Atlas ZR275 Instructions Books PDF

Atlas Copco
ZR 110, ZR 132, ZR 145, ZR 160, ZR 200, ZR 250, ZR 275,

ZT 110, ZT 132, ZT 145, ZT 160, ZT 200, ZT 250, ZT 275
Instruction book
Original instructions
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2015 - 09
No. 2920 1815 04
www.atlascopco.com
Page 3878 of 6229

Instruction book
Table of contents
1 Safety precautions..........................................................................................................7
1.1 SAFETY ICONS................................................................................................................................... 7
1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................7
1.3 SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 8
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 9
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR......................................................................... 10
2 General description...................................................................................................... 12
2.1 INTRODUCTION.................................................................................................................................12
2.2 AIR SYSTEM.................................................................................................................................... 20
2.3 COOLING AND CONDENSATE DRAIN SYSTEM........................................................................................... 25
2.4 ELEKTRONIKON REGULATED DRAIN (ERD)............................................................................................27
2.5 OIL SYSTEM.................................................................................................................................... 31
2.6 REGULATING SYSTEM........................................................................................................................ 33
2.7 ENERGY RECOVERY.......................................................................................................................... 36
2.8 LOW LOAD COMPENSATOR FOR IMD DRYER..........................................................................................39
2.9 SMARTBOX AND SMARTLINK.................................................................................................... 41
3 Elektronikon regulator................................................................................................. 44
3.1 ELEKTRONIKON® REGULATOR............................................................................................................. 44
3.2 CONTROL PANEL.............................................................................................................................. 46
3.3 FUNCTION KEYS............................................................................................................................... 47
3.4 SCROLL KEYS.................................................................................................................................. 48
3.5 EMERGENCY STOP BUTTON................................................................................................................ 48
3.6 CONTROL MODE SWITCH.................................................................................................................... 49
3.7 EXTERNAL COMPRESSOR STATUS INDICATION ........................................................................................50
3.8 EXTERNAL COMMUNICATION................................................................................................................50
3.9 CONTROL PROGRAMS........................................................................................................................52
2 2920 1815 04
Page 3879 of 6229

Instruction book
3.10 CALLING UP MENUS.......................................................................................................................... 53
3.11 MAIN SCREEN MENU......................................................................................................................... 53
3.12 STATUS DATA MENU..........................................................................................................................54
3.13 MEASURED DATA MENU..................................................................................................................... 56
3.14 HOURS MENU.................................................................................................................................. 56
3.15 SERVICE MENU................................................................................................................................ 57
3.16 TEST MENU..................................................................................................................................... 59
3.17 MODIFY SETTINGS MENU....................................................................................................................60
3.18 MODIFYING REGULATION SETTINGS...................................................................................................... 60
3.19 MODIFYING PROTECTION SETTINGS ..................................................................................................... 61
3.20 MODIFYING SERVICE SETTINGS............................................................................................................63
3.21 TIMERS MENU.................................................................................................................................. 64
3.22 CONFIGURATION MENU...................................................................................................................... 67
3.23 SAVED DATA MENU........................................................................................................................... 68
3.24 SHOW MORE MENU........................................................................................................................... 69
3.25 UNLOAD-LOAD MENU.........................................................................................................................70
3.26 PROGRAMMABLE SETTINGS.................................................................................................................70
4 Elektronikon regulator type overview.........................................................................75
4.1 ELEKTRONIKON® CONTROLLER TYPE OVERVIEW......................................................................................75
5 Elektronikon regulator................................................................................................. 77
5.1 ELEKTRONIKON® REGULATOR............................................................................................................. 77
5.2 CONTROL PANEL.............................................................................................................................. 79
5.3 FUNCTION KEYS............................................................................................................................... 80
5.4 SCROLL KEYS.................................................................................................................................. 81
5.5 EMERGENCY STOP BUTTON................................................................................................................ 81
5.6 EXTERNAL COMPRESSOR STATUS INDICATION ........................................................................................82
5.7 CONTROL PROGRAMS........................................................................................................................82
5.8 CALLING UP MENUS.......................................................................................................................... 84
2920 1815 04 3
Page 3880 of 6229

Instruction book
5.9 MAIN SCREEN MENU......................................................................................................................... 85
5.10 STATUS DATA MENU..........................................................................................................................86
5.11 MEASURED DATA MENU..................................................................................................................... 89
5.12 COUNTERS MENU............................................................................................................................. 90
5.13 TEST MENU..................................................................................................................................... 91
5.14 MODIFY PARAMETERS MENU............................................................................................................... 92
5.15 MODIFYING PARAMETERS................................................................................................................... 92
5.16 MODIFYING PROTECTION SETTINGS...................................................................................................... 93
5.17 MODIFYING SERVICE PLANS................................................................................................................ 94
5.18 PROGRAMMING CLOCK FUNCTION.........................................................................................................95
5.19 MODIFYING CONFIGURATION SETTINGS..................................................................................................99
5.20 SERVICE MENU.............................................................................................................................. 101
5.21 SAVED DATA MENU......................................................................................................................... 103
5.22 PROGRAMMABLE SETTINGS...............................................................................................................103
6 Elektronikon® GraphicPlus controller......................................................................112
6.1 ELEKTRONIKON® GRAPHICPLUS CONTROLLER..................................................................................... 112
6.2 CONTROL PANEL............................................................................................................................ 114
6.3 DIGITAL OUTPUT CONTACTS..............................................................................................................115
6.4 ICONS USED.................................................................................................................................. 116
6.5 MAIN SCREEN................................................................................................................................120
6.6 CALLING UP MENUS........................................................................................................................ 125
6.7 SERVICE MENU.............................................................................................................................. 126
6.8 PROTECTIONS MENU....................................................................................................................... 131
6.9 WEEK TIMER MENU.........................................................................................................................134
6.10 INFO MENU....................................................................................................................................144
6.11 TEST MENU................................................................................................................................... 145
6.12 COUNTERS....................................................................................................................................146
6.13 MODIFYING THE PRESSURE BAND...................................................................................................... 148
6.14 INPUTS MENU.................................................................................................................................150
4 2920 1815 04
Page 3881 of 6229

Instruction book
6.15 OUTPUTS MENU............................................................................................................................. 155
6.16 EVENT HISTORY MENU.....................................................................................................................157
6.17 MODIFYING SETTINGS......................................................................................................................158
6.18 PROGRAMMABLE SETTINGS...............................................................................................................164
6.19 WEB SERVER................................................................................................................................ 165
7 Installation...................................................................................................................174
7.1 DIMENSION DRAWING...................................................................................................................... 174
7.2 DIN TO JIS ADAPTOR FLANGES........................................................................................................190
7.3 INSTALLATION PROPOSAL................................................................................................................. 194
7.4 INSTALLATION REQUIREMENTS FOR RUBBER COMPENSATORS...................................................................206
7.5 ELECTRIC CABLE SIZE, FUSES AND CABLE LENGTH................................................................................ 213
7.6 ELECTRIC CONNECTION................................................................................................................... 226
7.7 QUALITY OF SAFETY COMPONENTS.....................................................................................................231
7.8 COOLING WATER REQUIREMENTS.......................................................................................................231
7.9 GENERAL PICTOGRAPHS.................................................................................................................. 234
7.10 PICTOGRAPHS, ELEKTRONIKON CONTROL SYSTEM................................................................................ 235
8 Operating instructions............................................................................................... 237
8.1 INITIAL START-UP............................................................................................................................237
8.2 BEFORE STARTING..........................................................................................................................261
8.3 ROUTINE STARTING.........................................................................................................................266
8.4 STARTING AFTER EMERGENCY STOP OR SHUTDOWN.............................................................................. 269
8.5 DURING OPERATION........................................................................................................................ 271
8.6 CHECKING THE DISPLAY...................................................................................................................273
8.7 MANUAL LOADING/UNLOADING...........................................................................................................274
8.8 STOPPING.....................................................................................................................................277
8.9 TAKING OUT OF OPERATION..............................................................................................................281
2920 1815 04 5
Page 3882 of 6229

Instruction book
9 Maintenance................................................................................................................ 282
9.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................282
9.2 MOTOR GREASING.......................................................................................................................... 285
9.3 OIL SPECIFICATIONS........................................................................................................................285
9.4 STORAGE AFTER INSTALLATION......................................................................................................... 285
10 Servicing procedures................................................................................................. 286
10.1 AIR FILTERS.................................................................................................................................. 286
10.2 OIL AND OIL FILTER CHANGE.............................................................................................................287
10.3 SAFETY VALVES............................................................................................................................. 289
10.4 COOLERS..................................................................................................................................... 289
11 Problem solving..........................................................................................................293
11.1 PROBLEM SOLVING......................................................................................................................... 293
12 Technical data.............................................................................................................298
12.1 READINGS.....................................................................................................................................298
12.2 SETTINGS OF SAFETY VALVES........................................................................................................... 299
12.3 SETTINGS FOR OVERLOAD RELAY.......................................................................................................299
12.4 REFERENCE CONDITIONS................................................................................................................. 310
12.5 LIMITATIONS.................................................................................................................................. 311
12.6 COMPRESSOR DATA........................................................................................................................313
12.7 DRYER DATA................................................................................................................................. 315
13 Pressure equipment directives................................................................................. 316
14 Documentation............................................................................................................322
6 2920 1815 04
Page 3883 of 6229

Instruction book
1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 General safety precautions

1. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel. The personnel should apply safe working practices by use of personal
protection equipment, appropriate tools and defined procedures.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing
quality, the compressed air must be adequately purified according to the applicable legislation and
standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.
Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with
extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
2920 1815 04 7
Page 3884 of 6229

Instruction book
9. If compressed air is used in the food industry and more specifically for direct food contact, Atlas
Copco recommends, for optimal safety, the use of certified Class 0 compressors in combination with
appropriate filtration depending on the application. Please contact your Atlas Copco Customer Center
for advice on specific filtration.
1.3 Safety precautions during installation

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

1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept
within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. In case the device is a compressor, place the machine where the ambient air is as cool and clean as
possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to
minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the
working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors and
particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people cannot
be drawn in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the electrical
isolating switch is open, locked and labelled with a temporary warning before any maintenance or
repair. As a further safeguard, persons switching on or off remotely controlled machines shall take
adequate precautions to ensure that there is no one checking or working on the machine. To this end,
a suitable notice shall be affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available
and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
12. The electrical connections must correspond to the applicable codes. The machines must be earthed
and protected against short circuits by fuses in all phases. A lockable power isolating switch must be
installed near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after voltage failure
is activated, a sign stating "This machine may start without warning" must be affixed near the
instrument panel.
8 2920 1815 04
Page 3885 of 6229

Instruction book
14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-
return valves (check valves) must not be relied upon for isolating pressure systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure relieving device or devices as required.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high temperature
piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the dryer,
safety valves must be installed in the vessels of the dryer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation

manufacturer.
Precautions during operation

1. Never touch any piping or components of the machine during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose
or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g.
to carry out routine checks. Wear ear protectors when opening a door.
On machines without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• No leaks occur
2920 1815 04 9
Page 3886 of 6229

Instruction book
• All fasteners are tight

• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to
avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
1.5 Safety precautions during maintenance or repair

manufacturer.
Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all damage or
injuries caused by the use of non-genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the
starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or
disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapors of cleaning liquids.
10 2920 1815 04
Page 3887 of 6229

Instruction book
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly. If removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged,
replace it by genuine material from the manufacturer to prevent the sound pressure level from
increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. Only if applicable, the following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
2920 1815 04 11
Page 3888 of 6229

Instruction book
2 General description
2.1 Introduction
General views
General view of ZR 110, ZR 132 and ZR 145 FF with Elektronikon controller
12 2920 1815 04
Page 3889 of 6229

Instruction book
General view of ZR 110, ZR 132 and ZR 145 FF with Elektronikon GraphicPlus controller (Model year 2010)
General view of ZR 110, ZR 132 and ZR 145 FF with Elektronikon GraphicPlus controller (Model year 2011)
2920 1815 04 13
Page 3890 of 6229

Instruction book
General view of ZR 160 up to ZR 275 FF with Elektronikon GraphicPlus controller
General view of ZT 110, ZT 132 and ZT 145 FF with Elektronikon controller
14 2920 1815 04
Page 3891 of 6229

Instruction book
General view of ZT 110, ZT 132 and ZT 145 FF with Elektronikon GraphicPlus controller (Model year 2010)
General view of ZT 110, ZT 132 and ZT 145 FF with Elektronikon GraphicPlus controller (Model year 2011)
2920 1815 04 15
Page 3892 of 6229

Instruction book
General view of ZT 160 up to ZT 275 FF with Elektronikon GraphicPlus controller
Ref. Name
AO Compressed air outlet
DRa Condensate drain receiver, aftercooler
DRi Condensate drain receiver, intercooler
MK4 Elektronikon regulator
MK5 Elektronikon GraphicPlus regulator
SVh Safety valve, high pressure
SVl Safety valve, low pressure
S2 Emergency stop button
WI Cooling water inlet
WO Cooling water outlet
These units are two-stage, electric motor driven screw compressors which deliver oil-free, pulsation-free
air.
ZR compressors are water-cooled.
ZT compressors are air-cooled.
The compressor is enclosed in a sound-insulated bodywork and includes mainly:
• Air filter
• Low-pressure compressor element
• Intercooler
• High-pressure compressor element
• Aftercooler
• Water separators
• Electric motor
• Drive coupling
16 2920 1815 04
Page 3893 of 6229

Instruction book
• Gear casing
• Elektronikon® control system
• Safety valves
Drive arrangement
On ARR E, the motor is flanged to the gear casing by means of a coupling housing. The motor/gear casing
unit is supported on the frame by vibration dampers.
On ARR 1, the motor is mounted on a separate subframe. The subframe and gear casing are supported on
the frame by vibration dampers.
Elektronikon control system

The compressor is controlled by an electronic regulator which:
• Controls the operation of the compressor
• Reduces the power consumption
• Warns the operator in case of an abnormal operating condition
• Protects the compressor
• Monitors components subject to service
• If activated, the regulator can automatically restart the compressor after voltage failure
Optional equipment
Following equipment is available as an option:
Full-Feature
The compressor is additionally provided with an IMD adsoption dryer. The dryer is integrated in the
bodywork and removes moisture from the compressed air.
Connections
This compressor can be provided on the compressed air outlet and water pipes with:
ANSI flanges
DIN flanges
DIN flanges + DIN to JIS adapter flanges
Separate air intake

This compressor is prepared to install separate ducting for cooling air flow and compressed air flow.
Motor temperature protection

Temperature sensors (PT1000) are embedded in the drive motor to warn the operator if the temperature
becomes too high and to shut down the compressor, thereby protecting the motor from overheating.
Motor bearing temperature protection

Temperature sensors (PT1000) are embedded in the drive motor to warn the operator if the temperature of
the bearings becomes too high and to shut down the compressor, thereby protecting the motor bearings
from overheating.
2920 1815 04 17
Page 3894 of 6229

Instruction book
Teflon-free compressor elements

The rotors of the compressor elements have an epoxy-based coating.
Hot air version

The cooling system does not cool the outgoing compressed air.
Automatic water shut-off

A water shut-off valve is provided in the cooling water system to shut off the system when the compressor
is not in operation.
Duplex oil filters

