compressor has
stopped.
6. Switch off the voltage, inspect the compressor and remedy.
7. The warning message will disappear automatically as soon as the warning condition
disappears.

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6.4 A service warning message exists

1. LED (7-Fig. 2.1) is alight and the main screen will change into a screen similar to that shown
in Fig. 6.5.

Compressor Outlet 7.0 bar

*Service Required *
Menu *** ***
F1 F2 F3

Fig. 6.5 Example of a warning screen

2. The indicators (***) are blinking and the service warning message appears.
3. Press the key Menu (F1) and the tabulator key (5-Fig. 2.1) to select the Status data menu: the
option Service is blinking.
4. Scroll to this option and select it by pressing the tabulator key (5-Fig. 2.1); two options may
blink:
<<Inputs>>: if the programmed service level of a component is exceeded (e.g. the maximum
pressure drop of the air filter).
<<Plans>>: if a service plan interval is exceeded.
5. Stop the compressor and switch off the voltage.
6. In case the service message was referring to <<Inputs>> (air filter): replace the filter, switch
on the voltage, scroll in the Status data menu to <<Inputs>> and press the Reset key to reset
the service message.
7. In case the service message was referring to <<Plans>>: carry out the service actions related
to the indicated plans. Reset the timers of the related plans as described in section 15.

6.5 A warning message exists

1. LED (7-Fig. 2.1) is alight and a warning message will appear on the screen.
2. The indicators (***) are blinking and the warning message appears. The warning indicates
that on Full-Feature compressors (compressors with integrated air dryer), the dewpoint
temperature exceeds the warning level.
3. Stop the compressor and wait until the compressor has stopped.
4. Switch off the voltage, inspect the compressor and remedy.

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7 Measured data menu

Function
To call up information regarding the actually measured data and the status of a number of inputs, such
as the motor overload protection.

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Measured data is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. By pressing the ↓ key, a number of actually measured data can be found (see Figs. 4.2 up to
4.10).
3. If one of the sensors is linked to a shut-down, service or warning function, both the actually
measured value as well as the corresponding shut-down, warning or service level can be
called up by pressing the tabulator key (5-Fig. 2.1).

8 Counters menu

Function
To allow the operator to call up the:
- running hours
- loaded hours
- number of motor starts
- regulator (module) hours (the hours the module has been under tension)
- load relay

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Counters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. By pressing the ↓ key, the above-mentioned items can be found (see also Figs. 4.2 up to
4.10).

Loaded Hours 98 hours ↑

Motor Starts 57 number
Module hours 123 hours ↓
Menu
F1 F2 F3

Fig. 8.1 Example of a counter screen

The display indicates that:

- the compressor has been in loaded condition for 98 hours
- there have been 57 motor starts
- the Elektronikon module has been under tension for 123 hours

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9 Test menu

Function
To carry out a display test, i.e. to check whether the display and LEDs are still intact.

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Test is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. The option Display test will be followed by a horizontal arrow.
3. After pressing the tabulator key (5-Fig. 2.1), the regulator will generate a series of patterns on
the display, which enable the operator to check that each pixel still functions normally; at the
same time the LEDs are lit.

10 Modify parameters

Function
The menu allows the operator to program:
- Parameters
- Protections
- Service Plan
- Clock Function
- Configuration

10.1 Modifying parameters

Function
To modify a number of settings as mentioned in Figs. 4.2 up to 4.10.

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by an horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. The first option (Parameters) will be followed by a horizontal arrow.
3. Press the tabulator key (5-Fig. 2.1): the first item (Loading pressure) and its setting will
appear.
4. Use the ↓ key to scroll until the parameter to be modified is followed by a horizontal arrow.

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Modifying the loading pressure setpoint

If desired, the operator can program two pressure bands (Loading pressure/Unloading pressure and
Loading pressure 2/Unloading pressure 2).

1. Consult the steps above to select <<Loading pressure>>.

2. The screen shows that the current setting is 6.4 bar(e). To modify this setting, press the key
Modify (F2); the setting will blink.
3. The key Limits (F2) can be used to find out the limitations for the parameter. Use the ↓ or ↑
arrow key to change the value.
4. Press the key Program (F1) to program the new setting or the key Cancel (F3) to cancel the
modification operation.
5. If required, the procedure to modify <<Unloading pressure>> is similar to the description
above.

Loading Pressure 6.4 bar

Unloading Pressure 7.0 bar
Loading Pressure 2 6.0 bar ↓
Menu Modify
F1 F2 F3

Fig. 10.1 Modify parameters screen, typical example

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11 Modifying protection settings

Function
1. To modify protection settings:
- shut-down (<<Shutdown>>), e.g. for element outlet temperature
- shut-down warning (<<Shutdown warning>>), e.g. for element outlet temperature
- warning (<<Warning>>), e.g. for cooling water outlet or dewpoint
- service warning (<<Service>>), e.g. Dp of oil separator (max. pressure drop)

2. To check some compressor conditions, e.g. the status of the emergency stop button. The list
of parameters is shown in Figs. 4.2 up to 4.10.

Note
Some parameters cannot be modified.

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. Use the ↓ key to scroll until the option Protections is followed by a horizontal arrow.
3. Press the tabulator key (5-Fig. 2.1): the first item (e.g. Compressor outlet) and its value will
appear.
4. Use the ↓ key to scroll until the parameter to be modified is followed by a horizontal arrow and
press tabulator key (5-Fig. 2.1).

11.1 Modifying settings for compressor element temperature

1. Consult the section above to select the parameter Element 1 outlet:

Element 1 Outlet 94 °C
→
Shutdown Maximum 110 °C
Menu Modify
F1 F2 F3

Fig. 11.1 Modify parameters menu

2. The screen shows that the current temperature is 94 °C and that the shut-down setting is 110
°C. To modify this setting, press the key Modify (F2):

Element 1 Outlet 94 °C

Shutdown Maximum 110°C (blinks) ↓

Program Limits Cancel
F1 F2 F3

Fig. 11.2 Modify parameters menu

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3. The key Limits (F2) can be used to find out the limitations for the parameter. Use the ↓ or ↑
arrow key to change the value.
4. Press the key Program (F1) to program the new setting or the key Cancel (F3) to cancel the
modification operation.
5. The screen shown in Fig. 11.1 shows an arrow pointing to the right to call up the screen to
modify the shut-down warning value:

Element 1 Outlet 94 °C

Shutd. Warn. Maximum 100 °C

Back Modify
F1 F2 F3

Fig. 11.3 Modify parameters menu

6. The screen shows that the current temperature is 94 °C and that the shut-down warning
setting is 100 °C. The modifying procedure is similar to the description above.

Note:
The modifying procedure for other settings is similar. For some settings, a delay can be programmed.
See section 17.

12 Modifying service plans

Function
To modify the hour intervals for the Service levels.

Service plans
The service operations to be carried out are grouped in plans called Service level A, B, C or D. When
reaching an interval, a message will appear on the screen indicating which Service plans are to be
carried out.

Important
Always consult Atlas Copco in case any timer setting should be changed. The intervals must not
exceed the programmed nominal values.

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13 Programming Clock function

To program:
- time-based start/stop commands for the compressor
- time-based change-over commands for the net pressure band (see also section 10)

13.1 Programming start/stop/pressure band commands

In this example, the compressor will be programmed as follows:

- On Monday at 06:15 starting in pressure band 1
- On Friday at 18:00 changing over to pressure band 2
- On Saturday at 18:00 stopping

1. Starting from the Main screen (see section 4.2):

- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. Use the ↓ key to scroll until the option Clock function is followed by a horizontal arrow. Press
the tabulator key (5-Fig. 2.1); following screen appears:

Clock Function →
Not activated

Menu Modify Delete

F1 F2 F3

3. Press the tabulator key (5-Fig. 2.1); following screen appears:

Monday →
Tuesday
Wednesday ↓
Menu Delete
F1 F2 F3

4. Use the ↓ or ↑ keys until the day on which a command must be programmed is followed by a
right pointing arrow. Press the tabulator key (5-Fig. 2.1); following screen appears:

--:-- ------------------------------- -|
--:-- -------------------------------
--:-- ------------------------------- ↓
Menu Modify Delete
F1 F2 F3

5. Press the key Modify (F2). The first two dashes will flash. Use the ↑ or ↓ key to enter
<<06>>. Press the tabulator key to jump to the following two dashes. Use the ↑ or ↓ key to
enter <<15>>. Press the tabulator key to jump to the row of dashes. Use the ↑ or ↓ key to
enter the command Start Compressor. Press the key Program to program the command:
06:15 Start Compressor.
6. Press the ↓ key: the symbol -| indicates that the second line is accessible. Press the key
Modify and modify this line in a similar way to the following command line: 06:15 Pressure
Band 1.
7. Press the key Menu (F1) and scroll to <<Friday>>:

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Thursday ↑
Friday →
Saturday ↓
Menu Delete
F1 F2 F3

8. Programming the command to change over to Pressure Band 2 at 18 o’clock is carried out in
a similar way as described above.
9. Press the key Menu (F1) and scroll to <<Saturday>>. Programming the command to
Compressor Stop at 18 o’clock is carried out in a similar way as described above.

13.2 To activate/deactivate the timer

1. Starting from the Main screen (see section 4.2):

- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. Use the ↓ key to scroll until the option Clock function is followed by a horizontal arrow. Press
the tabulator key (5-Fig. 2.1); following screen appears:

Clock Function
Not activated →

Menu Modify Delete

F1 F2 F3

3. Press the key Modify, <<Not activated>> starts blinking.

4. Press the ↓ key, <<Not activated>> changes into <<Activated>>.
5. Press the key Program.

Important:
1. It is necessary to program the start/stop/pressure band commands in successive order time
wise, e.g.:
07.30 start
07.30 band 1
08.30 band 2
17.00 stop
etc.