Duplex oil filters have a flow selector valve. When the handle of the valve is in the upright position, both
cartridges are connected in the oil circuit. When the handle is turned to the right, the left cartridge is out of
service and vice versa.
Energy recovery
The compressor is provided with an Atlas Copco energy recovery system to recover the major part of the
compression heat in the form of hot water.
SPM monitoring
A number of vibration sensors are provided on the drive motor and compressor elements. The readings can
be called up on the display of the Elektronikon regulator.
High ambient temperature (HAT)

The compressor is specially designed for continuous operation under humid and high ambient temperature
conditions. The maximum ambient temperature is 50˚C (122˚F).
Anchor pads
Steel plates, fitting in the forklift slots, and bolts are shipped loose with the compressor. With these plates
and bolts, the compressor frame can be fixed to the floor.
Pre-filter kit
Two extra compressed air inlet filters, delivered loose with the compressor, must be mounted in parallel on
the roof of the compressor. With the prefilters the interval between air filter exchange is nearly two times
longer. The two prefilters can be changed without stopping the compressor.
Anti-condensation heaters
Electric heaters are installed in the motor windings and connected to the compressor cubicle. When the
compressor is stopped, the heaters are automatically switched on. The heaters in the motor will prevent
condensation during stand-still.
18 2920 1815 04
Page 3895 of 6229

Instruction book
PDp filter (Only for ZR/ZT 110-145)

The high efficiency particle filter for dust protection PDp makes sure no dust particles with size above 0.01
µm enter the air net.
PDP sensor (Only for ZR/ZT 110-145)

The pressure dewpoint of the compressed air leaving the IMD dryer is continuously shown on the display
of the Elektronikon regulator. This allows to monitor the performance of the dryer and to make sure that
the compressed air is dry enough for the application.
Silicon-free rotor
With this option, the compressed air leaving the compressor is 100 % silicon-free.
Low load compensator for IMD dryer

When the compressor is frequently loading and unloading and when the load/unload cycles are short, the
rotor of the IMD will not be properly regenerated. This will lead to an increase of the pressure dewpoint
and a reduced lifetime of the rotor. The option low load compensator will make sure that the rotor is always
regenerated properly ensuring a good IMD performance and a long rotor lifetime.
Dryer by-pass
The dryer by-pass enables to use optional air piping to avoid air flow through the dryer. It is NOT allowed
to service the dryer when it is by-passed and the compressor is running!
Kit for purge of dry air during standstill

When frequent and long standstills occur, it is recommended to install a kit for purge of dry air to guarantee
the life time of the oil-free screw elements. During standstill, condensation (which triggers corrosion)
might occur. This results in an expected element lifetime reduction or even a compressor stage blocking
during standstill. Condensation is prevented by blowing a small amount of dry air through the small gap
between rotor-rotor and rotor-housing once the compressor is stopped. To avoid long standstills, regular
starting can be programmed in the Elektronikon controller or by a central Atlas Copco ES controller.
Oversized motor
The size of the motor is chosen in such a way that the Service Factor of the motor is never used.
SMARTBOX
When ordering the compressor, it is possible (except for Japan and Korea) to choose the free SMARTBOX
option which is mounted in the electrical cabinet. The SMARTBOX allows read-out of the compressor
parameters on a login-protected web site called SMARTLINK. The connected antenna is mounted on the
outside of the electrical cabinet. (Refer to the SMARTBOX and SMARTLINK section.)
2920 1815 04 19
Page 3896 of 6229

Instruction book
2.2 Air system
Flow diagram
Flow diagram of ZR 110 up to ZR 275 and ZR 132 VSD up to ZR 315 VSD compressors
20 2920 1815 04
Page 3897 of 6229

Instruction book
Flow diagram of ZR 110 up to ZR 275 Full-Feature compressors and ZR 132 VSD up to ZR 315 VSD Full-Feature
compressors
2920 1815 04 21
Page 3898 of 6229

Instruction book
Flow diagram of ZT 110 up to ZT 275 compressors and ZT 132 VSD up to ZT 315 VSD compressors
22 2920 1815 04
Page 3899 of 6229

Instruction book
Flow diagram of ZT 110 up to ZT 275 Full-Feature compressors and ZT 132 VSD up to ZT 315 VSD Full-Feature
compressors
Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
2920 1815 04 23
Page 3900 of 6229

Instruction book
Reference Name
Ca1 Pre-aftercooler
Ca Aftercooler
Ci1 Pre-intercooler
Ci Intercooler
Co Oil cooler
Cr Regeneration air cooler
CV Check valve
Eh High-pressure compressor element
El Low-pressure compressor element
FN Fan
MTa Moisture trap, aftercooler
MTi Moisture trap, intercooler
Nz Ejector nozzle
OF Oil filter
OP Oil pump
Ws Water separator
1 Demister
2 Rotor
3 Regulation valve for the inlet of the regeneration air
4 Strainer
Description
Air drawn through filter (AF) is compressed in low-pressure compressor element (El).
On ZR compressors, the compressed air is discharged to intercooler (Ci).
On ZT compressors, the compressed air is discharged to silencer, pre-intercooler (Ci1) and intercooler (Ci).
The cooled air is further compressed in high-pressure compressor element (Eh) and discharged through
silencer (AS) and aftercooler (Ca).
On ZR/ZT 110 up to ZR/ZT 275, a check valve (CV) is fitted downstream of the silencer.
The wet air from the aftercooler enters water separator (Ws) via ejector nozzle (Nz). In demister (1), the
water droplets are removed from the air. The air is then led through rotor (2), which adsorbs the water
vapour.
The compressed air leaves the compressor via the air outlet (AO).
Regenerating circuit of the dryer (only for Full-Feature units)

Hot regeneration air is branched off upstream of the aftercooler. The regeneration air passes through
regulation valve (3) and strainer (4), and is blown through the wet rotor channels.
The hot saturated air is then cooled down in regeneration air cooler (Cr). The regeneration air is then mixed
with the wet compressed air from the compressor aftercooler.
24 2920 1815 04
Page 3901 of 6229

Instruction book
2.3 Cooling and condensate drain system
Flow diagram
Flow diagram of ZR 110 up to ZR 275 compressors
2920 1815 04 25
Page 3902 of 6229

Instruction book
Flow diagram of ZT 110 up to ZT 275 compressors
Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
Ca1 Pre-aftercooler
Ca Aftercooler
26 2920 1815 04
Page 3903 of 6229

Instruction book
Reference Name
Ci1 Pre-intercooler
Ci Intercooler
Co Oil cooler
CV Check valve
FN Fan
OF Oil filter
OP Oil pump
Cooling system for ZR compressors

The cooling water flows through oil cooler (Co), the cooling jackets of high-pressure compressor element
(Eh) and low-pressure compressor element (El), as well as through intercooler (Ci) and aftercooler (Ca).
In case of a Full-Feature compressor, cooling water is also provided to the additional regeneration cooler of
the integrated dryer.
Cooling system for ZT compressors

The compressors are fitted with an oil cooler (Co), intercoolers (Ci1 and Ci) and aftercoolers (Ca1 and Ca).
The coolers are air-cooled, the cooling air is generated by fan (FN).
In case of a Full-Feature compressor, an additional regeneration cooler is mounted (in the integrated dryer).
Condensate drain
Two moisture traps are installed: one downstream of the intercooler (MTi) to prevent condensate from
entering compressor element (Eh) and one downstream of the aftercooler (MTa) to prevent condensate
from entering the air outlet pipe.
A Full-Feature compressor also contains condensate traps downstream of the dryer:
• two traps, in case of a water-cooled compressor
• three traps, in case of an air-cooled compressor.
On ZR/ZT 110 up to ZR/ZT 275, the moisture traps are connected to an ERD, see section Elektronikon
Regulated Drain.
2.4 Elektronikon regulated drain (ERD)
Description
The drain consists of a capacitive sensor which is incorporated in the drain collector and of a pilot valve
which is placed outside the drain collector. A drain opening delay timer is started when the collector is
filled up to the level of the capacitive sensor. As long as the delay timer is running, extra condensate will
be collected and the level will rise even higher than the position of the sensor. As soon as the delay timer
has expired, the pilot valve (normally open) is deactivated and the diaphragm opens the outlet, discharging
2920 1815 04 27
Page 3904 of 6229

Instruction book
the condensate. From the moment that the sensor is not detecting any condensate anymore, a drain closing
delay timer is started. The pilot valve will still drain the condensate during the run of this timer to make
sure that the remaining amount of condensate is drained. The pilot valve is activated when the timer has
expired, the outlet closes quickly without wasting compressed air.
for ZR compressors (before model year 2014)
for ZR compressors (from model year 2014)
28 2920 1815 04
Page 3905 of 6229

Instruction book
for ZT compressors (before model year 2014)
for ZT compressors (from model year 2014)
2920 1815 04 29
Page 3906 of 6229

Instruction book
Reference Description
1 Solenoid valve
2 Connector
3 Sensor
4 Bushing
5 Drain receiver
If the controller detects water in the intercooler or aftercooler drain receiver for too long a period, a
shutdown is generated. If water is detected on the integrated dryer drain receiver for too long a period, a
warning is generated.
The level switch is a capacitive sensor which generates a high signal when no water is present. The
solenoid valves of the intercooler and aftercooler/integrated dryer drains are different. The solenoid valve
of the intercooler drain has a high flow but cannot handle high pressures. The solenoid valve on the
aftercooler/integrated dryer drains has less flow but can handle higher pressures. It is not allowed to open
the valves as they can loose their set point. Special attention must be paid to the correct wiring of the
different level switches and solenoid valves.
The output of the level switch can be called up on the screen of the Elektronikon regulator. The reading
does not indicate whether the solenoid valve is open or closed, but indicates whether the level switch is
detecting water in the collector. Since there is a drain opening delay timer, the display on the Elektronikon
can show "Condensate Drain IC Open", while the solenoid valve is still closed. Changes to the
Elektronikon settings are not allowed. The "Always pressurized" bit must be activated on aftercooler and
integrated dryer drains. On the intercooler it is not allowed to activate this bit.
A functionality test is possible through the Elektronikon regulator. By performing this test, all solenoid
valves will be opened for a short time (e.g. 15 seconds). Refer to the Elektronikon chapter for more details.
30 2920 1815 04
Page 3907 of 6229

Instruction book
2.5 Oil system
Flow diagram
Flow diagram of ZR 110 up to ZR 275 compressors and ZR 132 VSD up to ZR 315 VSD compressors
2920 1815 04 31
Page 3908 of 6229

Instruction book
Flow diagram of ZT 110 up to ZT 275 compressors and ZT 132 VSD up to ZT 315 VSD compressors
Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
Ca1 Pre-aftercooler
Ca Aftercooler
32 2920 1815 04
Page 3909 of 6229

Instruction book
Reference Name
Ci1 Pre-intercooler
Ci Intercooler
Co Oil cooler
CV Check valve
FN Fan
OF Oil filter
OP Oil pump
Description
Oil is circulated by pump (OP) from the sump of the gear casing through cooler (Co).
On ZT compressors, the oil flows through the cooling jackets of the compressor elements (El and Eh).
The oil passes through oil filters (OF) towards the bearings and timing gears.
Valve (BV) opens if the oil pressure should rise above a given value.
2.6 Regulating system
General
The regulator keeps the net pressure within programmable pressure limits by automatically loading and
unloading the compressor depending on the air consumption.
2920 1815 04 33
Page 3910 of 6229

Instruction book
During 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 pressure), solenoid valve (Y1) is
de-energised. The plunger of solenoid valve (Y1) moves by spring force shutting off the control air supply
to unloader (UA).
Phase Description
1 Control pressure is vented from chamber (1) of unloader (UA) through solenoid valve
(Y1) and chamber (3) towards the inlet of compressor element (El).
2 As there is no longer any pressure difference between chambers (1 and 3), plunger (2)
returns by spring force keeping full-load/no-load valve (TV) closed and unloading valve
(UV) open.
3 Compressed air between check valve (CV) and valve (UV) is blown off through silencer
(US). Check valve (CV) closes.
4 As vacuum prevails in intercooler (Ci), diaphragm (4) switches to the left.
Air delivery is stopped (0%), the compressor runs unloaded.
34 2920 1815 04
Page 3911 of 6229

Instruction book
During loading
When the net pressure decreases to the lower limit of the working pressure (loading pressure), solenoid
valve (Y1) is energised. The plunger of solenoid valve (Y1) moves against the spring force opening the
control air supply port to unloader (UA).
Phase Description
1 Atmospheric pressure is allowed through solenoid valve (Y1) to chamber (1) of unloader
(UA). As this pressure is higher than the pressure in chamber (3), full-load/no-load valve
(TV) starts opening.
2 Intercooler pressure is building up causing diaphragm (4) to switch to the right. As the
pressure difference between chambers (1 and 3) increases, plunger (2) moves further
against the spring force until full-load/no-load valve (TV) is fully open and unloading
valve (UV) closed.
Air delivery is resumed (100%), the compressor runs loaded.
2920 1815 04 35
Page 3912 of 6229

Instruction book
2.7 Energy recovery
General
The system recovers the major part of the compression heat. The percentage of shaft input power available
for recovery is between 80 and 95, depending on the operating conditions.
If an MD dryer is installed downstream of the compressor, this percentage is reduced to approx. 70 of the
shaft input instead of approx. 90, as part of the heat in the compressed air is used for regeneration in the
drying process.
A complete energy recovery system includes:
• Compressor with modified cooling system (ZR)
• A pump unit (PU) to transfer the recovered energy from the compressor cooling system to the heat
consumer (HC)
• The heat consumer (HC), i.e. the equipment to transfer the energy to the industrial process
Modified cooling water system

The compressor cooling system has been modified to achieve both high cooling water temperatures and
sufficient cooling for the compressor.
The cooling water enters the oil cooler and then flows through the high-pressure compressor element, the
low-pressure compressor element and finally the intercooler and the aftercooler. This sequence ensures
optimal temperature differences with relation to the heat transfer in the individual components.
On Full-Feature compressors, additional connections are provided for the water circuit of the additional
aftercooler and the cooler of the IMD dryer. To ensure that the IMD dryer works properly, low-temperature
cooling water should be used for this cooling water circuit. The heat of this cooling water circuit is not
recovered by the energy recovery system.
36 2920 1815 04
Page 3913 of 6229

Instruction book
Pump unit
Atlas Copco supplies pump units to transfer the energy recovered from the compressor to the heat
consumer (HC). The pump unit constitutes a closed water circuit with the compressor cooling system.
Two water pumps (WP1/2) are fitted. One pump circulates the hot cooling water from the compressor
through the heat consumer and back to the compressor. The other is a stand-by pump. Check valves
(CV1/2) at the delivery side of the pumps prevent backflow of water in the stand-by pump. The pump unit
is fitted with a make-up water connection, an air trap with automatic de-aeration device (AT), a pressure
and temperature gauge (PI and TI), a safety valve (SV) and an expansion tank (ET).
Cooling water requirements

Closed recirculating water systems minimize make-up water requirements. Therefore, it is economically
feasible to use softened water to eliminate the problem of scaling deposits.
Corrosion control is important. The best results are obtained by adding corrosion inhibitors as used in
engine cooling systems.
Using anti-freeze products is an alternative solution to avoid problems, e.g. adding 20 % to 30 % ethylene-
glycol based anti-freeze to the tap water.
For open cooling water systems (e.g. boiler feed water preparation), consult the Atlas Copco Customer
Centre to avoid problems related to deposit control, corrosion control and microbiological growth control.
Water flow regulation through heat exchangers

Depending on the amount of energy transferred in the heat consumer (HC), the heat exchanger (HE) of the
pump unit is completely or partly by-passed by means of a thermostatic valve (RV2). The valve is normally
adjusted to achieve a cooling water temperature of 40 ˚C (corresponding to the maximum allowable
2920 1815 04 37
Page 3914 of 6229

Instruction book
temperature at the compressor inlet). It is advisable to adjust the setting of the valve as close as possible to
the temperature of the cooling water returning from the heat consumer (HC).
Depending on the amount of energy transferred in the heat consumer (HC), the heat exchanger (HE) of the
pump unit is completely or partly by-passed by means of a thermostatic valve (RV2). The valve is normally
adjusted to achieve a cooling water temperature of 104 ˚F (corresponding to the maximum allowable
temperature at the compressor inlet). It is advisable to adjust the setting of the valve as close as possible to
the temperature of the cooling water returning from the heat consumer (HC).
Sufficient low-temperature cooling water must be available for the heat exchanger to achieve a water
temperature that does not exceed 40 ˚C/104 ˚F.
Electrical system
The pumps (WP1 and WP2) are driven by an electric motor. Each motor is equipped with manual starting
equipment including a circuit breaker.
The first time it is started, check that the rotation direction matches the direction indicated by the arrows on
the motor flanges. If necessary, stop the unit, switch off the voltage and reverse two incoming electric
lines.
Important remarks
Compressed air quality and reliability of any compressor, dryer or other equipment should never be made
subordinate to the energy recovery system. In some cases, especially installations where air dryers are
installed, an additional aftercooler is required to reduce the compressor air outlet temperature to a level at
which the dryers operate at maximum efficiency. This aftercooler and the dryer (if water-cooled) need to
be cooled separately by low-temperature water. Consult the Atlas Copco Customer Centre.
The general temperature level of compressors with a modified cooling system for energy recovery is
approx. 20 to 25 ˚C (68 to 77 ˚F) higher than the level of compressors with a standard cooling system,
resulting in a slight decrease in free air delivery and a slight increase in shaft power.
In case the compressors operate in high ambient temperatures and with high water inlet temperatures, the
maximum working pressure is 0.5 bar (7.25 psi) lower than for standard compressors. Consult the Atlas
Copco Customer Centre.
Settings - limitations
Item Setting
Maximum cooling water temperature at compressor 90 ˚C (85 ˚C if MD dryer is fitted)
outlet 194 ˚F (185 ˚F if MD dryer is fitted)
Maximum cooling water temperature at compressor 40 ˚C
inlet 104 ˚F
Safety valve opening pressure 2.5 bar(e)
36.3 psig
38 2920 1815 04
Page 3915 of 6229

Instruction book
2.8 Low load compensator for IMD dryer
Description
Flow diagram of a ZT compressor with Low Load compensator functionality (during unload)
2920 1815 04 39
Page 3916 of 6229

Instruction book
Flow diagram of a ZR compressor with Low Load compensator functionality (during unload)
Reference Name
1 Outlet of compressed air (air net)
2a, 2b Non-return valve
3 Heater
4 Rotor
5 Motor
6 Cooler
40 2920 1815 04
Page 3917 of 6229

Instruction book
Reference Name
7a, 7b, 7c, 7d Solenoid valve
8 Nozzle of dryer inlet
9 Water separator
10 Silencer
11 Safety valve
12 Compressed air from compressor
13 Regeneration air from compressor
14 Symbol
15 Explanation
16 Air flow
17 Air flow direction
18 No air flow
19 Drain
20 Cooling water
To allow low load operation (load rate < 40%), a low load compensator is required during compressor
unload. The compensator keeps the pressure dew point (PDP) steady by purging a small amount of heated,
dried air through the dryer rotor (4).
2.9 SMARTBOX and SMARTLINK
General
The machine comes with a SMARTBOX mounted in the electrical cabinet.
The SMARTBOX allows read-out of a number of parameters of the machine on a user login-protected web
site called SMARTLINK. The connected antenna is mounted on the outside of the machine.
Safety precautions
It is important to follow all regulations regarding the use of radio equipment, in particular regarding the
possibility of radio frequency (RF) interference. Please follow the safety advice given below carefully.
• Respect restrictions on the use of radio equipment in fuel depots, chemical plants or other explosive
environments.
2920 1815 04 41
Page 3918 of 6229

Instruction book
• Avoid SMARTBOX operation close to inadequately protected personal medical devices such as
hearing aids and pacemakers. Consult the manufacturers of the medical device to determine if it is
adequately protected.
• Avoid SMARTBOX operation close to other electronic equipment which may also cause interference
if the equipment is inadequately protected. Observe any warning signs and manufacturer
recommendations.
• Respect a distance from the human body of at least 20 cm (8 inch) during SMARTBOX operation.
• Do not operate the SMARTBOX in areas where cellular modems are not advised without proper
device certifications. These areas include environments where cellular radio can interfere, such as
explosive atmospheres, medical equipment, or any other equipment which may be susceptible to any
form of radio interference. The modem can transmit signals that could interfere with this equipment.
SMARTLINK
The machine is SMARTLINK-ready.
SMARTLINK is Atlas Copco’s web-based platform to monitor compressed air installations. It is available
in 3 product levels:
• SMARTLINK Service
SMARTLINK Service rules out all uncertainties. Scheduling maintenance visits becomes as simple
and easy as it should be; the service log book is always just one click away and the online link with
Atlas Copco allows to request and quickly receive quotes for spare parts or additional services.
This product level is free of charge and available for 3 years following the machine purchase.
• SMARTLINK Uptime
SMARTLINK Uptime keeps your compressors up and running. By e-mail and/or text, you receive all
relevant machine indications (warnings and shutdowns) in advance. Based on this information, you
can then take all necessary actions and measures to avoid the risk of a breakdown.
This product level is available as a free of charge 3-month trial.
• SMARTLINK Energy
SMARTLINK Energy safeguards the performance of your equipment. It enables you to continuously
monitor and analyze the energy efficiency of the compressor room. You decide which performance
indicators, benchmarks and reports are created. You can make accurate and immediate improvements
when needed. The results can be used for energy monitoring according to ISO50001.
This product level is available as a free of charge 3-month trial.
Once a SMARTLINK level is chosen, gaining access is the next step. To gain access at least one machine
SMARTLINK-ready component (compressor, dryer, ...) is required. Follow the next steps:
• Gather the information about the SMARTLINK-ready machine(s) (e.g. picture of the data plate;
invoice,…)
• Go to the SMARTLINK web site http://www.atlascopco.com/smartlink
• Click on the left button in the screen below.
42 2920 1815 04
Page 3919 of 6229

Instruction book
• Use the data of the SMARTLINK–ready machine to register as a user.
• You will receive an e-mail with login credentials.

• Go to the SMARTLINK web site http://www.atlascopco.com/smartlink, log in with the user
credentials.
• Enjoy SMARTLINK!
• In case more SMARTLINK-ready machines are available, you can add these via My Profile.
2920 1815 04 43
Page 3920 of 6229

Instruction book
3 Elektronikon regulator
3.1 Elektronikon® regulator
Control panel
Introduction
In general, the Elektronikon regulator has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (made inactive)
•
Automatic control of compressor operation

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.
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.
Protecting the compressor

Shut-down
Several 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 display (1) and general alarm
LED (2) will blink.
44 2920 1815 04
Page 3921 of 6229

Instruction book
The compressor will also be stopped in case of:

• Overload of the drive motor
•
•
•
Remedy the trouble and reset the message on the display before restarting.
Before remedying, consult the Safety precautions.
Shut-down warning
If one of the measurements exceeds the programmed shut-down warning level, a message will appear on
display (1) and general alarm LED (2) will light up, to warn the operator that the shut-down warning level
is exceeded.
The message disappears as soon as the warning condition disappears.
Monitoring components subject to service

Service warning
The regulator continuously monitors critical components. Each input is compared to programmed limits. If
these limits are exceeded, a message will appear on display (1) to warn the operator to take the necessary
action.
Automatic restart after voltage failure

For compressors leaving the factory, this function is made inactive. If desired, the function can be
activated. Consult the Atlas Copco Customer Centre.
If activated and provided the regulator was in the automatic operation mode and the
compressor control mode (local, remote 1 or remote 2) was not changed during the
voltage failure, the compressor will automatically restart if the supply voltage to the
module is restored within a programmed time period (this time period is called the power
recovery time).
The power recovery time can be set between 1 and 254 seconds or to 0. If the power
recovery time is set to 0, the compressor will always restart after a voltage failure, no
matter how long it takes to restore the voltage.
2920 1815 04 45
Page 3922 of 6229

Instruction book
3.2 Control panel
Elektronikon regulator
Parts and functions
Reference Designation Function

1 Automatic Operation LED Indicates that the electronic regulator is
automatically controlling the compressor.
2 Voltage on LED Indicates that the voltage is switched on.
3 Display Indicates messages concerning:
• The compressor operating condition
• A service need
• A fault
See Main screen menu
4 Scroll keys Up and down keys to scroll with through the display.
See Scroll keys.
5 Start button Button to start the compressor.
6 Stop button Button to stop the compressor.
7 Tabulator key Key to go to the next field of the display.
8 Function keys Keys to control and program the compressor. The
function of the functions keys varies depending on
the displayed menu. The actual function is indicated
above the relevant key. See Function keys.
9 General Alarm LED • Lights up in case of a shut-down.
• Blinks in case of a shut-down.
• Blinks if an important sensor is out of order.
• Blinks after an emergency stop.
S2 Emergency stop button Button to stop the compressor immediately in case
of emergency. LED (1) goes out. See Emergency
stop button.
S5 Control mode switch Key switch to select the compressor control mode.
See Control mode switch.
46 2920 1815 04
Page 3923 of 6229

Instruction book
3.3 Function keys
Control panel
Function keys
The keys (1) are used:
• To manually load/unload the compressor
• 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 just
above the relevant key. The most common functions are listed below:
Designation Function
Add To add compressor start/stop commands (day/hour)
Cancel To cancel a programmed setting when programming parameters
Delete To delete compressor start/stop commands
Limits To show limits for a programmable setting
List To list programmed start/stop commands (day/hour)
Load To load the compressor manually
Main Screen To return from a menu to the main display
Menu • Starting from the main display, to initiate the main menu which gives access to
submenus
• Starting from a submenu, to return to the main menu
Modify To modify programmable settings
Show More To have a quick look at the compressor status
Program To program modified settings
Reset To reset a timer or message
Return To return to a previously shown option or menu
Select To select a submenu or to read more details of a selection shown on the display
Unload To unload the compressor manually
2920 1815 04 47
Page 3924 of 6229

Instruction book
3.4 Scroll keys
Control panel
The keys (1) allow the operator to scroll through the display.
As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll key
with the same symbol can be used to see the next item.
As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key
with the same symbol can be used to see the previous item.
3.5 Emergency stop button
Control panel
48 2920 1815 04
Page 3925 of 6229

Instruction book
In case of emergency, press button (S2) to stop the compressor immediately.
Before starting any maintenance or repairs, wait until the compressor has
stopped and open the isolating switch (customer's installation) to switch off the
voltage to the compressor.
Close the air outlet valve and open the manual condensate drain valves to
depressurize the air system.
Apply all relevant Safety precautions.
3.6 Control mode switch
Control panel
The switch (S5) allows the operator to select four compressor control modes.
2920 1815 04 49
Page 3926 of 6229

Instruction book
Key position Compressor control mode

1 Compressor off.
2 Local control mode.
The regulator will only react on commands entered by means of the buttons on the
control panel of the compressor.
3 Remote control mode 1.
The regulator will only react on start/stop commands generated by external switches.
The emergency stop button remains active. Compressor start/stop commands via
function Timers are still possible, if programmed and activated. It also remains possible
to call up data and to program the regulator. Consult Atlas Copco before connecting
external equipment to the regulator. Maintained-action buttons must not be used for the
remote start and stop functions.
4 Remote control mode 2.
The regulator will only react on start/stop and manual load/unload commands generated
by computer. Consult the Atlas Copco Customer Centre.
To avoid unauthorized switching over to another compressor control mode, take out the key
after selecting the mode.
The regulator will only react on a new control mode if the new position of the key switch is
maintained for 3 seconds.
3.7 External compressor status indication

Terminal strip (1X1) is provided with auxiliary contacts for external indication of:
Indication Relay Terminals on strip 1X1 Maximum load

Automatic operation K06 11-12 10 A / 230 V AC
Warning K07 13-14 10 A / 230 V AC
Shut-down K08 15-16 10 A / 230 V AC
Compressor loaded K11 17-18 2.5 A / 230 V AC
Compressor running K21 19-20 5.6 A / 230 V AC
Control mode REMOTE 1 -- 21-22 10 A / 230 V AC
Stop the compressor and switch off the voltage before connecting external equipment.
Consult Atlas Copco.
3.8 External communication
Description
If it is desired to connect the compressor to an Atlas Copco ES system an optional communication module
(COM1 or COM2) needs to be installed. If it is desired to connect the compressor to a profibus network, a
profibus module in combination with a COM2 module must be installed.
50 2920 1815 04
Page 3927 of 6229

Instruction book
Installation
Installation of communication module
Step Action
1 Slide the communication module with its guides (1) into slots (2) of the module of the
compressor regulator and fix it using plate (3).
2 Connect the 24V power supply from terminals (6 and 7) of terminal strip (1X1) to
connector (..X1) of the communication module.
3 Connect an earth cable between the communication module and the module of the
compressor regulator.
4 Connect the cable delivered with the communication module from connector (..X3) of
the communication module to a free ..X2 connector on a module of the compressor
regulator.
5 Consult Atlas Copco to check the installation and to have the communication software
loaded.
Installation of Profibus module
Step Action
1 Install the COM2 module as described above.
2920 1815 04 51
Page 3928 of 6229

Instruction book
Step Action
2 Connect the cable (delivered with the profibus module) from connector (DP) of the
profibus module to connector (7X16) of the (COM2) module.
3 Connect the profibus network to connector (PORT0) of the profibus module.
4 Connect the 24V power supply from terminals (6 and 7) of terminal strip (1X1) to
terminals (N and L1) on the profibus module.
5 Connect an earth cable between the profibus module and the module of the compressor
regulator.
6 Consult Atlas Copco to check the installation and to have the communication software
loaded.
3.9 Control programs
In order to facilitate programming and controlling, menu-driven control programs have been implemented
in the regulator.
Program Function
Main screen Shows in short the operation status of the compressor. Is the gateway to all
functions.
Status data Calling up the status of the compressor protection functions (shut-down, shut-
down warning and motor overload). Resetting of a shut-down and motor overload.
Measured data Calling up the actually measured data and the status of the motor overload
protection.
Hours Calling up the running hours, loading hours, regulator hours and number of motor
starts.
Service Calling up and resetting the service messages of the monitored components.
Test Display test.
Modify settings Modifying the settings for regulation (e.g. loading and unloading pressures), for
protection (e.g. temperature shut-down level) and for service (e.g. for the oil).
Timers Programming time-based compressor start/stop commands.
Configuration Programming the time, date, display language, units and date format.
Saved data Calling up the saved data: last shut-down, longest load and unload data and last
emergency stop data.
Show more Quick look at the actual status of the compressor.
Unload/Load To manually load and unload the compressor.
52 2920 1815 04
Page 3929 of 6229