2. Make sure that the clock function is activated (indicated as <<Activated>>). If not, the
programmed start/stop commands will not be executed.

13.3 To modify a command

Suppose the command to stop the compressor on Saturday 18:00 is to be modified: stopping at 17
o'clock instead of 18 o'clock:
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu

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2. Use the ↓ key to scroll until the option Clock function is followed by a horizontal arrow. Press
the tabulator key (5-Fig. 2.1); following screen appears:

Clock Function
Not activated →

Menu Modify Delete

F1 F2 F3

3. Press the tabulator key (5-Fig. 2.1); following screen appears:

Monday →
Tuesday
Wednesday ↓
Menu Modify Delete
F1 F2 F3

4. Scroll through the display until <<Saturday>> is followed by a horizontal arrow. Press the
tabulator key (5-Fig. 2.1). If necessary, scroll through the compressor start/stop/pressure band
commands until the command to be modified is followed by the horizontal arrow on the
screen. Press the key Modify, the first two digits of the command start blinking. Modify as
required using the scroll keys, i.e. in the example above change <<18>> into <<17>> using
the ↑ key.
5. If necessary, press the tabulator key (5-Fig. 2.1) to go to the next field to be modified, the
minutes indication and the start/stop/pressure band indication.
6. Press the key Program to program the new command or the key Cancel to quit without
reprogramming.

13.4 To add a command

Adding a command at the end of an existing list

1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu

2. Use the ↓ key to scroll until the option Clock function is followed by a horizontal arrow. Press
the tabulator key (5-Fig. 2.1); following screen appears:

Clock Function
Not activated →

Menu Modify Delete

F1 F2 F3

Suppose the command to stop the compressor at 18:00 must be added to the list of Monday:
- 06:15 start
- 06:15 band 1

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3. Press the tabulator key (5-Fig. 2.1); following screen appears:

Monday →
Tuesday
Wednesday ↓
Menu Modify Delete
F1 F2 F3

4. Scroll through the display until <<Monday>> is followed by a horizontal arrow. Press the
tabulator key (5-Fig. 2.1). Scroll through the compressor start/stop/pressure band commands
until the first empty command line is indicated by the horizontal arrow on the screen.
5. Press the key Modify; the first two digits of the command start blinking. Enter <<18:00 stop>>
using the scroll keys ↓ or ↑ to modify a field and the tabulator key (5-Fig. 2.1) to jump from one
field to another.
6. Press the key Program to program the new command or the key Cancel to quit without
reprogramming.

Adding a command between two existing commands

1. Suppose the command 17:00 band 2 must be added to following list:
- 06:00 start
- 06:00 band 1
- 18:00 stop
2. The regulator does not allow to enter a new command which is situated before the last
command in the list time wise.
3. Scroll through the display until the command before which the new command must be entered
is followed by the horizontal arrow (in the example above: 18:00 stop) and press the key
Modify. Change this command to the new command (in the example above: 17:00 band 2)
and press the key Program. Press the ↓ key, add the last command of the list (in the example
above: 18:00 stop) and press the key Program.

13.5 To delete a command

1. Starting from the Main screen (see section 4.2):

- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. Use the ↓ key to scroll until the option Clock function is followed by a horizontal arrow. Press
the tabulator key (5-Fig. 2.1); following screen appears:

Clock Function
Not activated →

Menu Modify Delete

F1 F2 F3

Deleting all commands

Press the key Delete (F3) in the screen above. A question to confirm the deleting operation will
appear.

Deleting all commands related to a specific day

Scroll through the display until the desired day is followed by a horizontal arrow. Press the key Delete
(F3). A question to confirm the deleting operation will appear.

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Deleting a specific start/stop/pressure band command

Scroll through the display until the command line to be deleted is followed by a horizontal arrow.
Press the key Delete (F3). A question to confirm the deleting operation will appear.

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14 Configuration menu

Function
To reprogram a number of parameters. See Figs. 4.2 up to 4.10.

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. Use the ↓ key to scroll until the option Configuration is followed by a horizontal arrow.
3. Press the tabulator key (5-Fig. 2.1): The first option shown is Time. If another option is
desired, scroll through the display (using ↓ or ↑ keys) and select it using the tabulator key (5-
Fig. 2.1).
4. In case of option Time, the second line on the screen indicates the actual setting, e.g. 14:30.
5. If it is desired to modify the time, press key Modify. If not, press key Menu to return to the
submenu.
6. After pressing the key Modify, the first field (14) will blink. Modify the hours using the ↓ or ↑
keys. Then press the tabulator key (5-Fig. 2.1) to go to the next field (i.e. 30). The setting of
this field can now be modified with the ↓ or ↑ keys.
7. The bottom line of the display will show two options:
- Program to program the new setting
- Cancel to cancel the new setting
8. Proceed in a similar way for the other parameters to be modified.

14.1 Programming compressor control modes

Compressor control modes

The compressor can be controlled locally, remotely or via a local area network (LAN - consult Atlas
Copco).

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. Use the ↓ key to scroll until the option Configuration is followed by a horizontal arrow.
3. Press the tabulator key (5-Fig. 2.1): The first option shown is Time. Scroll through the display
(using ↓ or ↑ keys) until the option CCM is followed by symbol -| and press the key Modify.
Following screen is shown:

CCM Local control

Program Cancel
F1 F2 F3

Fig. 14.1 Compressor control mode menu

4. <<Local control>> is blinking; use the ↓ or ↑ keys to select the desired control mode. Press
the Program key to program or the Cancel key to cancel the modification.

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15 Service menu

Function
- To reset the service plans which are carried out.
- To check for the next service plans to be carried out.
- To find out which service plans were carried out previously.

Service plans
- Contact your Atlas Copco customer centre for the service actions related to these plans.
- Consult section 12 if any modification to the intervals should be required.

When the service plan interval is reached, a message will appear on the screen. See section 6.

Example
Programmed service plan intervals ex-factory

Service plans Intervals

Service plan A Every 4000 running hours
Service plan B Every 8000 running hours
Service plan C Every 16000 running hours
Service plan D Every 40000 running hours

Resulting service actions to be carried out

Service actions according to At

Service plan A 4000 running hours
Service plan A and B 8000 running hours
Service plan A 12000 running hours
Service plan A, B and C 16000 running hours
… ….

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Service is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. A screen similar to the one below appears:

Service Timer
Running Hours →
7971 hrs ↓
Menu
F1 F2 F3

Fig. 15.1 Service menu

The screen shows that the total compressor running time is 7971 hrs.

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3. Press the tabulator key (5-Fig. 2.1):

Next Timer
Level AB
8000 hrs ↓
Back Reset
F1 F2 F3

Fig. 15.2 Service menu

The screen shows that the next service plans to be carried out are plans A and B and that these plans
are to be carried out every 8000 running hours.

4. Press the ↓ key to find out which service plans were carried out previously:

Previous Timer ↑
Level A
4008 hrs
Back
F1 F2 F3

Fig. 15.3 Service menu

The screen shows that service plan A was carried out at 4008 running hours.

5. Stop the compressor, switch off the voltage and carry out the service operations related to
plans A and B.
6. Switch on the voltage and scroll to the service screen shown in Fig. 15.2. Press the Reset
button (F3) to reset the timer. Confirm the question for resetting.

Notes
- The Reset button only appears when the Next Timer level is almost reached before elapsing
of the service plan interval.
- After pressing the ↓ key in Fig. 15.1, the Life time hours are shown (i.e. the number of hours
elapsed since initial programming ex-factory). This counter is not taken into account.

16 Saved data menu

Function
To call up some compressor data saved by the regulator. These data are:
- Last shut-down data
- Last emergency stop data

Procedure
1. Starting from the Main screen (see section 4.2):
- press the key Menu (F1)
- press the ↓ key until the option Saved data is followed by a horizontal arrow
- press the tabulator key (5-Fig. 2.1) to activate the menu
2. The first option is shown (<<Last shutdown 1>>).
3. Press the tabulator key (5-Fig. 2.1) to find out the date, time and other data reflecting the
status of the compressor at the last shut-down.
4. If desired, scroll through the other items.

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17 Programmable settings

17.1 GA90 (W) up to GA315 (W)

Remark: Consult the notes at the end of this chapter.