Instruction book
3.10 Calling up menus
When the voltage is switched on, the Main screen is shown automatically.
Calling up menus
Starting from the Main screen:
• Either use the key ”Menu” (F1) to scroll to the first submenu “Status data” and press the key “Select”
(F2) to select this submenu.
• Or use the key “Menu” (F1) to scroll to the first submenu “Status data”, then use keys (1) to scroll to
another submenu and press the key ”Select” (F2) to select this submenu.
• Or use the key “Show More” (F2) for a quick look at the actual status of the compressor.
Returning to the Main screen or other menus

• Whenever displayed on the bottom line of a submenu, press the key “Menu” (F1) to return to a
previous menu.
• Whenever displayed, press the key “MainScreen” to return the Main screen.
3.11 Main screen menu
Control panel
2920 1815 04 53
Page 3930 of 6229

Instruction book
Function
The Main screen menu shows in short the compressor operation status and is the gateway to all functions
implemented in the regulator.
Procedure
The Main screen is shown automatically when the voltage is switched on.
If the function keys or arrow keys (1, 2 and 3) are not used for about 4 minutes, the regulator will
automatically return to the Main screen.
Exception is made when the screen is left untouched when modifying data in the regulator. In this case, the
screen will remain unchanged, since the regulator does not take a decision whether to accept or refuse the
new data.
The display indicates:

• The name of the sensor of which the actual reading is displayed
• The unit and actual reading of the sensor
• Messages regarding the compressor operating condition (e.g. “Automatically Loaded”), a service
need or a fault (motor overload, shut-down, warning, sensor error)
• Just above the three function keys (F1/F2/F3), the actual functions of these keys
When more than one message needs to be displayed (e.g. both warning and service), the
messages will be displayed one after the other for 3 seconds.
3.12 Status data menu
Control panel
Function
The Status data submenu gives information regarding the status of the compressor protection functions
(shut-down, shut-down warning and motor overload) and allows resetting of a shut-down and motor
overload.
54 2920 1815 04
Page 3931 of 6229

Instruction book
Procedure
Starting from the Main screen (see Main screen menu), press key “Menu” (F1). Following screen appears:
.
Status data
.
MainScreen Select
F1 F2 F3
No shut-down warning message or shut-down message exists

• General alarm LED (1) is out.
• After pressing key “Select” (F2), a message will appear indicating that all conditions are normal:
.
All protection functions are OK
.
Menu
F1 F2 F3
• The top line of the display and the indicators (***) on the fourth line are blinking.
• It remains possible to scroll through other menus and then return to the “Status data menu”. In this
case, the first option (“Shut-downs”) will be shown. Press the key “Select” to return to the screen
shown above.
• Remedy the trouble.
A shut-down warning message exists

• LED (1) is alight and a shut-down warning message automatically appears on the display if a shut-
down warning exists.
• The indicators (***) are blinking and the warning message appears alternately with the compressor
status message.
• Press the key “Menu” (F1).
• Press the key “Select” (F2), scroll to the option ”Warnings” and select this option. A screen similar to
the one below appears:
• The screen indicates that the temperature at the outlet of compressor element 1 exceeds the
programmed shut-down warning level.
• The warning message will disappear automatically as soon as the warning condition disappears.
• Remedy the trouble.
Before starting any maintenance or repairs, press stop button (0), wait until the
compressor has stopped, press emergency stop button (S2) and open the isolating
switch (customer's installation) to switch off the voltage to the compressor.
Close the air outlet valve and depressurize the air system.
2920 1815 04 55
Page 3932 of 6229

Instruction book
Shut-down reset
• Switch off the voltage and remedy the trouble.
• Switch on the voltage and start the compressor. It may be necessary to reset the display after
remedying the fault: press the key “Reset”; the message “All protection functions are OK” will appear
whereupon the compressor can be restarted. Press the keys “Menu” and “MainScreen” to return to the
main screen.
3.13 Measured data menu
Control panel
Function
To call up the actually measured data. Consult the menu flow in section Control programs. If the output of
the sensor is linked to a protection function, the related shut-down and warning settings are also shown.
3.14 Hours menu
Control panel
Function
To call up:
56 2920 1815 04
Page 3933 of 6229

Instruction book
• The running hours

• The loading hours
• The number of hours the regulator has been in operation
• The number of motor starts
Procedure
Starting from the Main screen (see Main screen menu):
• Press key “Menu” (F1).
• Press key (1) until “Hours” is shown on the second line.
• Activate the menu by pressing key “Select” (F2); a screen similar to the one below appears:
.
Running hours 2455 hrs
Loading hours 1973 hrs
Menu Modify
F1 F2 F3
• By using scroll keys (1), the other items can be called up.
• The horizontal arrow shows the parameter which can be modified (if this should be required, consult
the Atlas Copco Customer Centre).
3.15 Service menu
Control panel
Function
To call up and reset service messages for the monitored components. See the menu flow in section Control
programs.
Procedure
• Press key (1) until “Service” is shown on the second line.
2920 1815 04 57
Page 3934 of 6229

Instruction book
• Activate the menu by pressing key “Select” (F2).
Calling up service messages

• The display will show the name of the first component and the message whether service is needed or
not.
Dp Air Filter
No service required
.
Menu Select Reset
F1 F2 F3
• A vertical arrow appears indicating to scroll through the display to check the condition of the other
monitored components.
• After pressing key Select (F2), the actual measured value is shown as well as the related level at
which the component needs to be replaced:
Dp Air Filter -0.022 bar

-0.3 psi
Related service settings
Service Maximum -0.044 bar
-0.6 psi
Return Reset
F1 F2 F3
• The example shows that the service life of the filter has not yet expired.
• If a vertical arrow is shown on the third line, it can be used to call up the service level in hours.
• The service level of almost all components is indicated in running hours similar to the example
below.
Calling up the actual measured value and service level

• Call up the related service item. Consult the section above.
• Press the key “Select” :
Oil filter 8010 hrs

Related service settings
Service Maximum 8000 hrs
***Return ***Reset
F1 F2 F3
• The example shows that the oil filter needs to be replaced.

• Stop the compressor. Replace the filter.
• Reset the service message as described below.
58 2920 1815 04
Page 3935 of 6229

Instruction book
Before starting any maintenance or repairs, apply all relevant Safety precautions.
Service reset
To reset the service timer:
• Take the necessary service action.
• Call up the service menu for the relevant component (see section “Procedure” above).
• Press the key “Reset”: a question appears to confirm the reset. After selecting “Yes”, the timer is reset
to 0.
Each service item must be reset individually.
3.16 Test menu
Control panel
Procedure
• Press key (1) until “Test” is shown on the second line.
• The display shows the option “Display test”. Press key “Select” (F2). During testing, 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.
• Press key “Menu” to return to the submenu.
2920 1815 04 59
Page 3936 of 6229

Instruction book
3.17 Modify settings menu
Function
To modify a number of programmable settings:
• Regulation settings (see section Modifying regulation settings).
• Protection settings (see section Modifying protection settings).
• Service settings (see section Modifying service settings).
3.18 Modifying regulation settings
Control panel
Function
To modify a number of regulation settings. Consult the menu flow in section Control programs.
Procedure
• Press key (1) until “Modify settings” is shown.
• The first item (“Regulation”) is shown. Press key “Select” (F2) and use keys (1) to scroll to the
setting to be modified.
• For each parameter, the modifying procedure is similar to the example below.
The regulator will not accept new values beyond the limitations.
It is possible to check the limitations which are valid for the parameter to be modified by
selecting “Limits”.
60 2920 1815 04
Page 3937 of 6229

Instruction book
3.19 Modifying protection settings
Control panel
Function
To modify a number of protection settings. Consult the menu flow in section Control programs.
Procedure
• The first item (“Regulation”) is shown. Press keys (1) to scroll to “Protection”.
• Press key “Select” (F2) and use keys (1) to scroll to the setting to be modified.
• For each setting, the modifying procedure is similar to the example below.
Modifying the shut-down setting for the oil pressure

• Consult the section above for selecting the option “Protection”.
• Press key “Select” (F2). The first item is shown (“Oil pressure”).
• Press key “Select” (F2). A display similar to that shown below will appear:
Oil 2.5 bar

Programmable settings
Shutdown Minimum 1.2 bar
Menu Modify
F1 F2 F3
The example indicates:

• The name of the sensor (“Oil”) and the actual measured value (“2.5 bar”)
• The type of parameter (“Shutdown”), the level type (“Minimum level”) and the actual programmed
value (“1.2 bar”)
• After pressing the key “Modify” the value of the parameter starts blinking and the functions of the
keys (F1, F2 and F3) change into “Program”, “Limits“ and “Cancel” respectively.
• Modify the value by means of scroll keys (1).
2920 1815 04 61
Page 3938 of 6229

Instruction book
• Press the key ”Program” to program the new value or the key “Cancel” to cancel the modification
operation (the original value will be retained).
Modifying the shut-down warning setting for the oil pressure

• The vertical arrow on the screen above indicates to use the scroll key to show the related warning
value:
Oil 2.5 bar

Shutd Warn Minimum 1.3 bar
Menu Modify
F1 F2 F3
• After pressing the key “Modify” the value of the parameter starts blinking and the functions of the
keys (F1, F2 and F3) change into “Program”, “Limits“ and “Cancel” respectively.
Delay at signal
• The vertical arrow on the screen above indicates to use the scroll key to show the programmed “Delay
at signal”:
Oil
Delay at Signal 15 sec
Menu Modify
F1 F2 F3
• If it should be necessary to modify the nominal setting, consult the Atlas Copco Customer Centre.
• The vertical arrow on the screen above indicates to use the scroll key to show the programmed “Delay
at start”. If it should be necessary to modify the nominal setting, consult the Atlas Copco Customer
Centre.
selecting Limits.
62 2920 1815 04
Page 3939 of 6229

Instruction book
3.20 Modifying service settings
Control panel
Function
To modify a number of service settings. Consult the menu flow in section Control programs.
Procedure
• The first item (“Regulation”) is shown. Press keys (1) to scroll to “Service”.
• Press key “Select” (F2) and use keys (1) to scroll to the setting to be modified.
• For each setting, the modifying procedure is similar to the example below.
Modifying the the setting for the oil service life

• Consult the section above for selecting the option “Service”.
• Press key “Select” (F2). The first item is shown.
• Use keys (1) to scroll to “Oil Lifetime”. Press key “Select” (F2). A display similar to that shown
below will appear:
Running hours 944 hrs

Service Maximum 16000 hrs
Menu Modify
F1 F2 F3
• To modify the setting of the oil service life, press the key “Modify” and use scroll keys (1).
• Use the key ”Program” to program the new value or the key “Cancel” to cancel the modification
2920 1815 04 63
Page 3940 of 6229

Instruction book
selecting “Limits”.
3.21 Timers menu
Control panel
Function
To program time-based start/stop commands for the compressor.
Procedure
• Press key (1) until “Timers” is shown.
Initially, the list with start/stop commands is empty, hence the timer function is switched off. Following
screen appears:
The timer is
Not activated
.
Menu Modify List
F1 F2 F3
Programming start/stop commands

• Press the key “List”. The display will show a message that the list is empty.
• Press the keys “Modify” and “Add”. The command “Monday 00:00 Stop Compressor” will be shown.
64 2920 1815 04
Page 3941 of 6229

Instruction book
• Using scroll keys (1), modify this command as required, as described below in section “Modifying a
command”. Add and delete commands as required, as described below in sections “Adding a
command” and “Deleting a command”.
• Activate the timer as described below.
Activating/deactivating the timer

• The timer can only be activated if at least one start/stop command is programmed.
• Select the menu “Timers”. Press the key “Modify”, the message “The Timer is not activated” will
blink.
• Use scroll keys (1) to change the message into “The Timer is activated”.
• Press the key “Program” to program the Timer active function or key “Cancel” to cancel the
modifying operation. If activated, the regulator will execute the programmed commands.
The timer can be deactivated again. In this case, the programmed start/stop commands will
not be executed (but remain in the memory of the regulator).
Displaying the list of commands

• Press the key “List” on the timer screen. A typical display is shown below:
Monday 06:00 Start compressor

Monday 17:00 Stop compressor
Tuesday 07:00 Start compressor
Menu Modify List
F1 F2 F3
• The vertical arrows at the right-hand side indicate to use the vertical scroll keys to select the next and
previous start/stop commands. The horizontal arrow indicates the command which is accessible at
that moment.
• Use the key “Menu“ to return to the submenu or the key “Modify” to modify the start/stop
commands.
• After pressing the key “Modify”, three selections are shown on the bottom line of the display:
Monday 06:00 Start compressor

Monday 17:00 Stop compressor
Tuesday 07:00 Start compressor
Modify Add Delete
F1 F2 F3
Use key:
• “Modify” to modify the command indicated by the horizontal arrow.
• “Add” to add a new command at the location of the horizontal arrow.
• “Delete” to delete start/stop commands.
2920 1815 04 65
Page 3942 of 6229

Instruction book
Modifying a command
• Suppose the command “Monday 17:00 Stop Compressor” is to be modified, i.e. stopping at 18
o'clock instead of 17 o'clock.
• Press the key “List” and scroll through the compressor start/stop commands until the command to be
modified is indicated by the horizontal arrow on the screen. Press the key “Modify”. Press the key
“Modify” again. The day indication will blink. If desired, the day can be modified using scroll keys
(1).
• Press tabulator key (2) to go to the next field to be modified (the hour indication). Modify using keys
(1); in the example above, use the keys to change “17” into “18”.
• Proceed in the same way to modify, if desired, the minutes indication and the start/stop indication.
• Press the key “Program” to program the new command or the key “Cancel” to quit without
reprogramming.
• The regulator will ask if it is desired to change more commands.
It is necessary to program the start/stop commands in successive order timewise. Program

the commands from Monday till Sunday, e.g.: Monday 07.30 start, Monday 18.00 stop,
Tuesday 08.00 start, Tuesday 17.00 stop, etc.
The regulator does not accept a new compressor start/stop command unless it is situated
between the next and previous start/stop command timewise. If not, the new command is
not accepted and the command line remains blinking. In this case, either modify the
command or use the key “Cancel” to quit the modification operation.
Make sure that the timer function is activated “(Timer active”). If not, the programmed start/
stop commands will not be executed.
Adding a command
• Press the key “List” and scroll through the commands until the command after which a new command
is to be added appears, followed by a horizontal arrow.
• Press the keys “Modify” and “Add”. The command which was indicated by the horizontal arrow will
be copied and the day indication of the copied command will blink.
• The way of modifying this command is similar to the description in the section above.
Deleting a command
• Press the key “List” and scroll through the commands until the command to be deleted appears,
followed by a horizontal arrow.
• Press the keys “Modify” and “Delete”. The bottom line of the screen shows following selections:
“All” to delete all commands, “This” to delete the command indicated by the horizontal arrow or
“Cancel” if the delete selection must not be carried out.
• When selecting “All”, the regulator will ask “Are you sure to delete all commands?”. By pressing the
key “Yes” all commands are deleted.
66 2920 1815 04
Page 3943 of 6229

Instruction book
3.22 Configuration menu
Control panel
Function
To reprogram a number of parameters. Consult the menu flow in section Control programs.
Two languages are programmed.
The function “Auto restart after voltage failure” can only be activated by an Atlas Copco
Customer Centre.
For the date format: “DD MM YY” stands for day/month/year - “MM DD YY” stands for
month/day/year - “YY MM DD” stands for year/month/day.
Procedure
• Press key (1) until “Configuration” is shown.
• Activate the menu by pressing key “Select” (3).
• Press key “Select” (3).
• The first option shown is “Time”. If another option is desired, scroll through the display (using scroll
keys 1) and select (using key 3).
• In case of option “Time”, the second line on the screen indicates the actual setting, e.g. “14:30”.
• If it is desired to modify the time, press key “Modify” (3). If not, press key “Menu” to return to the
submenu.
• After pressing the key “Modify”, the first field (“14”) will blink. Modify the hours using scroll keys
(1). Then press tabulator key (2) to go to the next field (“30”). The setting of this field can now be
modified with the scroll keys.
• The bottom line of the display will show two options: “ Program” to program the new setting and
“ Cancel” to cancel the new setting
• Proceed in the same way for the other parameters to be modified. Use scroll keys (1) to modify the
parameter.
2920 1815 04 67
Page 3944 of 6229

Instruction book
3.23 Saved data menu
Control panel
Function
To call up the compressor data saved by the electronic regulator:
• The data of the five last shut-downs (indicated “Last shutdown 1”, “Last shutdown 2”, ...): cause of
the shut-down, time, date and other data reflecting the condition of that moment.
• The data of the two last emergency stops (indicated “Last emergency stop 1”, “Last emergency stop
2”): time, date and other data reflecting the condition of that moment.
• The longest load data (time, date, duration and other data reflecting the condition of that moment).
• The longest unload data (time, date, duration and other data reflecting the condition of that moment).
Procedure
• Press key (1) until “Saved data” is shown.
• Activate the menu by pressing key “Select” (3).
• The first option shown is “Last shutdown 1”. Use scroll keys (1) to select possible other shutdown or
emergency stop data.
• Press key “Select” (3).
• By using scroll keys (1) a number of data are shown reflecting the condition of the compressor at the
moment of shut-down or emergency stop.
• Press the key “Menu” to return to the submenu.
68 2920 1815 04
Page 3945 of 6229

Instruction book
3.24 Show more menu
Control panel
Function
To have a quick look at the most important compressor data as shown in the menu flow in section Control
programs.
Procedure
• Press key “Show more” (F2). A screen similar to the one below appears:
Automatic operation
Locally controlled
Start/Stop Timer is active
MainScreen Show More Unload
F1 F2 F3
• The first line indicates that the regulator is automatically controlling the compressor, i.e. loading,
unloading, stopping and automatic restarting.
• The second line 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 the Atlas Copco Customer Centre.
• The third line indicates whether the timer which generates time-based start and stop commands is
activated or not (see section Timers menu).
• Use scroll keys (1) to call up the other data.
2920 1815 04 69
Page 3946 of 6229

Instruction book
3.25 Unload-load menu
Control panel
Function
To load and unload the compressor manually.
Normally, the compressor is running in automatic operation, i.e. loading, unloading, stopping and
automatic restarting. LED (1) is then alight.
If required, the compressor can be unloaded manually: the compressor will run unloaded unless it is loaded
again manually.
Manually unloading
Starting from the Main screen (see Main screen menu): press key Unload (2). LED (1) goes out. The
message “Manually Unloaded” appears on the display.
Manually loading
Starting from the Main screen (see Main screen menu): press key Load (2). LED (1) lights up.
Note
The compressor is not forced to loaded condition, but the operation of the compressor is
switched to automatic operation again and will be loaded if required by the air net pressure.
3.26 Programmable settings
Regulation settings
Minimum Factory Maximum

setting setting setting
Motor running time in star sec 10 15 30
Load delay time (star-delta) sec 10 10 30
70 2920 1815 04
Page 3947 of 6229

Instruction book

Load delay time (not star-delta) sec 20 20 30
Number of motor starts (low-voltage motor) starts/hr 0 3 5
Number of motor starts (high-voltage starts/day 0 3 Consult motor
motor) manufacturer
Required stop period sec 5 5 60
Power recovery time sec 1 3 See
Elektronikon
regulator
Minimum stop time sec 20 20 99
Unloading pressure bar(e) 4.1 7.0 7.5
Unloading pressure psig 59.5 101.5 108.8
Unloading pressure psig 59.5 130.5 145
Loading pressure bar(e) 4.0 6.0 7.4
Loading pressure psig 58 87 107.3
Protection settings

Compressor element 1 outlet temperature ˚C 100 210 219
(shut-down warning level)
Compressor element 1 outlet temperature ˚F 212 410 426
(shut-down level)
(shut-down level)
2920 1815 04 71
Page 3948 of 6229

Instruction book

(shut-down level)
(shut-down level)
Protection settings

(shut-down level)
(shut-down level)
(shut-down level)
(shut-down level)
Protection settings

Compressor element 2 inlet temperature ˚C 40 65 79
Compressor element 2 inlet temperature ˚F 104 149 174
(shut-down level)
(shut-down level)
Oil temperature (shut-down warning level) ˚C 40 65 79
Oil temperature (shut-down warning level) ˚F 104 149 174
Oil temperature (shut-down level) ˚C 40 70 80
Oil temperature (shut-down level) ˚F 104 158 176
Oil pressure (shut-down warning level) bar(e) 1.0 1.3 1.2
Oil pressure (shut-down warning level) psig 14.5 18.9 17.4
72 2920 1815 04
Page 3949 of 6229

Instruction book

Oil pressure (shut-down level) bar(e) 1.0 1.2 1.9
Oil pressure (shut-down level) psig 14.5 17.4 27.6
Delay at starting (oil pressure) sec 15 15 20
Service settings

Drive motor regreasing time (running hr 0 See Motor --
hours) greasing
Oil filter lifetime (running hours) hr 0 8000 --
Oil lifetime (running hours) hr 0 16000 --
Fixed settings

Delay at signal sec 0 60 255
Terminology
Term Explanation
Compressor Element 1 and element 2 stands for the low-pressure and high-pressure compressor
element 1/2 element respectively.
The regulator does not accept illogical settings, e.g. if the warning level is programmed
at 210˚C, the minimum limit for the shut-down level changes into 211˚C. The
recommended difference between the warning level and shut-down level is 10 ˚C.
Compressor Element 1 and element 2 stands for the low-pressure and high-pressure compressor
element 1/2 element respectively.
at 410 ˚F, the minimum limit for the shut-down level changes into 411 ˚F. The
recommended difference between the warning level and shut-down level is 18 ˚F.
Oil Use Atlas Copco Roto-Z oil. The change interval for this oil is after 16000 running hours
or 2-yearly.
Oil filters Use Atlas Copco filters. The change interval is after 8000 running hours or yearly.
Air filters Use Atlas Copco filters. Replace the filters when the warning level is reached or yearly.
Required stop Once the compressor is automatically stopped, it will remain stopped for the minimum
period/Minimum stop time (approx. 20 seconds), whatever happens with the air net pressure. In
stop time automatic operation, the compressor will not be stopped by the regulator until a
standstill period of at least the sum of the minimum stop time and required stop period is
expected. However, if the decrease in air net pressure should require a new start of the
compressor, the regulator will start the compressor after the minimum stop time.
Power recovery Is the period within which the voltage must be restored to have an automatic restart. Is
time accessible if the automatic restart is activated. To activate the automatic restart function,
consult Atlas Copco.
2920 1815 04 73
Page 3950 of 6229

Instruction book
Term Explanation
Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is
Loading pressure programmed at 7.5 bar(e), the maximum limit for the loading pressure changes into 7.4
bar(e). The recommended minimum pressure difference between loading and unloading
is 1 bar.
Loading pressure programmed at 109 psi, the maximum limit for the loading pressure changes into 108
psi. The recommended minimum pressure difference between loading and unloading is
14.5 psi.
Delay at starting Is the time interval within which the oil pressure must be built up.
Delay at signal Is the period during which the signal is ignored.
74 2920 1815 04
Page 3951 of 6229

Instruction book
4 Elektronikon regulator type overview
4.1 Elektronikon® controller type overview
Type overview
Depending on the manufacturing date or the ordered configuration, the compressor is equipped with
• the Elektronikon controller
• the Elektronikon Graphic controller
• the Elektronikon GraphicPlus controller
Elektronikon controller
Elektronikon Graphic controller for fixed speed compressors
2920 1815 04 75
Page 3952 of 6229

Instruction book
Elektronikon Graphic controller for variable speed drive (VSD) compressors
Elektronikon GraphicPlus controller for fixed speed compressors
Elektronikon GraphicPlus controller for variable speed drive (VSD) compressors
76 2920 1815 04
Page 3953 of 6229

Instruction book
5 Elektronikon regulator
5.1 Elektronikon® regulator
Control panel
Introduction
In general, the Elektronikon regulator has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (made inactive)
Automatic control of compressor operation

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.
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.
Protecting the compressor

Shut-down
Several 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 display (1) and general alarm
LED (2) will blink.
2920 1815 04 77
Page 3954 of 6229

Instruction book
Remedy the trouble and reset the message. See also the Status data menu.
Before remedying, consult the Safety precautions.
Shut-down warning
A shut-down warning level is a programmable level below the shut-down level.
If one of the measurements exceeds the programmed shut-down warning level, a message will appear on
display (1) and general alarm LED (2) will light up, to warn the operator that the shut-down warning level
is exceeded.
The message disappears as soon as the warning condition disappears.
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 (1) to warn the operator to carry
out the service actions belonging to that level.
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 the Atlas Copco Customer Centre.
If activated and provided the regulator was in the automatic operation mode, the
compressor will automatically restart if the supply voltage to the module is restored
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 1 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.
78 2920 1815 04
Page 3955 of 6229

Instruction book
5.2 Control panel
Control panel
Parts and functions

1 Start button Button to start the compressor. LED (8) lights up
indicating that the Elektronikon regulator is
operative.
2 Display Shows messages about the compressor operating
condition, a 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 the
horizontal arrow. Only the parameters followed by an
arrow pointing to the right can be modified.
5 Function keys Keys to control and program the compressor.
6 Voltage on LED Indicates that the voltage is switched on.
7 General alarm LED Is lit if a shut-down warning condition exists or
maintenance is required.
7 General alarm LED Flashes if a shut-down condition exists, if an
important sensor is out of order or after an
emergency stop.
8 Automatic operation LED Indicates that the regulator is automatically
controlling the compressor.
9 Stop button Button to stop the compressor. LED (8) goes out.
S2 Emergency stop button Push button to stop the compressor immediately in
the event of an emergency. After remedying the
trouble, unlock the button by pulling it out.
2920 1815 04 79
Page 3956 of 6229

Instruction book
5.3 Function keys
Control panel
Function keys
The keys (1) are used:
• To manually load/unload the compressor (not for VSD compressors)
• To call up or to program settings
• To reset a motor overload, shut-down or service message, or an emergency stop
• To access all data collected by the regulator
The functions of the keys vary depending on the displayed menu. The actual function is indicated just
above the relevant key. The most common functions are listed below:
“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
“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
“Menu” Starting from the main screen, to have access to the submenus
“Menu” Starting from a submenu, to return to a previous menu
“Modify” To modify programmable settings
“Program” To program modified settings
“Reset” To reset a timer or message
“Return” To return to a previously shown option or menu
“Unload” To unload the compressor manually
“Extra” To find the module configuration of the regulator
80 2920 1815 04
Page 3957 of 6229

Instruction book
5.4 Scroll keys
Control panel
The keys (1) allow the operator to scroll through the display.
As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll key
with the same symbol can be used to see the next item.
As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key
with the same symbol can be used to see the previous item.
When the scroll key is kept pressed, the scrolling is continued.
5.5 Emergency stop button
Control panel
In case of emergency, press button (S2) to stop the compressor immediately.

At the occurrence of an emergency stop, the compressor element is stopped immediately and the solenoid
valve will be deactivated by Elektronikon ® regulator. No unload status is reached. The check valve
prevents oil flow back from reversed rotation of the compressor element.
2920 1815 04 81
Page 3958 of 6229

Instruction book
Before starting any maintenance or repairs, wait until the compressor has
stopped and open the isolating switch (customer's installation) to switch off the
voltage to the compressor.
Close the air outlet valve and open the manual condensate drain valves to
depressurize the air system.
Apply all relevant Safety precautions.
5.6 External compressor status indication
Warning
Stop the compressor and switch off the voltage before connecting external equipment.
Consult the Safety precautions.
Connections for external compressor status indication

Terminal strip (1X7) is fitted with auxiliary contacts for external indication of:
Indication Relay Terminals on strip 1X1 Maximum load

Automatic operation K07 11-12 10 A / 230 V AC
Warning K08 13-14 10 A / 230 V AC
Shut-down K09 15-16 10 A / 230 V AC
Compressor loaded K11 19-20 10 A / 230 V AC
Compressor running K21 17-18 10 A / 230 V AC
5.7 Control programs
Description
In order to facilitate programming and controlling, menu-driven control programs have been implemented
in the regulator.
82 2920 1815 04
Page 3959 of 6229

Instruction book
Menu flow for ZR/ZT 110 up to ZR/ZT 275 and ZR 300 up to ZR 750 (simplified)
Main menu
Program Function
Main screen Shows in short the operation status of the compressor. Is the gateway to all
functions.
2920 1815 04 83
Page 3960 of 6229

Instruction book
Program Function
“Status data” Calls up the status of the compressor protection functions (shut-down, shut-down
warning, service warning and warning). Resets a shut-down, motor overload and
service condition.
“Measured data” Calls up the data currently measured and the status of a number of inputs.
“Counters” Calls up the running hours, regulator (module) hours and number of motor starts.
“Test” Display test.
“Modify parameters” Modifies the settings for:
• Parameters (e.g. loading and unloading pressures)
• Protections (e.g. temperature shut-down level)
• Service plans (timers for service plans)
• Clock functions (automatic compressor start/stop/pressure band commands)
• Configuration (time, date, display language,...)
“Service” Calls up service plans and resets the timers after carrying out the service actions
belonging to a plan.
“Saved data” Calls up the saved data: last shut-down, last emergency stop data.
“Unload/Load” Loads and unloads the compressor manually.
Description
Control panel
When the voltage is switched on, the Main screen is shown automatically.
Example of Main screen of ZR 110 up to ZR 750
“Compressor Outlet” 7.5 bar

.
“Automatically Loaded”
“Menu” “Unload”
F1 F2 F3
84 2920 1815 04
Page 3961 of 6229

Instruction book
Example of Main screen of ZT 110 up to ZT 275

.
F1 F2 F3
After pressing the “Menu” (F1) key, the option “Status Data” will be followed by a horizontal arrow:
• Either press the tabulator key (2) to select this menu,
• or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow and then
press the tabulator key (2) to select this menu.
The arrow down key (1) can be used for a quick look at the actual compressor status.
5.9 Main screen menu
Function
Control panel
The Main screen menu shows the status of the compressor operation and is the gateway to all functions
implemented in the regulator.
Procedure
The Main screen is shown automatically when the voltage is switched on.
If the function or arrow keys (1, 2 and 3) are not used for some minutes, the regulator will automatically
return to the Main screen.
Whenever displayed on a submenu screen, press the “Mainscreen” (F1) key to return to the Main screen.
2920 1815 04 85
Page 3962 of 6229