17.1.1 Parameters
For GA90 (W) up to GA315 (60 Hz) (W)

Minimum Nominal Maximum

Motor running time in star sec 10 10 20
Load delay time (star-delta) sec 0 0 20
Load delay time (no star-delta) sec 10 10 20
Number of motor starts (star-delta) starts/day 0 72 72
Number of motor starts (no star-delta) starts/day 0 3 3
Minimum stop time sec 20 20 99
Programmed stop time sec 30 30 30
Permissive start time sec 0 30 255
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60

Unloading pressure
- 7.5 bar Pack compressors bar(e) 4.5 7.0 7.505
- 8.5 bar Pack compressors bar(e) 4.5 8.0 8.505
- 10 bar Pack compressors bar(e) 4.5 9.5 10.005
- 13 bar Pack compressors bar(e) 4.5 12.5 13.005
- 100 psi Pack compressors bar(e) 4.5 6.9 7.405
- 125 psi Pack compressors bar(e) 4.5 8.6 9.105
- 150 psi Pack compressors bar(e) 4.5 10.3 10.805
- 200 psi Pack compressors bar(e) 4.5 13.3 13.805

- 7.5 bar Full-Feature compressors bar(e) 4.5 6.75 7.255

- 8.5 bar Full-Feature compressors bar(e) 4.5 7.75 8.255
- 10 bar Full-Feature compressors bar(e) 4.5 9.25 9.755
- 13 bar Full-Feature compressors bar(e) 4.5 12.25 12.755
- 100 psi Full-Feature compressors bar(e) 4.5 6.65 7.155
- 125 psi Full-Feature compressors bar(e) 4.5 8.35 8.855
- 150 psi Full-Feature compressors bar(e) 4.5 10.05 10.555
- 200 psi Full-Feature compressors bar(e) 4.5 13.05 13.650

- 7.5 bar Full-Feature compressors with DD filter bar(e) 4.5 6.4 6.905
- 8.5 bar Full-Feature compressors with DD filter bar(e) 4.5 7.4 7.905
- 10 bar Full-Feature compressors with DD filter bar(e) 4.5 8.9 9.405
- 13 bar Full-Feature compressors with DD filter bar(e) 4.5 11.9 12.405
- 100 psi Full-Feature compressors with DD filter bar(e) 4.5 6.3 6.805
- 125 psi Full-Feature compressors with DD filter bar(e) 4.5 8.0 8.505
- 150 psi Full-Feature compressors with DD filter bar(e) 4.5 9.7 10.205
- 200 psi Full-Feature compressors with DD filter bar(e) 4.5 12.7 13.305

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Minimum Nominal Maximum

Loading pressure
- 7.5 bar Pack compressors bar(e) 4.5 6.4 7.505
- 8.5 bar Pack compressors bar(e) 4.5 7.4 8.505
- 10 bar Pack compressors bar(e) 4.5 8.9 10.005
- 13 bar Pack compressors bar(e) 4.5 11.9 13.005
- 100 psi Pack compressors bar(e) 4.5 6.3 7.405
- 125 psi Pack compressors bar(e) 4.5 8.0 9.105
- 150 psi Pack compressors bar(e) 4.5 9.7 10.805
- 200 psi Pack compressors bar(e) 4.5 12.7 13.805

- 7.5 bar Full-Feature compressors bar(e) 4.5 6.15 7.255

- 8.5 bar Full-Feature compressors bar(e) 4.5 7.15 8.255
- 10 bar Full-Feature compressors bar(e) 4.5 8.65 9.755
- 13 bar Full-Feature compressors bar(e) 4.5 11.65 12.755
- 100 psi Full-Feature compressors bar(e) 4.5 6.05 7.155
- 125 psi Full-Feature compressors bar(e) 4.5 7.75 8.855
- 150 psi Full-Feature compressors bar(e) 4.5 9.45 10.555
- 200 psi Full-Feature compressors bar(e) 4.5 12.45 13.650

- 7.5 bar Full-Feature compressors with DD filter bar(e) 4.5 5.8 6.905
- 8.5 bar Full-Feature compressors with DD filter bar(e) 4.5 6.8 7.905
- 10 bar Full-Feature compressors with DD filter bar(e) 4.5 8.3 9.405
- 13 bar Full-Feature compressors with DD filter bar(e) 4.5 11.3 12.405
- 100 psi Full-Feature compressors with DD filter bar(e) 4.5 5.7 6.805
- 125 psi Full-Feature compressors with DD filter bar(e) 4.5 7.4 8.505
- 150 psi Full-Feature compressors with DD filter bar(e) 4.5 9.1 10.205
- 200 psi Full-Feature compressors with DD filter bar(e) 4.5 12.1 13.305

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For GA315 W (50 Hz) up to GA500 W

Minimum Nominal Maximum

Motor running time in star sec 10 10 20
Load delay time (star-delta) sec 0 0 20
Load delay time (DOL) sec 10 10 20
Number of motor starts (star-delta) starts/day 0 72 72
Number of motor starts (DOL) starts/day 0 3 3
Minimum stop time sec 20 20 99
Programmed stop time sec 30 30 30
Permissive start time sec 0 30 255
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60

Unloading pressure
- 7.5 bar Pack compressors bar(e) 4.5 7.0 7.505
- 8.5 bar Pack compressors bar(e) 4.5 8.0 8.505
- 10 bar Pack compressors bar(e) 4.5 9.5 10.005
- 13 bar Pack compressors bar(e) 4.5 12.5 13.005
- 100 psi Pack compressors bar(e) 4.5 6.9 7.405
- 125 psi Pack compressors bar(e) 4.5 8.6 9.105
- 150 psi Pack compressors bar(e) 4.5 10.3 10.805
- 200 psi Pack compressors bar(e) 4.5 13.3 13.805

Loading pressure
- 7.5 bar Pack compressors bar(e) 4.5 6.4 7.505
- 8.5 bar Pack compressors bar(e) 4.5 7.4 8.505
- 10 bar Pack compressors bar(e) 4.5 8.9 10.005
- 13 bar Pack compressors bar(e) 4.5 11.9 13.005
- 100 psi Pack compressors bar(e) 4.5 6.3 7.405
- 125 psi Pack compressors bar(e) 4.5 8.0 9.105
- 150 psi Pack compressors bar(e) 4.5 9.7 10.805
- 200 psi Pack compressors bar(e) 4.5 12.7 13.805

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17.1.2 Protections
For GA90 (W) up to GA315 (60 Hz) (W)

Minimum Nominal Maximum

Compressor outlet pressure bar(e) 0 16.5 17.0
(shut-down warning level)
Compressor outlet pressure bar(e) 0 17.0 17.0
(shut-down level)
Oil injection pressure, element (start protection) bar(e) 2.0 2.5 13.2
Compressor outlet temperature (without DD filter) °C 0 66 120
(shut-down warning level)
Compressor outlet temperature (without DD filter) °C 0 80 120
(shut-down level)
Compressor outlet temperature (with DD filter) °C 0 66 100
(shut-down warning level)
Compressor outlet temperature (with DD filter) °C 0 80 100
(shut-down level)
Compressor outlet temperature (delay at signal) sec 5 5 5
Compressor element outlet temperature (no energy °C 80 100 110
recovery)
(shut-down warning level)
Compressor element outlet temperature (no energy °C 80 110 110
recovery)
(shut-down level)
Compressor element outlet temperature (energy °C 80 114 120
recovery)
(shut-down warning level)
Compressor element outlet temperature (energy °C 80 120 120
recovery)
(shut-down level)
Compressor element outlet temperature (delay at sec 5 5 5
signal)
Oil separator temperature °C 0 120 120
Delay at start, motor overload sec 0 1 1
Delay at signal, motor overload sec 0 1 1
Delay at start, fan motor overload sec 0 1 3
Delay at signal, fan motor overload sec 0 1 3
Delay at start, starter feedback contact = open sec 0 13 60
Delay at signal, starter feedback contact = closed sec 0 2 3
Delay at start, electric condensate drain sec 0 15 60
Delay at signal, electric condensate drain sec 5 5 5
Delay at signal, dryer/dryer fan overload sec 0 1 3

For Full-Feature also:

Dryer LAT temperature (warning) °C 3 15 50
Dryer LAT temperature (shut-down) °C 3 16 50
Delay at signal sec 0 3 10
Delay at starting sec 0 255 255

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For GA315W (50 Hz) up to GA500 W

Minimum Nominal Maximum

Compressor outlet pressure bar(e) 0 16.5 17.0
(shut-down warning level)
Compressor outlet pressure bar(e) 0 17.0 17.0
(shut-down level)
Oil injection pressure, element 1 and 2 (start protection) bar(e) 2.0 2.5 13.2
Compressor outlet temperature °C 20 60 80
(shut-down warning level)
Compressor outlet temperature °C 20 70 80
(shut-down level)
Compressor outlet temperature (delay at signal) sec 5 5 5
Compressor element 1 and 2 outlet temperature °C 80 100 120
(shut-down warning level)
Compressor element 1and 2 outlet temperature °C 80 110 120
(shut-down level)
Compressor element outlet temperature (delay at signal) sec 5 5 5
Cooling water outlet temperature (without energy °C 60 65 90
recovery)
(shut-down warning)
Cooling water outlet temperature (without energy °C 60 75 90
recovery)
(shut-down level)
Cooling water outlet (delay at signal) sec 0 20 60
Cooling water outlet temperature (with energy recovery) °C 90 95 100
(shut-down warning)
Cooling water outlet temperature (with energy recovery) °C 90 95 100
(shut-down level)
Cooling water outlet (delay at signal) (with energy sec 0 10 60
recovery)
Oil separator 1 and 2 temperature °C 120 120 120
Delay at start / signal, motor overload (low voltage motor) sec 0 1 1
Delay at start / signal, motor overload( medium voltage sec 0 0 0
motor)
Delay at start, starter feedback contact = open sec 0 13 60
Delay at signal, starter feedback contact = closed sec 0 2 3
Delay at start, electric condensate drain sec 0 15 60
Delay at signal, electric condensate drain sec 5 5 5

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17.1.3 Service settings

For GA90 (W) up to GA315 (60 Hz) (W)

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan D (running hours) hr 24000
Service plan I (running hours) hr 2000

Analog signals
Oil separator Dp mbar 0 800 800
Delay at signal, oil separator Dp sec 0 60 255
Air filter Dp mbar -100 -50 -50
Delay at signal, air filter Dp sec 0 60 255
DD filter Dp mbar 100 350 350
Delay at signal, DD filter Dp sec 0 60 255

For GA315 W (50 Hz) up to GA500 W

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan D (running hours) hr 24000
Service plan I (running hours) hr 2000

Analog signals
Oil separator 1 and Dp mbar 800 800 1500
(shut-down warning)
Oil separator 1 and 2 Dp mbar 800 1500 1500
(shut-down level)
Delay at signal, oil separator Dp sec 0 60 255
Air filter Dp mbar -50 -50 -50
Delay at signal, air filter Dp sec 0 60 255

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17.2 GR110 (W) up to GR200 (W)

Remark: Consult the notes at the end of this chapter.