Instruction book
Example of Main screen of ZR 110 up to ZR 750

.
F1 F2 F3
Example of Main screen of ZT 110 up to ZT 275

.
F1 F2 F3
The display indicates:

• The name of the sensor and its actual reading
• Messages regarding the compressor operating condition
• Just above the function keys (3), the actual functions of these keys
5.10 Status data menu
Warning
Before starting any maintenance or repairs, press the stop button (4), wait until the
compressor has stopped, press the red emergency stop button and open the isolating
switch (customer's installation) to switch off the voltage to the compressor.
Close the air outlet valve and depressurize the air system.
Function
Control panel
86 2920 1815 04
Page 3963 of 6229

Instruction book
The Status data submenu gives information regarding the status of the compressor protection functions
(shut-down, shut-down warning and service warning) and allows resetting of a shut-down, motor overload
and service condition.
Procedure
• Press the key “Menu” (F1): the option “Status Data” will be followed by a horizontal arrow.
• Press the tabulator key (2).
No message exists
• General alarm LED (1) is out and the message on the display will indicate that all conditions are
normal:
“All Conditions Are OK”

.
.
“Menu” “Help”
F1 F2 F3
A shut-down message exists

• In case the compressor is shut down, LED (1) will blink.
• In case of a shut-down due to too high a temperature at the outlet of the compressor element:
“Element Outlet” 114˚C

.
“Shutdown” “Maximum” 110˚C
“Menu”*** “Help” ***”Reset”
F1 F2 F3
• The indicators (***) are blinking. The screen shows the actual reading and the shut-down setting.
• 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 (2) to return to the above shut-down screen.
Shut-down reset
• 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” (F3).
• Press the keys “Menu” and “Mainscreen” to return to the Main screen and restart the compressor by
means of start button (3).
A shut-down warning message exists

A shut-down warning level is a programmable level below the shut-down level.
2920 1815 04 87
Page 3964 of 6229

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

.
*** “Shutdown Warning” ***
“Menu”*** ***”Unload”
F1 F2 F3
• The message “Shutdown Warning” appears.

• Press the key “Menu” (F1) and the tabulator key (2) to select the “Status data” menu; the option
“Protection” is blinking.
• Scroll to this option and select it by pressing the tabulator key (2). A screen similar to the one below
appears:
“Element 1 Outlet” 103˚C

.
“Shutd. Warn.” “Maximum” 100˚C
“Menu”*** ***
F1 F2 F3
• The screen indicates that the temperature at the outlet of compressor element 1 exceeds the
programmed shut-down warning level.
• If necessary, stop the compressor by means of stop button (4) and wait until it has stopped.
• Switch off the voltage, inspect and remedy.
• The warning message will disappear automatically as soon as the warning condition disappears.
A service warning exists

• LED (1) is alight. The Main screen will change into a screen similar to the one below:

.
“*Service Required*”
“Menu”*** ***”Unload”
F1 F2 F3
• The indicators (***) are blinking and the service warning message appears.
• Press the key Menu (F1) and the tabulator key (2) to select the “Status data” menu: the option
“Service” is blinking.
• Scroll to this option and select it by pressing the tabulator key (2); 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).
• “Plan”: if a service plan interval is exceeded.
• Stop the compressor and switch off the voltage.
• 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.
88 2920 1815 04
Page 3965 of 6229

Instruction book
• In case the service message was referring to “Plan”: carry out the service actions related to the
indicated plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See
Service menu.
5.11 Measured data menu
Control panel
Function
To call up information regarding the actually measured data and the status of some inputs such as the motor
overload protection. Consult the menu flow in section Control programs.
Procedure
• Press the arrow down key (1) until “Measured Data” is followed by a horizontal arrow.
• Activate the menu by pressing the tabulator key (2).
• By pressing the scroll keys (1), a number of actually measured data can be found.
• 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
key (2).
2920 1815 04 89
Page 3966 of 6229

Instruction book
5.12 Counters menu
Control panel
Function
To call up:
• The loaded hours
• The number of hours the regulator (module) has been under tension
• The number of load cycles
Procedure
• Press the arrow down key (1) until “Counters” is followed by a horizontal arrow.
• Press the tabulator key (2) to activate the menu.
• By pressing the arrow key (1), the above-mentioned data can be found.
Example of a Counters screen
.
“Running Hours” 2455 “hrs”
“Loaded Hours” 1973 “hrs”
“Motor Starts” 945
“Menu”
F1 F2 F3
90 2920 1815 04
Page 3967 of 6229

Instruction book
5.13 Test menu
Control panel
Function
To carry out a display test, i.e. to check whether the display and LEDs are still intact.
To test the Electronic Water Drains (EWD)
Procedure
• Starting from the Main screen (see Main screen menu), press the “Menu” (F1) key.
• Press arrow down key (1) until “Test” is followed by a horizontal arrow.
• Activate the menu by pressing the key (2).
To perform a display test:
• If necessary, scroll through the menu until “Display Test” is followed by a horizontal arrow.
• Press the key (2).
• During testing, the regulator will generate a series of patterns on the display which enable the
operator to check that each pixel still functions normally; the LEDs are lit at the same time.
• Press the “Menu” key (F1) to return to the submenu.
To test the Electronic Water Drains (on compressors designed for an ambient temperature of 40 ˚C
(104 ˚F):
• Press the arrow down key until the option “Outputs” is followed by a horizontal arrow.
• Press the “Start” key.
• Check that the valve opens for condensate discharge.
• Release the “Start” key after testing.
• Press the “Back” key to return to the previous menu.
• Press the “Menu” key (F1) to return to the submenu.
2920 1815 04 91
Page 3968 of 6229

Instruction book
5.14 Modify parameters menu
Function
To modify a number of programmable settings:
• Parameters (see section Modifying parameters).
• Protections (see section Modifying protections).
• Service plan settings (see section Modifying service plan settings).
• Clock function settings (see section Modifying clock function settings).
• Configuration settings (see section Modifying configuration settings).
5.15 Modifying parameters
Control panel
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
• Press the arrow down key (1) until “Modify Parameters” is followed by a horizontal arrow.
• The first item “Parameters” will be followed by a horizontal arrow.
• Press the tabulator key (2): the first items and their settings will appear.
• Press the arrow down key (1) until the parameter to be modified is followed by a horizontal arrow.
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).
• Consult the section Procedure to select “Loading Pressure”.
92 2920 1815 04
Page 3969 of 6229

Instruction book
• The screen shows the current setting. To modify this setting, press the key “Modify” (F2); the setting
will blink.
• The key “Limits” (F2) can be used to find out the limitations for the parameter.
• Use the scroll keys (1) to change the setting.
• Press the key ”Program” (F1) to program the new value or the key “Cancel” (F3) to cancel the
modification operation.
• The procedure to modify other parameters pressure is similar.
The regulator will not accept new values beyond the limitations. Press the key “Limits” to
check the limitations for the parameter. Consult Programmable settings for the most
important settings.
5.16 Modifying protection settings
Control panel
Function
To modify protection settings:
• “Shutdown”, e.g. for the compressor element outlet temperature
• “Shutdown warning”, e.g. for the compressor element outlet temperature
• “Warning”, e.g. for the dew-point temperature
• “Service warning”, e.g. for the maximum pressure drop over the air filter
To check various compressor conditions, e.g. the status of the emergency stop button. Some parameters
cannot be modified.
Procedure
• Press the “Menu” (F1) key.
• Press the arrow down key (1) until “Modify parameters” is followed by a horizontal arrow.
2920 1815 04 93
Page 3970 of 6229

Instruction book
• Press the arrow down key (1) until “Protections” is followed by a horizontal arrow.
• Press the tabulator key (2): the first items will appear.
• Press the arrow down key (1) until the item to be modified is followed by a horizontal arrow and
press the tabulator key (2).
Modifying settings for the compressor element temperature

• Consult the section Procedure above to select the parameter “Element 1 outlet”.
• The screen (see example below) shows the current temperature on the first line and the shut-down
setting on the third line. To modify the setting, press the “Modify” (F2) key; the setting will flash.
• The “Limits” (F2) key can be used to find out the limits for the parameter.
• Use the scroll keys (1) to change the setting.
• Press ”Program” (F1) to program the new value or “Cancel” (F3) to cancel the modification
operation.
• The screen (see example below) shows a horizontal arrow indicating that the shut-down warning
value can be modified (the procedure is similar to the description above).
• The procedure to modify other items is similar. For some settings, a delay can be programmed.
Example of the screen for ZR/ZT compressors
“Element 1 outlet” 178˚C
“Shutdown” “Maximum” 235˚C

“Menu” “Modify”
F1 F2 F3
The regulator will not accept new values beyond the limits. Press the key “Limits” to check
the limits for the parameter. Consult Programmable settings for the most important settings.
5.17 Modifying service plans
Function
To modify the hour intervals for the service levels.
Service plans
The service actions 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.
Always consult your Atlas Copco Customer Centre in case any timer should be changed.
The intervals must not exceed the programmed nominal values.
94 2920 1815 04
Page 3971 of 6229

Instruction book
5.18 Programming clock function
Control panel
Function
To program:
• Time-based start/stop commands for the compressor
• Time-based change-over commands for the net pressure band
Programming start, stop and 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
• Press the arrow down key (1) until “Modify Parameters” is followed by a horizontal arrow.
• Activate the menu by pressing tabulator key (2).
• Use the arrow down key (1) to scroll until the option “Clock Function” is followed by a horizontal
arrow.
• Activate the menu by pressing tabulator key (2); following screen appears:
“Clock Function”
“Not Activated”
.
“Menu” “Modify” “Delete”
F1 F2 F3
• Press the tabulator key (2), following screen appears:
2920 1815 04 95
Page 3972 of 6229

Instruction book
“Monday”
“Tuesday”
“Wednesday”
“Menu” “Delete”
F1 F2 F3
• Use the scroll keys (1) until the day on which a command must be programmed is followed by a
horizontal arrow. Press the tabulator key (2); following screen appears:
--:-- ----------------------
--:-- ----------------------
--:-- ----------------------
F1 F2 F3
• Press the key “Modify” (F2). The first two dashes will flash. Use the scroll keys (1) to enter “06”.
Press the tabulator key (2) to jump to the following two dashes. Use the scroll keys to enter “15”.
Press the tabulator key to jump to the row of dashes. Use the scroll keys to enter the command “Start
Compressor”.
• Press the key “Program” to program the command : “06:15 Start Compressor”.
• Press the arrow down key (1): the horizontal arrow indicates that the second line is accessible. Press
the key “Modify” and modify this line in a similar way to the following command: ”06:15 Pressure
Band 1”.
• Press the key “Menu” (F1) and scroll to “Friday”:
“Thursday”
“Friday”
“Saturday”
F1 F2 F3
• Programming the command to change over at 18 o’clock to “Pressure Band2” is carried out in a
similar way as described above.
• Press the key “Menu” (F1) and scroll to “Saturday”. Programming the command “18:00 Compressor
Stop” is carried out in a similar way as described above.
Activating/deactivating the timer

• The timer can only be activated if at least one start/stop command is programmed.
• Starting from the Main screen, press the key “Menu” (F1).
• Use arrow down key (1) until the option “Modify Parameters” is followed by a horizontal arrow.
• Use the arrow down key until the option “Clock Function” is followed by a horizontal arrow, press
the tabulator key (2), following screen appears:
96 2920 1815 04
Page 3973 of 6229

Instruction book
“Not Activated”
.
F1 F2 F3
• Press the key “Modify”, “Not Activated” starts blinking.

• Press the arrow down key (1) “Not Activated” changes to “Activated”.
• Press the key “Program”.
It is necessary to program the start/stop commands in successive order timewise. Program

the commands from Monday till Sunday, e.g.:
• 07.30 Start Compressor
• 07.30 Pressure Band 1
• 08.30 Pressure Band 2
• 18.00 Stop Compressor
Make sure that the timer function is activated (“Activated”). If not, the programmed start/
stop commands will not be executed.
The timer can be deactivated again. In this case, the programmed start/stop commands will
not be executed (but remain in the memory of the regulator).
Modifying a command
Suppose the command to stop the compressor on Saturday 18:00 is to be modified, i.e. stopping at 17
o'clock instead of 18 o'clock.
• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key (1) until the
option “Modify Parameters” is followed by a horizontal arrow.
arrow. Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
“Monday”
“Tuesday”
“Wednesday”
F1 F2 F3
• Scroll through the display until “Saturday” is followed by a horizontal arrow. Press the tabulator key
(2). If necessary, scroll through the commands until the command to be modified is followed by a
horizontal arrow. Press the key “Modify”, the first two digits of the command start blinking. Modify
2920 1815 04 97
Page 3974 of 6229

Instruction book
as required using the scroll keys, i.e. in the example above change “18” into “17” using the arrow up
key (1).
• If necessary, press the tabulator key (2) to go to the next field to be modified, the minutes indication
and the start/stop/pressure band indication.
reprogramming.
Adding a command at the end of an existing list

• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the option
“Modify Parameters” is followed by a horizontal arrow.
arrow. Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
Suppose the command to stop the compressor at 18:00 must be added to the list of Monday
“Monday”
“Tuesday”
“Wednesday”
F1 F2 F3
• Scroll through the display until “Monday” is followed by a horizontal arrow. Press the tabulator key
(2). Scroll through the compressor start/stop/pressure band commands until the first empty command
line is indicated by the horizontal arrow.
• Press the key “Modify”; the first two digits start blinking. Enter “18:00 Compressor Stop” using the
scroll keys (1) to modify a field and the tabulator key (2) to jump from one field to another.
reprogramming.
Adding a command between two existing commands

Suppose the command “17:00 Pressure Band 2” must be added to the following list:
• 06:00 Start Compressor
• 06:00 Pressure Band 1
• 18:00 Stop Compressor
The regulator does not allow to enter a new command which is situated before the last command in the list
timewise.
Scroll through the display until the command before which the new command must be entered is followed
by a horizontal arrow (in the example above: “18:00 Stop Compressor”) and press the key “Modify”.
98 2920 1815 04
Page 3975 of 6229

Instruction book
Change this command to the new command (in the example above “17:00 Pressure Band 2”)
Press the arrow down key and add the last command of the list (in the example above “18:00 Stop
Compressor” and press the key “Program”.
Deleting a command
• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the option
“Modify Parameters” is followed by a horizontal arrow.
• Use the scroll keys (1) to scroll until the option “Clock Function” is followed by a horizontal arrow.
Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
Deleting all commands

• Press the key “Delete” in the screen above. A question to confirm the deleting operation will appear.
Deleting all commands of a specific day
• Scroll through the display until the desired day is followed by a horizontal arrow. Press the key
“Delete”, a question to confirm the deleting operation will appear.
Deleting a specific command
• Scroll through the display until the command to be deleted is followed by a horizontal arrow. Press
the key “Delete”, a question to confirm the deleting operation will appear.
5.19 Modifying configuration settings
Control panel
2920 1815 04 99
Page 3976 of 6229

Instruction book
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
• Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to the right.
• Press the arrow down key (1) to scroll until “Configuration” is followed by a horizontal arrow.
• Activate the menu by pressing tabulator key (2): the first item will appear. Scroll through the display
until the option to be modified is followed by a horizontal arrow. Select the option by pressing the
tabulator key (2).
• In case of the option “Time”, the second line on the screen indicates the actual setting, e.g. “14:30”.
To modify this setting, press the key “Modify” (F2); the first field “14” will blink.
• Use the scroll keys (1) to change the setting, then press the tabulator key (2) to go to the next field
“30”. The setting of this field can now be modified using the scroll keys (1).
• Press the key ”Program” (F1) to program the new value or the key “Cancel” (F3) to cancel the
modification operation (the original value will be retained).
• The procedure to modify other parameters is similar.
Programming compressor control modes

The compressor can be controlled locally, remotely or via a local area network (LAN).
Procedure
• Activate the menu “Configuration” as described above.
• Scroll through the display until the option “C.C.M.” is indicated and press the “Modify” key.
Following screen appears:
.
“C.C.M.” “Local Control”
.
“Program” “Cancel”
F1 F2 F3
• “Local Control” is blinking, use the scroll keys (1) to select the desired control mode.
• Press the key “Program” to program the new control mode or “Cancel” to quit without
reprogramming.
100 2920 1815 04
Page 3977 of 6229

Instruction book
5.20 Service menu
Control panel
Function
• To reset the service plans which are carried out.
• To check when the next service plans are to be carried out.
• To find out which service plans were carried out previously.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level stands for a
number of service actions to be carried out at the time intervals programmed in the Elektronikon regulator.
When a service plan interval is reached, a message will appear on the screen, see section Status data. After
carrying out the service actions related to the indicated levels, the timers are to be reset.
Example
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 actions according to Intervals

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
... ...
2920 1815 04 101
Page 3978 of 6229

Instruction book
Procedure
• Press the arrow down key (1) until “Service” is followed by a horizontal arrow.
• A screen similar to the one below appears:
“Service Timer”
“Running Hours”
7971 “hrs”
“Menu” “Reset”
F1 F2 F3
• The screen shows that the total compressor running time is 7971 hours.
“Next Timer”
“Level” AB
8000 “hrs”
“Back” “Reset”
F1 F2 F3
• 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.
• Press the arrow down key (1) to find out which service plans were carried out previously, following
screen appears:
“Previous Timer”
“Level” A
4008 “hrs”
“Back”
F1 F2 F3
• The screen shows that plan A was carried out at 4008 running hours.
• Stop the compressor, switch off the voltage and carry out the service operations related to the
indicated service plans, see section Preventive maintenance schedule.
• Switch on the voltage and scroll to the “Next Timer” service screen.
• Press the “Reset” button (F3). Confirm the question for resetting.
The “Reset” button only appears when the “Next Timer” level is almost reached.
After pressing the arrow down key in the “Service Timer” screen, the “Life Time” hours are
shown, i.e. the number of hours elapsed since initial programming ex-factory. This timer is
not taken into account.
102 2920 1815 04
Page 3979 of 6229

Instruction book
5.21 Saved data menu
Control panel
Function
To call up some data saved by the regulator. These data are:
• Last shut-down data
• Last emergency stop data
Procedure
• Press the arrow down key (1) until “Saved Data” is followed by a horizontal arrow.
• The first option is shown “Last shutdown 1”.
• Press the tabulator key (2) to find out the date, time and other data reflecting the status of the
compressor at the last shut-down.
• If desired, scroll through the other items.
Parameters

Load delay time (star-delta) sec 3 10 30
Load delay time (no star-delta) sec 13 20 30
Minimum stop time sec 20 20 99
Programmed stop time sec 0 3 20
Power recovery time (ARAVF) sec 15 15 3600
Restart delay sec 0 3 255
2920 1815 04 103
Page 3980 of 6229

Instruction book

Communication time-out sec 10 20 60
Permissive start function failure sec 0 30 255
Unloading pressure (7 bar Pack bar(e) 4.0 6.5 7.0
compressors)
Unloading pressure (100 psi Pack psig 58 94 101.5
compressors)
Unloading pressure (7 bar Full-Feature bar(e) 5.0 6.5 7.0
compressors)
Unloading pressure (100 psi Full-Feature psig 73 94 101.5
compressors)
Unloading pressure (7.5 bar Pack bar(e) 4.0 7.0 7.5
compressors)
Unloading pressure (110 psi Pack psig 58 101.5 108.8
compressors)
Unloading pressure (7.5 bar Full-Feature bar(e) 5.5 7.0 7.5
compressors)
Unloading pressure (110 psi Full-Feature psig 80 101.5 108.8
compressors)
Unloading pressure (8.6 bar compressors) bar(e) 4.0 7.0 8.6
Unloading pressure (125 psi compressors) psig 58 101.5 124.7
compressors)
Unloading pressure (145 psi Pack psig 58 130.5 145
compressors)
compressors)
Unloading pressure (145 psi Full-Feature psig 109 130.5 145
compressors)
Unloading pressure (10.4 bar Pack bar(e) 4.0 9.0 10.4
compressors)
compressors)
Unloading pressure (10.4 bar Full-Feature bar(e) 7.5 9.0 10.4
compressors)
compressors)
compressors)
Unloading pressure (190 psi Pack psig 58 174 188.5
compressors)
compressors)
Unloading pressure (190 psi Full-Feature psig 138 174 188.5
compressors)
Loading pressure (7 bar Pack bar(e) 4.0 6.0 7.0
compressors)
104 2920 1815 04
Page 3981 of 6229

Instruction book

Loading pressure (100 psi Pack psig 58 87 101.5
compressors)
Loading pressure (7 bar Full-Feature bar(e) 5.0 6.0 7.0
compressors)
Loading pressure (100 psi Full-Feature psig 73 87 101.5
compressors)
Loading pressure (7.5 bar Pack bar(e) 4.0 6.0 7.5
compressors)
compressors)
Loading pressure (7.5 bar Full-Feature bar(e) 5.5 6.0 7.5
compressors)
compressors)
compressors)
compressors)
compressors)
compressors)
compressors)
Loading pressure (145 psi Pack psig 58 116 145
compressors)
compressors)
Loading pressure (145 psi Full-Feature psig 109 116 145
compressors)
compressors)
compressors)
compressors)
compressors)
compressors)
Loading pressure (190 psi Pack psig 101.5 152 188.5
compressors)
compressors)
compressors)
2920 1815 04 105
Page 3982 of 6229

Instruction book
Protections
ZR/ZT 110 up to ZR/ZT 275

Compressor outlet pressure (warning) bar(e) 0 14.0 17.0
Compressor outlet pressure (warning) psig 0 203 246.5
Compressor outlet pressure (shut-down) bar(e) 0 15.0 17.0
Compressor outlet pressure (shut-down) psig 0 217.5 246.5
Oil pressure (shut-down warning level) bar(e) 1.0 1.3 2.0
Oil pressure (shut-down warning level) psig 14.5 19 29
Oil pressure (shut-down level) bar(e) 1.0 1.2 2.0
Oil pressure, ZR/ZT 110 up to ZR/ZT 275 psig 14.5 17.4 29
(shut-down level)
Delay at start, oil pressure sec 15 15 20
Delay at signal, oil pressure sec 0 1 3
Compressor element 1 outlet temperature
(shut-down warning level) (7.0, 7.5 and 8.6
bar or 100, 110 and 115 psi compressors)
Compressors designed for a maximum ˚C 100 210 220
inlet temperature of 40 ˚C
Compressors designed for a maximum ˚F 212 410 428
inlet temperature of 104 ˚F
(shut-down level) (7.0, 7.5 and 8.6 bar or
100, 110 and 115 psi compressors)
(shut-down warning level) (10.0, 10.4 and
12.0 bar (175 psi) compressors)
106 2920 1815 04
Page 3983 of 6229

Instruction book

(shut-down level) (10.0, 10.4 and 12.0 bar
(175 psi) compressors)
(shut-down warning level) (13.0 bar (190
psi) compressors)
(shut-down warning level) (13.0 bar (190
psi) compressors)
(shut-down level) (13.0 bar (190 psi)
compressors)
(shut-down level) (13.0 bar (190 psi)
compressors)
(shut-down warning level) (7.0, 7.5 and 8.6
bar or 100, 110 and 115 psi compressors)
(shut-down level) (7.0, 7.5 and 8.6 bar or
100, 110 and 115 psi compressors)
2920 1815 04 107
Page 3984 of 6229

Instruction book

(shut-down warning level) (10.0, 10.4 and
12.0 bar compressors)
ZR Compressors designed for a maximum ˚C 100 225 235
ZR Compressors designed for a maximum ˚F 212 437 455
ZT Compressors designed for a maximum ˚C 100 255 260
ZT Compressors designed for a maximum ˚F 212 491 500
(shut-down warning level) (13.0 bar
compressors)
(shut-down level) (10.0, 10.4 and 12.0 bar
compressors)
(shut-down level) (13.0 bar compressors)
108 2920 1815 04
Page 3985 of 6229

Instruction book

If an energy recovery system is provided
on a Full-Feature compressor, the factory
setting is increased to 70 ˚C
setting is increased to 158 ˚F
(shut-down level)
setting is increased to 80 ˚C
(shut-down level)
Delay at signal (all compressor element sec 0 1 3
temperatures)
Oil temperature (shut-down warning level) ˚C 40 65 80
Oil temperature (shut-down warning level) ˚F 104 149 176
Oil temperature (shut-down level) ˚C 40 70 80
On ZT compressors designed for an inlet
temperature of 50 ˚C, the maximum setting
is increased to 85 ˚C
Oil temperature (shut-down level) ˚F 104 158 176
On ZT compressors designed for an inlet
temperature of 122 ˚F, the maximum
Delay at start, oil temperature sec 50 70 100
Delay at start, motor overload for sec 0 1 1
compressors with YD starter
Delay at start, motor overload for sec 0 0 0
compressors with DOL starter
2920 1815 04 109
Page 3986 of 6229

Instruction book

Delay at signal, motor overload for sec 0 1 1
compressors with YD starter
Delay at signal, motor overload for sec 0 0 0
compressors with DOL starter
Delay at start, starter feed-back contact sec 0 18 33
(shut-down)
Delay at signal, starter feed-back contact sec 0 2 3
(shut-down)
Delay at start, compressor electronic sec 0 15 60
condensate drain (warning)
Delay at signal, compresor electronic sec 5 5 5
Delay at start, dryer electronic condensate sec 0 15 60
drain (warning)
Delay at signal, dryer electronic sec 5 5 5
Service warning level for DP of air filter mbar 50 44 44
Service warning level for DP of air filter psi 0.73 0.6 0.6
Delay at signal, DP of air filter sec 0 60 255
Service plans

Service plan A (operating hours) hr See remark 4000 See remark
Service plan B (operating hours) hr See remark 8000 See remark
Service plan C (operating hours) hr See remark 16000 See remark
Service plan D (operating hours) hr See remark 40000 See remark
Service plan I (operating hours) hr See remark 2000 See remark
Remark
A number of service operations are grouped (Level A, Level B, ...). Each level stands for a number of
service operations to be carried out at the programmed intervals. Consult your Atlas Copco Service Centre.
Terminology
Term Explanation
ARAVF Automatic restart after voltage failure. See Elektronikon regulator.
Compressor Element 1 is the low-pressure compressor element; element 2 is the high-pressure
elements 1/2 compressor element.
at 205 ˚C/401 ˚F, the minimum limit for the shut-down level changes to 206 ˚C/402 ˚F.
The recommended difference between the warning level and shut-down level is 10
˚C/18 ˚F.
110 2920 1815 04
Page 3987 of 6229

Instruction book
Term Explanation
Required stop Once the compressor has automatically stopped, it will remain stopped for the minimum
period/Minimum stop time (approx. 20 seconds), whatever the net air pressure. In automatic operation,
stop time the compressor will not be stopped by the regulator until a standstill period of at least
the sum of the minimum stop time and required stop period is expected. However, if the
decrease in net air pressure should require a new start of the compressor, the regulator
will start the compressor after the minimum stop time.
Power recovery Is the period within which the voltage must be restored to have an automatic restart. Is
time accessible if the automatic restart is activated. To activate the automatic restart function,
consult Atlas Copco.
Loading pressure programmed at 7.0 bar(e)/101 psig, the maximum limit for the loading pressure changes
to 6.9 bar(e)/100 psig. The recommended minimum pressure difference between
loading and unloading is 0.6 bar/9 psig.
Delay at shut- Is the time for which the signal must exist before the compressor is shut down. If it
down signal should be required to program this setting to another value, consult Atlas Copco.
2920 1815 04 111
Page 3988 of 6229

Instruction book
6 Elektronikon® GraphicPlus controller
6.1 Elektronikon® GraphicPlus controller
Control panel
Display of the Elektronikon® GraphicPlus controller
Introduction
The Elektronikon controller has following functions:
• Automatic compressor control
• Compressor protection
• Service warning
• Automatic restart after voltage failure (disabled)
Automatic compressor control

The controller keeps the net pressure between adjustable boundaries by automatically loading and
unloading the compressor. A number of adjustable settings, e.g. the (un)loading pressure, the minimum
stop time and the maximum number of motor starts are taken into account.
The controller switches the regime to unload when the selected unloading pressure is reached and stops the
compressor to reduce power consumption when it has been running unloaded for a given time. In case the
net pressure drops down to the loading pressure while the compressor is running unloaded, the compressor
is kept running and switches to load to avoid short standstills and energy waste.
When the compressor has stopped automatically and the net pressure decreases, the controller will start the
compressor before the net pressure has dropped to the loading pressure to prevent the net pressure from
reaching the programmed minimum level. When stopping the compressor manually, the controller will
unload the compressor for a given time and then stop the compressor.
A number of time based automatic start/stop commands may be set. Be aware that a
start command will be executed (if set and enabled), even after manually stopping the
compressor unit with the controller.
112 2920 1815 04
Page 3989 of 6229

Instruction book
Compressor protection
Shutdown warning
A shutdown warning level is set less critical than the shutdown level.
The compressor is equipped with several sensors to check pressures and temperatures. If one of these
measurements exceeds the set shutdown warning level, a message will be displayed and the general alarm
LED (next to the exclamation mark) will be lit to warn the operator.
The warning message disappears as soon as the measurement is below warning level.
Shutdown
If one of the sensors reaches a set shutdown level, the compressor will be stopped. This will be displayed
on the controller and the general alarm LED will blink.
Solve the problem and reset the message. See also the Inputs menu.
Before remedying, always check the applicable safety precautions.
Service warning
A number of service intervals are grouped into Service Plans, all with their own time frame. If a service
interval is reached, a message will appear on the controller display to warn the operator to carry out the
prescribed service actions stated in a certain Service Plan.
Automatic restart after voltage failure (ARAVF)

The controller allows automatic restart of the compressor unit if the supply is restored after voltage failure.
For compressors leaving the factory, this function is disabled. If desired, this function can be enabled by
your local Atlas Copco Customer Center.
Assuming the controller was running in automatic operation, the compressor unit will
restart when the supply voltage to the module is restored if ARAVF is enabled. As long
as the emergency stop is enabled, ARAVF is disabled.
2920 1815 04 113
Page 3990 of 6229

Instruction book
6.2 Control panel
Parts and functions

1 Display Shows the compressor operating condition and a
number of icons to navigate through the menu.
2 Pictogram Automatic operation
3 Pictogram General alarm
4 General alarm LED Blinks when operating in shutdown warning
condition.
5 Pictogram Service
6 Service LED Lights up when service is needed.
7 Automatic operation LED Indicates that the controller runs in automatic mode.
8 Voltage on LED Lights up when supply is switched on. Compressor
unit might start automatically!
9 Pictogram Voltage on
10 Enter key Enter and confirmation key
11 Escape key To navigate to previous screen or to cancel current
action
12 Scroll keys Keys to scroll through the menu
13 Stop button Button to stop the compressor. LED (7) dims.
14 Start button Button to start the compressor. LED (7) lights up,
indicating that the Elektronikon controller is
operational.
114 2920 1815 04
Page 3991 of 6229

Instruction book
6.3 Digital output contacts
Warning
Voltage-free outputs may only be used to control or monitor functional systems.