17.2.1 Parameters

Minimum Nominal Maximum

Motor running time in star sec 10 10 20
Load delay time (star-delta) sec 0 0 20
Load delay time (no star-delta) sec 10 10 20
Number of motor starts (star-delta) starts/day 0 72 72
Number of motor starts (no star-delta) starts/day 0 3 3
Minimum stop time sec 20 20 99
Programmed stop time sec 30 30 30
Permissive start time sec 0 30 255
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60

Unloading pressure
- 13 bar Pack compressors bar(e) 4.5 12.5 13.005
- 20 bar Pack compressors bar(e) 9.5 19.0 20.005
- 200 psi Pack compressors bar(e) 4.5 13.3 13.805
- 13 bar Full-Feature compressors bar(e) 4.5 12.25 12.755
- 20 bar Full-Feature compressors bar(e) 9.5 18.75 19.755
- 200 psi Full-Feature compressors bar(e) 4.5 13.05 13.650
- 13 bar Full-Feature compressors with DD filter bar(e) 4.5 11.9 12.405
- 200 psi Full-Feature compressors with DD filter bar(e) 4.5 12.7 13.305

Loading pressure
- 13 bar Pack compressors bar(e) 4.5 11.9 13.005
- 20 bar Pack compressors bar(e) 9.5 18.0 20.005
- 200 psi Pack compressors bar(e) 4.5 12.7 13.805
- 13 bar Full-Feature compressors bar(e) 4.5 11.65 12.755
- 20 bar Full-Feature compressors bar(e) 9.5 17.75 19.755
- 200 psi Full-Feature compressors bar(e) 4.5 12.45 13.650
- 13 bar Full-Feature compressors with DD filter bar(e) 4.5 11.3 12.405
- 200 psi Full-Feature compressors with DD filter bar(e) 4.5 12.1 13.305

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17.2.2 Protections

Minimum Nominal Maximum

Compressor outlet pressure, 13 bar or 200 psi bar(e) 0 16.5 17.0
compressors
(shut-down warning level)
Compressor outlet pressure, 13 bar or 200 psi bar(e) 0 17.0 17.0
compressors
(shut-down level)
Compressor outlet pressure, 20 bar compressors bar(e) 0 24.5 25.0
(shut-down warning level)
Compressor outlet pressure, 20 bar compressors bar(e) 0 25.0 25.0
(shut-down level)
Oil injection pressure, element (start protection) bar(e) 2.0 2.5 13.2
Compressor outlet temperature (without DD filter) °C 0 66 120
(shut-down warning level)
Compressor outlet temperature (without DD filter) °C 0 80 120
(shut-down level)
Compressor outlet temperature (with DD filter) °C 0 66 100
(shut-down warning level)
Compressor outlet temperature (with DD filter) °C 0 80 100
(shut-down level)
Compressor outlet temperature (delay at signal) sec 5 5 5
Compressor element 1 outlet temperature °C 80 114 120
(shut-down warning level)
Compressor element 1 outlet temperature °C 80 120 120
(shut-down level)
Compressor element 2 outlet temperature °C 80 114 120
(shut-down warning level)
Compressor element 2 outlet temperature °C 80 120 120
(shut-down level)
Compressor element outlet temperature (delay at sec 5 5 5
signal)
Oil separator temperature °C 0 120 120
Delay at start, motor overload sec 0 1 3
Delay at signal, motor overload sec 0 1 3
Delay at start, fan motor overload sec 0 1 3
Delay at signal, fan motor overload sec 0 1 3
Delay at start, starter feedback contact = open sec 0 13 60
Delay at signal, starter feedback contact = closed sec 0 2 3
Delay at start, electric condensate drain sec 0 15 60
Delay at signal, electric condensate drain sec 5 5 5
Delay at signal, dryer/dryer fan overload sec 0 1 3

For Full-Feature also:

Dryer LAT temperature (warning) °C 3 15 50
Dryer LAT temperature (shut-down) °C 3 16 50
Delay at signal sec 0 3 10
Delay at starting sec 0 255 255

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17.2.3 Service settings

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan D (running hours) hr 24000
Service plan I (running hours) hr 2000

Analog signals
Oil separator Dp mbar 0 800 800
Delay at signal, oil separator Dp sec 0 60 255
Air filter Dp mbar -100 -50 -50
Delay at signal, air filter Dp sec 0 60 255
DD filter Dp mbar 100 350 350
Delay at signal, DD filter Dp sec 0 60 255

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17.3 ZE/ZA3-4

Remark: Consult the notes at the end of this chapter.

17.3.1 Parameters

Minimum Nominal Maximum

Motor running time in star sec 10 20 30
Load delay time (star-delta) sec 5 5 30
Load delay time (no star-delta) sec 20 20 30
Number of motor starts (star-delta) starts/day 0 72 120
Number of motor starts (no star-delta) starts/day 0 3 5
Minimum stop time sec 20 20 99
Programmed stop time (without full-load/no-load valve) sec 0 0 20
Programmed stop time (with full-load/no-load valve) sec 0 3 20
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60

Unloading pressure
- 1 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.0 1.25
- 1.25 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.25 1.5
- 1.5 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.5 1.75
- 1.75 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.75 2.0
- 2 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.0 2.25
- 2.25 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.25 2.5
- 2.5 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.5 2.75
- 2.75 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.75 3.0
- 3 bar ZE/ZA compressors without aftercooler bar(e) 0.5 3.0 3.25
- 3.25 bar ZE/ZA compressors without aftercooler bar(e) 0.5 3.25 3.5
- 3.5 bar ZE/ZA compressors without aftercooler bar(e) 0.5 3.5 3.6

- 1 bar ZE compressors with aftercooler bar(e) 0.5 0.9 1.15

- 1.25 bar ZE compressors with aftercooler bar(e) 0.5 1.15 1.4
- 1.5 bar ZE compressors with aftercooler bar(e) 0.5 1.43 1.68
- 1.75 bar ZE compressors with aftercooler bar(e) 0.5 1.68 1.93
- 2 bar ZE compressors with aftercooler bar(e) 0.5 2.0 2.18
- 2.25 bar ZE compressors with aftercooler bar(e) 0.5 2.2 2.45
- 2.5 bar ZE compressors with aftercooler bar(e) 0.5 2.45 2.7
- 2.75 bar ZE compressors with aftercooler bar(e) 0.5 2.7 2.95
- 3 bar ZE compressors with aftercooler bar(e) 0.5 2.95 3.2
- 3.25 bar ZE compressors with aftercooler bar(e) 0.5 3.2 3.45
- 3.5 bar ZE compressors with aftercooler bar(e) 0.5 3.35 3.6

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Unloading pressure
- 1 bar ZE4 high-speed compressors with aftercooler bar(e) 0.45 0.75 1.0
- 1.25 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 1.00 1.25
- 1.5 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 1.25 1.5
- 1.75 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 1.5 1.75
- 2 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 1.8 2.05
- 2.25 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.1 2.35
- 2.5 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.35 2.6
- 2.75 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.6 2.85
- 3 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.85 3.1
- 3.25 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 3.15 3.4
- 3.5 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 3.3 3.55

Minimum Nominal Maximum

Loading pressure
- 1 bar ZE/ZA compressors without aftercooler bar(e) 0.5 0.7 1.25
- 1.25 bar ZE/ZA compressors without aftercooler bar(e) 0.5 0.95 1.5
- 1.5 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.2 1.75
- 1.75 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.45 2.0
- 2 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.7 2.25
- 2.25 bar ZE/ZA compressors without aftercooler bar(e) 0.5 1.95 2.5
- 2.5 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.2 2.75
- 2.75 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.45 3.0
- 3 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.7 3.25
- 3.25 bar ZE/ZA compressors without aftercooler bar(e) 0.5 2.95 3.5
- 3.5 bar ZE/ZA compressors without aftercooler bar(e) 0.5 3.2 3.6

- 1 bar ZE compressors with aftercooler bar(e) 0.5 0.6 1.15

- 1.25 bar ZE compressors with aftercooler bar(e) 0.5 0.85 1.4
- 1.5 bar ZE compressors with aftercooler bar(e) 0.5 1.13 1.68
- 1.75 bar ZE compressors with aftercooler bar(e) 0.5 1.38 1.93
- 2 bar ZE compressors with aftercooler bar(e) 0.5 1.7 2.18
- 2.25 bar ZE compressors with aftercooler bar(e) 0.5 1.9 2.45
- 2.5 bar ZE compressors with aftercooler bar(e) 0.5 2.15 2.7
- 2.75 bar ZE compressors with aftercooler bar(e) 0.5 2.4 2.95
- 3 bar ZE compressors with aftercooler bar(e) 0.5 2.65 3.2
- 3.25 bar ZE compressors with aftercooler bar(e) 0.5 2.9 3.45
- 3.5 bar ZE compressors with aftercooler bar(e) 0.5 3.05 3.6

- 1 bar ZE4 high-speed compressors with aftercooler bar(e) 0.45 0.45 1.0
- 1.25 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 0.7 1.25
- 1.5 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 0.95 1.5
- 1.75 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 1.2 1.75
- 2 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 1.5 2.05
- 2.25 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 1.8 2.35
- 2.5 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.05 2.6
- 2.75 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.3 2.85
- 3 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.55 3.1
- 3.25 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 2.85 3.4
- 3.5 bar ZE4 high-speed compressors with aftercooler bar(e) 0.5 3.0 3.55

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17.3.2 Protections

Minimum Nominal Maximum

Compressor outlet pressure (compressors without full- bar(e) 0 Consult Atlas Consult Atlas
load/no-load valve) Copco Copco
(shut-down warning level)
Compressor outlet pressure (compressors without full- bar(e) 0 Consult Atlas Consult Atlas
load/no-load valve) Copco Copco
(shut-down level)
Compressor outlet pressure (compressors with full- bar(e) 0 4.5 5.0
load/no-load valve)
(shut-down warning level)
Compressor outlet pressure (compressors with full- bar(e) 0 5.0 5.0
load/no-load valve
(shut-down level)
Oil pressure bar(e) 1.0 1.5 2.0
(shut-down warning level)
Oil pressure bar(e) 1.0 1.4 2.0
(shut-down level)
Delay at start, oil pressure sec 15 20 30
Delay at signal, oil pressure sec 0 1 3
Element 1 outlet temperature, ZE 1 up to 2.75 bar °C 100 230 240
(shut-down warning level)
Element 1 outlet temperature, ZE 1 up to 2.75 bar °C 100 240 240
(shut-down level)
Element 1 outlet temperature, ZE 3 up to 3.5 bar °C 100 255 265
(shut-down warning level)
Element 1 outlet temperature, ZE 3 up to 3.5 bar °C 100 265 265
(shut-down level)
Element 1 outlet temperature, ZA 1 up to 2.75 bar °C 100 225 235
(shut-down warning level)
Element 1 outlet temperature, ZA 1 up to 2.75 bar °C 100 235 235
(shut-down level)
Element 1 outlet temperature, ZA 3 up to 3.5 bar °C 100 250 260
(shut-down warning level)
Element 1 outlet temperature, ZA 3 up to 3.5 bar °C 100 260 260
(shut-down level)
Delay at signal, element 1 outlet temperature sec 0 1 3
Oil temperature °C 40 66 80
(shut-down warning level)
Oil temperature °C 40 70 80
(shut-down level)
Delay at start, oil temperature sec 50 70 100
Delay at signal, oil temperature sec 0 1 3
Delay at start, motor overload sec 0 1 3
Delay at signal, motor overload sec 0 1 3
Delay at start, fan motor overload sec 0 1 3
Delay at signal, fan motor overload sec 0 1 3
Delay at start, starter feedback contact = open sec 0 23 40
Delay at signal, starter feedback contact = closed sec 0 2 3
Delay at start, electric condensate drain sec 0 15 60
Delay at signal, electric condensate drain sec 5 5 5
Delay at signal, dryer/dryer fan overload sec 0 1 3
Delay at signal, phase sequence sec 0 1 2

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17.3.3 Service settings

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan D (running hours) hr 40000
Service plan I (running hours) hr 2000

Analog signals
Air filter Dp mbar -55 -44 -44
Delay at signal, air filter Dp sec 0 60 255

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17.4 ZA5-6

Remark: Consult the notes at the end of this chapter.

17.4.1 Parameters

Minimum Nominal Maximum

Motor running time in star sec 10 10 20
Load delay time (star-delta) sec 5 5 30
Load delay time (no star-delta) sec 20 20 30
Number of motor starts (star-delta) starts/day 0 72 120
Number of motor starts (no star-delta) starts/day 0 3 5
Minimum stop time sec 20 20 99
Programmed stop time (without full-load/no-load valve) sec 0 0 20
Programmed stop time (with full-load/no-load valve) sec 0 3 20
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60

Unloading pressure
- 1 bar ZA compressors without aftercooler bar(e) 0.5 1.0 1.25
- 1.25 bar ZA compressors without aftercooler bar(e) 0.5 1.25 1.5
- 1.5 bar ZA compressors without aftercooler bar(e) 0.5 1.5 1.75
- 1.75 bar ZA compressors without aftercooler bar(e) 0.5 1.75 2.0
- 2 bar ZA compressors without aftercooler bar(e) 0.5 2.0 2.25
- 2.25 bar ZA compressors without aftercooler bar(e) 0.5 2.25 2.5
- 2.5 bar ZA compressors without aftercooler bar(e) 0.5 2.5 2.75
- 2.75 bar ZA compressors without aftercooler bar(e) 0.5 2.75 3.0
- 3 bar ZA compressors without aftercooler bar(e) 0.5 3.0 3.25
- 3.25 bar ZA compressors without aftercooler bar(e) 0.5 3.25 3.5
- 3.5 bar ZA compressors without aftercooler bar(e) 0.5 3.5 3.6

- 1 bar ZA5 compressors with aftercooler bar(e) 0.5 0.94 1.19

- 1.25 bar ZA5 compressors with aftercooler bar(e) 0.5 1.19 1.44
- 1.5 bar ZA5 compressors with aftercooler bar(e) 0.5 1.49 1.69
- 1.75 bar ZA5 compressors with aftercooler bar(e) 0.5 1.69 1.94
- 2 bar ZA5 compressors with aftercooler bar(e) 0.5 1.94 2.19

- 1 bar ZA6 compressors with aftercooler bar(e) 0.5 0.99 1.24

- 1.25 bar ZA6 compressors with aftercooler bar(e) 0.5 1.24 1.49
- 1.5 bar ZA6 compressors with aftercooler bar(e) 0.5 1.49 1.74
- 1.75 bar ZA6 compressors with aftercooler bar(e) 0.5 1.74 1.99
- 2 bar ZA6 compressors with aftercooler bar(e) 0.5 1.99 2.24

- 2.25 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.19 2.44
- 2.5 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.44 2.69
- 2.75 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.69 2.94
- 3 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.94 3.19
- 3.25 bar ZA5-6 compressors with aftercooler bar(e) 0.5 3.19 3.44
- 3.5 bar ZA5-6 compressors with aftercooler bar(e) 0.5 3.44 3.59

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Unloading pressure Minimum Nominal Maximum

- 1 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 0.9 1.15
- 1.25 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 1.15 1.4
- 1.5 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 1.4 1.65
- 1.75 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 1.65 1.9
- 2 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 1.9 2.15

- 1 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 0.98 1.23
- 1.25 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.23 1.48
- 1.5 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.48 1.73
- 1.75 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.73 1.98
- 2 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.98 2.23
- 2.25 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.15 2.4
- 2.5 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.4 2.65
- 2.75 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.65 2.9
- 3 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.9 3.15
- 3.25 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 3.15 3.4
- 3.5 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 3.4 3.5

Loading pressure Minimum Nominal Maximum

- 1 bar ZA compressors without aftercooler bar(e) 0.5 0.7 1.25
- 1.25 bar ZA compressors without aftercooler bar(e) 0.5 0.95 1.5
- 1.5 bar ZA compressors without aftercooler bar(e) 0.5 1.2 1.75
- 1.75 bar ZA compressors without aftercooler bar(e) 0.5 1.45 2.0
- 2 bar ZA compressors without aftercooler bar(e) 0.5 1.7 2.25
- 2.25 bar ZA compressors without aftercooler bar(e) 0.5 1.95 2.5
- 2.5 bar ZA compressors without aftercooler bar(e) 0.5 2.2 2.75
- 2.75 bar ZA compressors without aftercooler bar(e) 0.5 2.45 3.0
- 3 bar ZA compressors without aftercooler bar(e) 0.5 2.7 3.25
- 3.25 bar ZA compressors without aftercooler bar(e) 0.5 2.95 3.5
- 3.5 bar ZA compressors without aftercooler bar(e) 0.5 3.2 3.6

- 1 bar ZA5 compressors with aftercooler bar(e) 0.5 0.64 1.19

- 1.25 bar ZA5 compressors with aftercooler bar(e) 0.5 0.89 1.44
- 1.5 bar ZA5 compressors with aftercooler bar(e) 0.5 1.14 1.69
- 1.75 bar ZA5 compressors with aftercooler bar(e) 0.5 1.39 1.94
- 2 bar ZA5 compressors with aftercooler bar(e) 0.5 1.64 2.19

- 1 bar ZA6 compressors with aftercooler bar(e) 0.5 0.69 1.24

- 1.25 bar ZA6 compressors with aftercooler bar(e) 0.5 0.94 1.49
- 1.5 bar ZA6 compressors with aftercooler bar(e) 0.5 1.19 1.74
- 1.75 bar ZA6 compressors with aftercooler bar(e) 0.5 1.44 1.99
- 2 bar ZA6 compressors with aftercooler bar(e) 0.5 1.69 2.24

- 2.25 bar ZA5-6 compressors with aftercooler bar(e) 0.5 1.89 2.44
- 2.5 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.14 2.69
- 2.75 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.39 2.94
- 3 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.64 3.19
- 3.25 bar ZA5-6 compressors with aftercooler bar(e) 0.5 2.89 3.44
- 3.5 bar ZA5-6 compressors with aftercooler bar(e) 0.5 3.14 3.59

- 1 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 0.6 1.15
- 1.25 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 0.85 1.4
- 1.5 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 1.1 1.65
- 1.75 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 1.35 1.9
- 2 bar ZA5 high-speed compressors with aftercooler bar(e) 0.5 1.6 2.15

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Loading pressure Minimum Nominal Maximum

- 1 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 0.68 1.23
- 1.25 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 0.93 1.48
- 1.5 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.18 1.73
- 1.75 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.43 1.98
- 2 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.68 2.23
- 2.25 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 1.85 2.4
- 2.5 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.1 2.65
- 2.75 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.35 2.9
- 3 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.6 3.15
- 3.25 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 2.85 3.4
- 3.5 bar ZA6 high-speed compressors with aftercooler bar(e) 0.5 3.1 3.5

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17.4.2 Protections

Minimum Nominal Maximum

Compressor outlet pressure (compressors without full- bar(e) 0 Consult Atlas Consult Atlas
load/no-load valve) Copco Copco
(shut-down warning level)
Compressor outlet pressure (compressors without full- bar(e) 0 Consult Atlas Consult Atlas
load/no-load valve) Copco Copco
(shut-down level)
Compressor outlet pressure (compressors with full- bar(e) 0 4.5 5.0
load/no-load valve)
(shut-down warning level)
Compressor outlet pressure (compressors with full- bar(e) 0 5.0 5.0
load/no-load valve
(shut-down level)
Oil pressure bar(e) 1.0 1.5 2.0
(shut-down warning level)
Oil pressure bar(e) 1.0 1.4 2.0
(shut-down level)
Delay at start, oil pressure sec 15 20 30
Delay at signal, oil pressure sec 0 1 3
Element 1 outlet temperature, 1 up to 2.75 bar °C 100 225 235
(shut-down warning level)
Element 1 outlet temperature, 1 up to 2.75 bar °C 100 235 235
(shut-down level)
Element 1 outlet temperature, 3 up to 3.5 bar °C 100 250 260
(shut-down warning level)
Element 1 outlet temperature, 3 up to 3.5 bar °C 100 260 260
(shut-down level)
Delay at signal, element 1 outlet temperature sec 0 1 3
Oil temperature °C 40 66 80
(shut-down warning level)
Oil temperature °C 40 70 80
(shut-down level)
Delay at start, oil temperature sec 50 70 100
Delay at signal, oil temperature sec 0 1 3
Delay at start, motor overload sec 0 1 3
Delay at signal, motor overload sec 0 1 3
Delay at start, fan motor overload sec 0 1 3
Delay at signal, fan motor overload sec 0 1 3
Delay at start, starter feedback contact = open sec 0 23 40
Delay at signal, starter feedback contact = closed sec 0 2 3
Delay at start, electric condensate drain sec 0 15 60
Delay at signal, electric condensate drain sec 5 5 5
Delay at signal, dryer/dryer fan overload sec 0 1 3
Delay at signal, phase sequence sec 0 1 2

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17.4.3 Service settings

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan D (running hours) hr 40000
Service plan I (running hours) hr 2000

Analog signals
Air filter Dp mbar -55 -44 -44
Delay at signal, air filter Dp sec 0 60 255

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17.5 ZT15 up to ZT45 / ZR30 up to ZR45

Remark: Consult the notes at the end of this chapter.

17.5.1 Parameters

Minimum Nominal Maximum

Motor running time in star sec 5 10 10
Load delay time sec 0 0 10
Number of motor starts starts/day 0 240 240
Minimum stop time sec 0 20 30
Programmed stop time sec 30 30 30
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 0 1200
Communication time-out sec 10 30 60

Unloading pressure
- 7.5 bar Pack compressors bar(e) 4.0 7.0 7.5
- 8.6 bar Pack compressors bar(e) 4.0 8.1 8.6
- 7.5 bar Full-Feature compressors bar(e) 4.0 7.0 7.3
- 8.6 bar Full-Feature compressors bar(e) 4.0 8.1 8.4

Loading pressure
- 7.5 bar Pack compressors bar(e) 4.0 6.4 7.5
- 8.6 bar Pack compressors bar(e) 4.0 7.5 8.6
- 7.5 bar Full-Feature compressors bar(e) 4.0 6.4 7.3
- 8.6 bar Full-Feature compressors bar(e) 4.0 7.5 8.4

17.5.2 Protections

Minimum Nominal Maximum

Oil pressure bar(e) 1.0 2.0 2.0
(shut-down warning level)
Oil pressure bar(e) 1.0 1.9 2.0
(shut-down level)
Delay at start, oil pressure sec 15 15 20
Delay at signal, oil pressure sec 0 6 9
Element 1 outlet temperature °C 100 220 225
(shut-down warning level)
Element 1 outlet temperature °C 100 225 225
(shut-down level)
Element 2 inlet temperature °C 60 85 90
(shut-down warning level)
Element 2 inlet temperature °C 60 90 90
(shut-down level)
Delay at start, element 2 inlet temperature sec 0 0 255
Delay at signal, element 2 inlet temperature sec 0 0 255
Element 2 outlet temperature °C 100 220 225
(shut-down warning level)
Element 2 outlet temperature °C 100 225 225
(shut-down level)
Intercooler pressure bar(e) -0.68 -0.68 -0.68
(warning level)
Delay at start, motor overload sec 0 0 0

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Delay at signal, motor overload sec 1 1 1

Delay at start, fan motor overload sec 0 0 0
Delay at signal, fan motor overload sec 1 1 1
Delay at start, electric condensate drain sec 0 0 255
Delay at signal, electric condensate drain sec 0 0 255
Delay at signal, phase sequence sec 0 1 2

17.5.3 Service settings

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan D (running hours) hr 40000
Service plan I (running hours) hr 2000

Analog signals
Air filter Dp mbar -100 -44 -44
Delay at start, air filter Dp sec 0 0 0
Delay at signal, air filter Dp sec 0 60 255

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17.6 ZT55 up to ZT90 / ZR55 up to ZR90

Remark: Consult the notes at the end of this chapter.

17.6.1 Parameters

Minimum Nominal Maximum

Motor running time in star sec 10 10 30
Load delay time (star-delta) sec 10 10 30
Number of motor starts (star-delta) starts/day 0 240 240
Minimum stop time sec 20 20 99
Programmed stop time sec 3 3 3
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60

Unloading pressure
- 7.25 bar compressors bar(e) 4.5 7.0 7.25 (7.00 for Full-Feature)
- 7.5 bar compressors bar(e) 4.5 7.0 7.5 (7.25 for Full-Feature)
- 8.6 bar compressors bar(e) 4.5 8.0 8.6 (8.35 for Full-Feature)
- 9 bar compressors bar(e) 4.5 8.0 9.0 (8.75 for Full-Feature)
- 10 bar compressors bar(e) 4.5 9.0 10.0 (9.75 for Full-Feature)
- 10.4 bar compressors bar(e) 4.5 9.0 10.4 (10.15 for Full-Feature)

Loading pressure
- 7.25 bar compressors bar(e) 4.5 6.5 7.25 (7.00 for Full-Feature)
- 7.5 bar compressors bar(e) 4.5 6.5 7.5 (7.25 for Full-Feature)
- 8.6 bar compressors bar(e) 4.5 7.5 8.6 (8.35 for Full-Feature)
- 9 bar compressors bar(e) 4.5 7.5 9.0 (8.75 for Full-Feature)
- 10 bar compressors bar(e) 4.5 8.0 10.0 (9.75 for Full-Feature)
- 10.4 bar compressors bar(e) 4.5 8.0 10.4 (10.15 for Full-Feature)

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17.6.2 Protections

Minimum Nominal Maximum

Oil pressure bar(e) 1.0 1.3 1.9
(shut-down warning level)
Oil pressure bar(e) 1.0 1.2 1.9
(shut-down level)
Delay at start, oil pressure sec 15 15 20
Delay at signal, oil pressure sec 0 6 9
Element 1 outlet temperature, 7.25 and 7.5 bar °C 100 210 220
(shut-down warning level)
Element 1 outlet temperature, 7.25 and 7.5 bar °C 100 220 220
(shut-down level)
Element 1 outlet temperature, 8.6, 9, 10 and 10.4 bar °C 100 225 235
(shut-down warning level)
Element 1 outlet temperature, 8.6, 9, 10 and 10.4 bar °C 100 235 235
(shut-down level)
Element 2 inlet temperature °C 40 65 80
(shut-down warning level)
Element 2 inlet temperature °C 40 70 80
(shut-down level)
Element 2 outlet temperature, 7.25 and 7.5 bar °C 100 210 220
(shut-down warning level)
Element 2 outlet temperature, 7.25 and 7.5 bar °C 100 220 220
(shut-down level)
Element 2 outlet temperature, 8.6, 9, 10 and 10.4 bar °C 100 225 235
(shut-down warning level)
Element 2 outlet temperature, 8.6, 9, 10 and 10.4 bar °C 100 235 235
(shut-down level)
Oil temperature (ZR) °C 40 65 80
(shut-down warning level)
Oil temperature (ZR) °C 40 70 80
(shut-down level)
Dryer inlet temperature (for Full-Feature) (warning °C 53 53 58
level)
Temperature, dryer regeneration air inlet (for Full- °C 100 110 110
Feature) (warning level)
Calculated temperature, element Delta T (for Full- °C 90 100 100
Feature) (warning level)

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17.6.3 Service settings

Minimum Nominal Maximum

Service plans
Service plan A (50 Hz) (running hours) hr 4000
Service plan A (60 Hz) (running hours) hr 3600
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan I (running hours) hr 2000

Analog signals
Air filter Dp mbar -100 -44 -44
Delay at signal, air filter Dp sec 0 60 255

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17.7 ZT110 up to ZT275 / ZR110 up to ZR750

Remark: Consult the notes at the end of this chapter.

17.7.1 Parameters

Minimum Nominal Maximum

Motor running time in star sec 10 15 30
Load delay time (star-delta) sec 10 10 30
Load delay time (no star-delta) sec 20 20 30
Number of motor starts (star-delta) starts/day 0 72 120
Number of motor starts (no star-delta) starts/day 0 3 5
Minimum stop time sec 20 20 99
Programmed stop time sec 0 3 20
Power recovery time (ARAVF) sec 15 15 3600
Restart delay (ARAVF) sec 0 3 255
Communication time-out sec 10 20 60

Unloading pressure
- 7.5 bar compressors bar(e) 4.0 7.0 7.505
- 8.6 bar compressors bar(e) 4.0 7.0 8.605
- 10 bar compressors bar(e) 4.0 9.0 10.005
- 10.4 bar compressors bar(e) 4.0 9.0 10.405

Loading pressure
- 7.5 bar compressors bar(e) 4.0 6.0 7.505
- 8.6 bar compressors bar(e) 4.0 6.0 8.605
- 10 bar compressors bar(e) 4.0 8.0 10.005
- 10.4 bar compressors bar(e) 4.0 8.0 10.405

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17.7.2 Protections

Minimum Nominal Maximum

Compressor outlet pressure bar(e) 0 14.0 17.0
(shut-down warning level)
Compressor outlet pressure bar(e) 0 15.0 17.0
(shut-down level)
Compressor outlet pressure (delay at start) sec 0 1 3
Compressor outlet pressure (delay at signal) sec 0 1 3
Oil pressure, ZT/ZR110-275 bar(e) 1.0 1.3 2.0
(shut-down warning level)
Oil pressure, ZT/ZR110-275 bar(e) 1.0 1.2 2.0
(shut-down level)
Oil pressure, ZR300-750 bar(e) 1.0 1.3 1.9
(shut-down warning level)
Oil pressure, ZR300-750 bar(e) 1.0 1.2 1.9
(shut-down level)
Delay at start, oil pressure sec 15 15 20
Delay at signal, oil pressure sec 0 1 3
Element 1 outlet temperature, 7.5 and 8.6 bar °C 100 210 220
(shut-down warning level)
Element 1 outlet temperature, 7.5 and 8.6 bar °C 100 220 220
(shut-down level)
Element 1 outlet temperature, 10 and 10.4 bar °C 100 225 235
(shut-down warning level)
Element 1 outlet temperature, 10 and 10.4 bar °C 100 235 235
(shut-down level)
Element 2 inlet temperature °C 40 65 80
(shut-down warning level)
Element 2 inlet temperature °C 40 70 80
(shut-down level)
Element 2 outlet temperature, 7.5 and 8.6 bar °C 100 210 220
(shut-down warning level)
Element 2 outlet temperature, 7.5 and 8.6 bar °C 100 220 220
(shut-down level)
Element 2 outlet temperature, 10 and 10.4 bar °C 100 225 235
(shut-down warning level)
Element 2 outlet temperature, 10 and 10.4 bar °C 100 235 235
(shut-down level)
Delay at signal of all element temperatures sec 0 1 3
Oil temperature °C 40 65 80
(shut-down warning level)
Oil temperature °C 40 70 80
(shut-down level)
Delay at signal, oil temperature sec 50 70 100
Delay at start, motor overload sec 0 1 3
Delay at signal, motor overload sec 0 1 3
Delay at start, fan motor overload sec 0 1 3
Delay at signal, fan motor overload sec 0 1 3
Delay at start, starter feedback contact = open sec 0 18 33
Delay at signal, starter feedback contact = closed sec 0 2 3
Delay at start, electric condensate drain sec 0 15 60
Delay at signal, electric condensate drain sec 5 5 5
Delay at signal, phase sequence sec 0 1 2

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17.7.3 Service settings

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000
Service plan C (running hours) hr 16000
Service plan D (running hours) hr 40000
Service plan I (running hours) hr 2000

Analog signals
Air filter Dp, ZT/ZR110-275 mbar -50 -44 -44
Air filter Dp, ZR300-750 mbar -58 -52 -52
Delay at signal, air filter Dp sec 0 60 255

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17.8 AQ30-55
17.8.1 Parameters

Minimum Nominal Maximum

Motor running time in star sec 2 10 20
Load delay time sec 0 0 30
Number of motor starts starts/day 0 240 720
Minimum stop time sec 0 20 99
Programmed stop time sec 30 30 180
Power recovery time (ARAVF) sec 10 10 3600
Restart delay (ARAVF) sec 0 0 1200
Communication time-out sec 10 30 60

Unloading pressure
- 7.5 bar Pack compressors bar(e) 4.0 7.0 7.5
- 10 bar Pack compressors bar(e) 4.0 9.5 10.0
- 13 bar Pack compressors bar(e) 4.0 12.5 13.0
- 100 psi Pack compressors bar(e) 4.0 6.894 7.376
- 125 psi Pack compressors bar(e) 4.0 8.618 9.118
- 150 psi Pack compressors bar(e) 4.0 10.341 10.841
- 175 psi Pack compressors bar(e) 4.0 12.065 12.565

- 7.5 bar Full-Feature compressors bar(e) 4.0 7.0 7.3

- 10 bar Full-Feature compressors bar(e) 4.0 9.5 9.8
- 13 bar Full-Feature compressors bar(e) 4.0 12.5 12.8
- 100 psi Full-Feature compressors bar(e) 4.0 6.894 7.176
- 125 psi Full-Feature compressors bar(e) 4.0 8.618 8.918
- 150 psi Full-Feature compressors bar(e) 4.0 10.341 10.641
- 175 psi Full-Feature compressors bar(e) 4.0 12.065 12.365

Loading pressure
- 7.5 bar Pack compressors bar(e) 4.0 6.4 7.5
- 10 bar Pack compressors bar(e) 4.0 8.9 10.0
- 13 bar Pack compressors bar(e) 4.0 11.9 13.0
- 100 psi Pack compressors bar(e) 4.0 6.294 7.376
- 125 psi Pack compressors bar(e) 4.0 8.018 9.118
- 150 psi Pack compressors bar(e) 4.0 9.741 10.841
- 175 psi Pack compressors bar(e) 4.0 11.465 12.565

- 7.5 bar Full-Feature compressors bar(e) 4.0 6.4 7.3

- 10 bar Full-Feature compressors bar(e) 4.0 8.9 9.8
- 13 bar Full-Feature compressors bar(e) 4.0 11.9 12.8
- 100 psi Full-Feature compressors bar(e) 4.0 6.294 7.176
- 125 psi Full-Feature compressors bar(e) 4.0 8.018 8.918
- 150 psi Full-Feature compressors bar(e) 4.0 9.741 10.641
- 175 psi Full-Feature compressors bar(e) 4.0 11.465 12.365

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17.8.2 Protections

Minimum Nominal Maximum

Blocking air (shut-down warning) bar(e) 1.0 1.2 1.5
Blocking air (shut down level) bar(e) 1.0 1.0 1.5
Blocking air (delay at signal) sec 0 10 60
Compressor outlet pressure bar(e) 16.0 16.0 16.0
(shut-down level)
Element outlet (Permissive start) bar(e) 2.0 2.0 2.0
Water injection pressure, element (Permissive start) bar(e) 0.3 0.3 0.3
Water injection pressure, element bar(e) 2.0 3.5 4.0
(Shut-down warning)
Water injection pressure, element bar(e) 2.0 3.0 4.0
(Shut-down level)
Water injection pressure (delay at start) sec 0 5 10
Water injection pressure (delay at signal) sec 0 10 60
Level sensor, water low (delay at signal) hrs 4 4 4
Temperature difference over element °C 10 15 25
(Shut-down warning)
Temperature difference over element °C 10 20 25
(Shut-down level)
Compressor element outlet temperature °C 60 60 70
(shut-down warning level)
Compressor element outlet temperature °C 60 65 70
(shut-down level)
p water injection / p separator (shut-down warning) bar 0.5 0.75 0.8
p water injection / p separator (shut-down level) bar 0.5 0.7 0.8
p water injection / p separator (delay at start) sec 5 10 10
p water injection / p separator (delay at signal) sec 0 1 10
Delay at start, motor overload sec 0 0 0
Delay at signal, motor overload sec 1 1 1
Delay at start, pump motor overload sec 0 0 0
Delay at signal, pump motor overload sec 1 1 1

For Full-Feature also:

Dryer LAT temperature (warning) °C 0 25 99
Delay at signal sec 0 3 255
Delay at starting sec 0 255 255

17.8.3 Service settings

Minimum Nominal Maximum

Service plans
Service plan A (running hours) hr 4000
Service plan B (running hours) hr 8000

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17.9 Notes chapter 17

ARAVF - Power recovery time

If desired, the ARAVF (Automatic Restart After Voltage Function) can be activated by Atlas Copco. The power
recovery time is the period within which the voltage must be restored to have an automatic restart.
Consult section 1.4 for more information.

Shut-down – shut-down warning

The regulator does not accept illogical settings, e.g. if the warning level is programmed at 100 °C, the minimum
limit for the shut-down level changes to 101 °C. The recommended difference between the warning level and
shut-down level is equal to the difference of the stated nominal values. Consult section 1.2 for more
information.

Delay at signal
Is the time period during which the warning signal must exist before the warning message appears.

Delay at starting
Is the time period during which the warning signal is ignored after starting.

Service plans
Always consult Atlas Copco in case any timer setting should be changed.
Consult section 12 for more information.

Unloading pressure/loading pressure

For ZE/ZA3/4 and ZA5/6, the settings are valid for compressors with full-load/no-load valve. Consult Atlas
Copco for compressors without full-load/no-load valve.

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Notes:

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Notes:

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O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
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SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations 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.

In addition to normal safety rules which should be observed with stationary
air compressors and equipment, the following safety directions and
precautions are of special importance.
When operating this unit, the operator must employ safe working practices
and observe all related local work safety requirements and ordinances.
The owner is responsible for maintaining the unit in a safe operating
condition. Parts and accessories shall be replaced if unsuitable for safe
operation.
Installation, operation, maintenance and repair shall only be performed
by authorized, trained, competent personnel.
Normal ratings (pressures, temperatures, time settings, etc.) shall be
durably marked.
Any modification on the compressor or air dryer shall only be performed
in agreement with Atlas Copco and under supervision of authorized,
competent personnel.
If any statement in this book, especially with regard to safety, does not
comply with local legislation, the stricter of the two shall apply.
If necessary, install a suction duct. Never obstruct the air inlet. Care
shall be taken to minimize the entry of moisture with the inlet air.
4. The aspirated air shall be free from flammable fumes or vapours,
e.g. paint solvents, that can lead to internal fire or explosion.
5. Air-cooled units shall 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 inlet.
6. Arrange the air intake so that loose clothing of people cannot be
sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
air dryer or air net is free to expand under heat and that it is not in
contact with or close to flammable material.
8. No external force may be exerted on the air outlet valve; the connected
pipe must be free of strain.
9. If remote control is installed, the unit shall bear an obvious sign
reading:

These precautions are general and cover several machine types and
equipment; hence some statements may not apply to the unit(s) described
in this book.
Installation
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed:
1. A compressor or air dryer shall be lifted only with adequate equipment
in conformity with local safety rules.
Loose or pivoting parts shall be securely fastened before lifting. It is
strictly forbidden to dwell or stay in the risk zone under a lifted load.
Lifting acceleration and retardation shall be kept within safe limits.
W ear a safety helmet when working in the area of overhead or lifting
equipment.
2. Any blanking flanges, plugs, caps and desiccant bags shall be
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working
pressure.
3. Place the unit where the ambient air is as cool and clean as possible.
DANGER: This machine is remotely controlled and may start
without warning.
As a further safeguard, persons switching on remotely controlled
units 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.
10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
instrument panel.
11. In multiple compressor systems manual valves shall be installed to
isolate each compressor. Non-return valves (check valves) shall not
be relied upon for isolating pressure systems.
12. Never remove or tamper with the safety devices, guards or insulations
fitted on the unit. Every pressure vessel or auxiliary installed outside
the unit to contain air above atmospheric pressure shall be protected
by a pressure-relieving device or devices as required.
13. Pipework or other parts with a temperature in excess of 80 degrees
celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
pipework shall be clearly marked.

2920 1377 03 1/2 (continued on inside of cover)

 SAFETY PRECA UTIONS
14. If the ground is not level or can be subject to variable inclination,
consult Atlas Copco.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses.
Operation
1. Air hoses shall be of correct size and suitable for the working pressure.
Never use frayed, damaged or deteriorated hoses. 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.
Never play with compressed air. Do not apply it to your skin or
direct an air stream at people. Never use it to clean dirt from your
clothes. When using it to clean equipment, do so with extreme caution
and use eye protection.
2. The compressor is not considered as capable of producing air of
breathing quality. For breathing air quality, the compressed air must
be adequately purified according to local legislation and standards.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes.
4. Never operate the units at pressures below or in excess of their limit
ratings as indicated on the Principal Data sheet.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear
protectors when opening a door.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors.
7. Periodically check that:
a. All guards are in place and securely fastened
b. All hoses and/or pipes inside the unit are in good condition, secure
and not rubbing
c. There are no leaks
d. All fasteners are tight
e. All electrical leads are secure and in good order
.
f Safety valves and other pressure-relief devices are not obstructed
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds,
valves, hoses, etc. are in good repair, free of wear or abuse
8. 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.
9. Do not remove any of, or tamper with, the sound-damping material.
Maintenance
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job.
1. Use only the correct tools for maintenance and repair work.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be
undertaken when the unit is stopped, the main power supply is
switched off and the machine has cooled down. Take positive
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in
progress; do not start" shall be attached to the starting equipment.
4. Before removing any pressurized component, effectively isolate the
unit from all sources of pressure and relieve the entire system of
pressure.
(continued)
5. Never use flammable solvents or carbon tetrachloride for cleaning
parts. Take safety precautions against toxic vapours of cleaning
liquids.
6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
clean cloth, paper or tape.
7. 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.
Whenever there is an indication or any suspicion that an internal
part of a machine is overheated, the machine shall be stopped but no
inspection covers shall be opened before sufficient cooling time
has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapour when air is admitted.
Never use a light source with open flame for inspecting the interior
of a machine, pressure vessel, etc.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
and that the control and shut-down devices function correctly. If
removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
10. 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.
11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
12. Make sure that all sound-damping material, e.g. on the bodywork
and in the air inlet and outlet systems of the compressor, is in good
condition. If damaged, replace it by genuine Atlas Copco material
to prevent the sound pressure level from increasing.
13. Never use caustic solvents which can damage materials of the air
net, e.g. polycarbonate bowls.
14. The following safety precautions are stressed when handling
refrigerant:
a. Never inhale refrigerant vapours. Check that the working area
is adequately ventilated; if required, use breathing protection.
b. Always wear special gloves. In case of refrigerant contact with
the skin, rinse the skin with water. If liquid refrigerant contacts
the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all
refrigerant is flushed away; then seek medical first aid.
c. Always wear safety glasses.
15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
Note: W ith stationary machine units driven by an internal combustion
engine, allowance has to be made for extra safety precautions, e.g. spark
arrestors, fuelling care, etc. Consult Atlas Copco.
All responsibility for any damage or injuryresulting from neglecting
these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
not expressly mentioned in this book, will be disclaimed by Atlas
Copco.
2920 1377 03 2/2

BEFORE STARTING
Consult the Instruction book,
section "Initial start-up",
before starting the compressor
for the first time.
1. The air inlet temperature
should be between 0 and 40
degrees Celsius.
2. Switch on the voltage. LED
(6) lights up.
3. Close the condensate drain
valves.
4. Open the air outlet valve.
5. Check the oil level indicator:
the pointer should be in the
green range or orange range.
6. For GA Full-feature, check
that valve (15) is closed and
that valves (16 and 17) are
open.
7. On GA W, open the water
shut-off valves and regulating
valve.
STARTING
1. Press start button (1). The
compressor starts running in
unloaded condition and LED
(11) lights up.
2. Approx. 10 seconds 2) later,
the compressor starts running
loaded.
3. On GA W, regulate the
cooling water flow, if
necessary, during loaded
operation.
1) For full operating and complete maintenance instructions, safety precautions, location of components, consult both the Instruction book and the User Manual. Damage or malfunction caused by unauthorized parts is not covered by
supplier’s Warranty or Product Liability.
2) Programmable.
3) If this function is not indicated at the bottom of display (4), press key <<Menu>> (5) until function <<Main Screen>> appears above key (F1), then press <<Main Screen>>.
2002-10
Registration code: APC G³90/'99 / 38 / 962
GA90 - GA110 - GA132 - GA160 - GA200 - GA250 - GA315
GA90 W - GA110 W - GA132 W - GA160 W - GA200 W - GA250 W - GA315 W 1)
From serial number AIF-078 300 onwards (GA/GA W 90/160) or from AIF-078 302 onwards (GA/GA W 200/315)
DURING OPERATION
1. Check the display.
Regularly press ¯ key (3) to
call up the compressor status
(pressures, temperatures,
etc.).
2. Remedy the trouble if alarm
LED (8) is alight or blinks.
3. To unload the compressor
manually, press key
<<Unload>> (12) 3). To put
the compressor back into
automatic operation, press
key <<Load>> (12). 3)
Important
When automatic operation LED
(11) is alight, starting and
stopping of the motor are
controlled automatically.
If the compressor start/stop
timer is active, the compressor
may start automatically, even if
it was stopped manually.
STOPPING
1. Press stop button (13). The
compressor will run
unloaded for 30 seconds,
after which it will stop.
2. To stop the compressor
immediately, press
emergency stop button (5).
Alarm LED (8) starts
blinking. After remedying
the trouble, unlock the
button by pulling it out.
3. Close the air outlet valve.
OPERATING INSTRUCTIONS
4. Open the condensate drain
valve(s).
5. On GA W, close the water
shut-off valves. If freezing
temperatures are expected,
drain the compressor
cooling water system
completely.
6. Switch off the voltage.
LUBRICATION
Use oil as specified in the
Instruction book.
1 Start button
2 Display
3 Scroll keys to scroll through the
display
4 Tabulator key to select the parameter
indicated by an arrow pointing to the
right
5 Emergency stop button
6 Voltage on LED
8 Alarm LED
11 Automatic operation LED
12 Function keys to control and
program the compressor
13 Stop button
14 Compressed air outlet
15 By-pass valve (Full-feature
compressors only)
16 By-pass valve (Full-feature
compressors only)
17 By-pass valve (Full-feature 19 Switch off the voltage and 22 Consult the Instruction book before 26 Cooling water inlet
depressurize the compressor before greasing 27 Cooling water outlet
compressors only)
maintenance or repair 23 Switch off the voltage before 28 Warning: under tension
Pictographs 20 Before connecting the compressor removing the protecting cover 29 Automatic condensate drain
7 Voltage on electrically, consult the Instruction inside the electric cabinet 30 Automatic condensate drain for
book for the motor rotation 24 Oil the gaskets, screw on the filters optional oil/water separator (type
9 General alarm
10 Automatic operation direction and tighten by hand (approx. one OSD)
18 Read Instruction book before starting 21 Torques for steel (Fe) or brass half turn) 31 Manual condensate drain
(CuZn) bolts 25 Consult the Instruction book before 32 Stop the compressor before
the compressor
maintenance or repair maintenance or repair
Printed Matter No. 2920 1475 10
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