They should NOT be used to control, switch or interrupt safety related circuits.
Stop the compressor and switch off the supply before connecting external equipment.
Check the Safety precautions.
Connections for external equipment

The Elektronikon (Mk5) always comes with expansion module IO2 that has a number of digital output
contacts which can be used to connect external equipment.
Depending on the optional equipment, extra expansion modules are added to the machine configuration
(IO2, IO34).
Expansion Module IO2 for Elektronikon (Mk5)
The digital output contacts have following specifications:
Relay Connector Maximum load

K01 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K02 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
2920 1815 04 115
Page 3992 of 6229

Instruction book
Relay Connector Maximum load

K03 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K04 3 X 31 10 A / 250 V AC
10 A / 30 V DC
resistive load
K05 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K06 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K07 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K08 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K09 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K10 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K11 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K12 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K13 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K14 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K15 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
* = Resistor Capacitor
6.4 Icons used
Status icons
Name Icon Description
116 2920 1815 04
Page 3993 of 6229

Instruction book
When the compressor is stopped, the icon is motionless.

Stopped / Running
When the compressor is running, the icon rotates.
Compressor status Motor stopped
Local start / stop
Machine control mode

Remote start / stop
Network control
Automatic restart after voltage

Automatic restart after voltage failure is enabled
failure
Week timer Week timer is active
Emergency stop
Active protection functions Shutdown
Warning
Service Service required
Main screen Displayed when 2 or 4 line layout is picked.
Displayed when chart layout is picked.
2920 1815 04 117
Page 3994 of 6229

Instruction book
Menu icons
Icon Description
Service
Alarms (warnings, shutdowns)
Week timer
Info
Test
Counters
Regulation setpoints
Inputs
Outputs
SPM readings
ESi
Event history (saved data)
Settings
118 2920 1815 04
Page 3995 of 6229

Instruction book
Input icons
Icon Description
Pressure
Temperature
Digital input
Special protection
System icons
Icon Description
Compressor element (LP, HP, ...)
Dryer
Fan (icon only visible when installed on compressor unit)
Drain(s) (icon only visible when Electronically Regulated Drain (ERD) is installed on
compressor unit)
Filter(s)
Motor
Expansion module (Failure)
Cooler
Energy Recovery
Network settings/problem
2920 1815 04 119
Page 3996 of 6229

Instruction book
General alarm
Oil circuit
Regulation
General settings
Access key / User password
Navigation arrows
Icon Description
Up
Down
6.5 Main screen
Control panel
Control panel
120 2920 1815 04
Page 3997 of 6229

Instruction book
(1) Enter key

(2) Escape key
(3) Scroll keys
Function
The main screen shows the status of the compressor operation and is the gateway to all functions
implemented in the controller.
The main screen is shown automatically when the voltage is switched on and a key is pushed. The display
switches to sleep mode when no keys are pushed for several minutes.
Five different main screens can be chosen:
1. Two value lines
2. Four value lines
3. Chart (High resolution)
4. Chart (Medium resolution)
5. Chart (Low resolution)
Value views
Typical Main screen (Two value lines)
2920 1815 04 121
Page 3998 of 6229

Instruction book
Typical Main screen (Four value lines)
Text on figures
(1) Compressor Outlet

(2) Loaded hours
(3) Text varies upon the compressor's actual condition
(4) Menu
(5) Running hours
(6) Element outlet (when no aftercooler is mounted)
(6) Compressor outlet
(7) Load
• Section A displays information regarding the compressor operation (e.g. outlet pressure (1),
temperature at compressor outlet (2)).
• Section B displays Status icons. Following icon types are shown in this field:
• Fixed icons
These icons are always shown in the main screen and cannot be selected by the cursor (e.g.
Compressor stopped or running)
• Shortcut icons
These icons are always shown in the main screen. If the icon is selected and the Enter key is
pushed, the screen will jump to the corresponding menu (e.g. if the icon for Motor stopped or
Running Loaded is selected, the screen will jump directly to the regulation menu after pressing
the enter key).
• Control mode icons
These icons are always shown in the main screen. If the icon is selected and the Enter key is
pushed, the screen jumps to the control mode menu. Following control modes are available:
122 2920 1815 04
Page 3999 of 6229

Instruction book
Local control
Remote control
Network control
• Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer,
automatic restart after voltage failure, etc.)
• Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To show more information about displayed icons, select the icon using the scroll keys and push the
Enter key.
• Section C is called the Status bar
This bar shows the text that corresponds to the selected icon.
• Section D shows the Action buttons. These buttons are used:
• to call-up or program settings
• to reset a shutdown, service message or emergency stop
• to have access to all data collected by the controller
The function of the buttons depends on the displayed menu. The most common functions are:
Menu To go to the menu
Modify To modify programmable settings
Reset To reset a timer or message
To enable an action button, highlight this button by using the Scroll keys and push the Enter key.
To go back to the previous menu, push the Escape key.
Chart views
2920 1815 04 123
Page 4000 of 6229

Instruction book
When the Chart (High Resolution) display is selected, a chart with an X-axis covering 4 minutes is
displayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chart
dot represents 1 second.
When the Chart (Medium Resolution) display is selected, a chart with an X-axis covering 4 hours is
displayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chart
dot represents a 1 minute average value.
When the Chart (Low Resolution) display is selected, a chart with an X-axis covering 10 days is displayed.
The value displayed on the Y-axis depends on the selection made in the input screen. Each chart dot
represents a 1 hour average value.
124 2920 1815 04
Page 4001 of 6229

Instruction book
Control panel
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Description
When the voltage is switched on, the main screen is shown automatically (see section Main screen):
• To go to the Menu screen, highlight the Menu button (4), using the Scroll keys.
• Press the Enter key to select the menu. Following screen appears:
2920 1815 04 125
Page 4002 of 6229

Instruction book
• The screen shows a number of icons. Each icon indicates a menu item. The status bar shows the name
of the menu that corresponds with the selected icon.
• Use the Scroll keys to select an icon.
• Press the Enter key to activate the menu or press the Escape key to return to the Main screen.
6.7 Service menu
Control panel
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Service
126 2920 1815 04
Page 4003 of 6229

Instruction book
Function
If the controller should indicate another time interval for the service plans than the one
stated in the instruction book, see section Preventive maintenance; the most strict
should be carried out. The compressor owner is responsible to carry out maintenance at
the given time intervals of the spare parts
• To reset the service plans that have been carried out.

• To check when the next service plans should be carried out.
• To check which service plans were carried out in the past.
• To modify the programmed service intervals.
Procedure
Starting from the Main screen (see Main screen),
• Move the cursor to the Menu action key and push the Enter key. Following screen appears:
• Use the Scroll keys to move the cursor to the Service icon.
• Push the Enter key and following screen appears:
2920 1815 04 127
Page 4004 of 6229

Instruction book
Text on figure
(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History
• Scroll through the items and select the desired item. Push the Enter key to display the details as
explained below.
Overview
Text on figure
(1) Overview
(2) Running Hours
(3) Real Time Hours
(4) Reset
Running hours are the clocked times during which the compressor stage motor has been running. Real
Time Hours are programmable timers which keep counting even when the compressor isn't running. E.g.
when a customer would like to change a part yearly or every 4000 running hours, service level A can be
put on Running Hours 4000 hours and Real Time Hours 8800 (8760 hours = 1 year). A service warning
will be displayed after one year or sooner (after 4000 running hours ) if the compressor has been running a
lot.
The figures at the left of the progress bars are the programmed service interval Running or Real Time
Hours. Those at the right count down and show the number of hours that need to be covered to reach the
next service intervention.
Colored letters indicate the next upcoming service level.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level represents a
number of service actions to be carried out at the time intervals programmed in the Elektronikon controller.
When a service plan interval is reached, a message will be displayed.
128 2920 1815 04
Page 4005 of 6229

Instruction book
After carrying out the service actions related to the indicated levels, the timers must be reset manually.
From the Service menu above, select Service plan (3) and press Enter. Following screen appears:
Text on figure
(1) Service plan

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

Depending on the operating conditions, it might be necessary to modify the service intervals. To do so, use
the Scroll keys to select the value to be modified. A screen similar to the one below appears:
Push the Enter key. Following screen appears:
2920 1815 04 129
Page 4006 of 6229

Instruction book
Modify the value as required using the ↑ or ↓ scroll key and push the Enter key to confirm.
Note: Running hours and real time hours can be modified in steps of 100 hours.
Next Service
Text on figure
(1) Next service

(2) Level
(3) Running hours
(4) Actual
In the example above, the I Service level is programmed at 2000 running hours, of which 0 hours have
passed.
History
The History screen shows a list of all service actions carried out in the past, sorted by date. The date at the
top is the most recent service action. To see the details of a completed service action (e.g. Service level,
Running hours or Real time hours), use the Scroll keys to select the desired action and push the Enter key.
130 2920 1815 04
Page 4007 of 6229

Instruction book
6.8 Protections menu
Control panel
Menu icon, Protections
Function
• To display and reset the protections.
Before resetting a warning or shutdown message, always solve the problem. Frequently
resetting these messages without remedying may damage the compressor.
Procedure
Starting from the Main screen (see Main screen):
• Move the cursor to the Menu action button and push the enter key (2). Following screen appears:
• Using the Scroll keys (1), move the cursor to the protections icon.
• Push the Enter key (2). Following screen appears:
2920 1815 04 131
Page 4008 of 6229

Instruction book
A number of icons is shown, allowing to display and reset protections
Typical example of a general alarm screen
Text on figure:
(1) General
(2) Compressor outlet
(3) Level high
(4) Shutdown warning
(5) Shutdown
(6) Reset
(7) Modify
The screen shows that the actual reading for the compressor outlet is 2.53 bar. The screen shows also
the settings for the shutdown warning (3.60 bar) and shutdown (3.70 bar).
On the bottom of the screen are two buttons:
• Reset: to reset the alarm after remedying the problem.
• Modify: to change the alarm settings
Depending on the machine type and the installed optional equipment less/more/different
icons and/or relevant underlying menus are displayed.
132 2920 1815 04
Page 4009 of 6229

Instruction book
The displayed and resettable protections are :

•
General:
• Compressor outlet warning/shutdown level (High)
• Compressor outlet warning level (Low)
• Emergency stop status
• No valid pressure control: Triggered if the compressor outlet pressure sensor fails.
•
Element(s):
• Warning level (Low) of intercooler pressure
• Shutdown level (Low) of intercooler pressure
• Warning/shutdown level of element 1 outlet temperature
• Warning/shutdown level of element 2 inlet temperature
• Warning/shutdown level of element 2 outlet temperature
•
Fan:
• Overload Fan Motor: Triggered if the overload of the fan motor trips.
•
Drain(s):
• Condensate Drain IC not ok (IC= Intercooler)
• Condensate Drain AC not ok (AC= Aftercooler)
• Condensate drain AC2 (AC2 = additional aftercooler for Full-Feature compressors with
energy recovery)
• Condensate drain RC in (RC = Regeneration cooler)
• Condensate drain RC out (RC = Regeneration cooler)
• Condensate drain MD (MD = MD Dryer )
•
Filters
• Warning/shutdown level (Low) of DP air filter (DP: delta pressure or pressure drop)
• DP air filter service level (Low)
•
Main Motor
• Overload Motor
• Starter Feedback Contact Open: monitors position of the delta contactor
• Starter Feedback Contact Close: monitors position of the delta contactor
•
Expansion Module Communication

• Not triggered: if Triggered the communication between the Elektronikon and the
expansion module failed.
2920 1815 04 133
Page 4010 of 6229

Instruction book
Cooler
• Low level warning alarm of intercooler pressure
• High level warning alarm of cooling air inlet
•
Oil circuit
• Warning/shutdown level (Low) of oil pressure
• Warning/shutdown level (High) of oil temperature
6.9 Week timer menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Week timer
Function
• To program time-based start/stop commands for the compressor
• To program time-based net pressure band change commands
The timer function allows 4 different Week Action Schemes. These can be combined into a sequence of 10
weeks in a Week Cycle.
134 2920 1815 04
Page 4011 of 6229

Instruction book
Important notice:
The Elektronikon controller allows a number of successive commands. Be aware that 2
successive commands need at least 1 minute time lapse to ensure flawless operation.
For example Start Compressor: 5:00 AM, Pressure Setpoint change: 5:01 AM.
Procedure
Starting from the Main screen (see Main screen section),
• Move the cursor to the Menu action button and push the Enter key. Use the Scroll buttons to select
the Timer icon.
• Press the Enter key on the controller. Following screen appears:
(1) Week Timer

(2) Week Action Schemes
(3) Week Cycle
(4) Status
(5) Week 1
(6) Remaining Running Time
The selected item is highlighted in grey. Select the desired item and push the Enter key on the
controller to modify.
2920 1815 04 135
Page 4012 of 6229

Instruction book
Programming week schemes

• Select Week Action Schemes and push Enter. A new window opens. The first item in the list is
highlighted in grey. Push the Enter key on the controller to modify Week Action Scheme 1.

(2) Week Action Scheme 1
• When entering a Week Action Scheme, the corresponding week is displayed. The selected day is
highlighted in grey and the desired action can be set by pushing Enter.

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
136 2920 1815 04
Page 4013 of 6229

Instruction book
• A new window opens. The Modify action button is selected. Push the Enter key on the controller
twice to create the first action.
(1) Monday
(2) Modify
• A new window appears. Select an action from the displayed list by using the Scroll keys on the
controller. Push the Enter key to insert e.g. a first startup time.
(1) Monday
(2) Actions
(3) Remove
(4) Start
(5) Stop
(6) Modify
• A new window opens. The startup action is now visible on Monday of Week Action Scheme 1/4.
2920 1815 04 137
Page 4014 of 6229

Instruction book
(1) Monday
(2) Start
(3) Save
(4) Modify
• To adjust the startup time, use the Scroll keys on the controller and push the Enter key to confirm.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A window appears. Use the ↑ or ↓ scroll keys to modify the hour values. Use the ← or → Scroll keys
to select the minutes and modify the values using the ↑ or ↓ scroll keys.
138 2920 1815 04
Page 4015 of 6229

Instruction book
(1) Monday
(2) Time
(3) Save
(4) Modify
• Push the Escape key on the controller. The Modify action button is selected. Use the Scroll keys to
select the action Save.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A new window appears. Use the Scroll keys on the controller to select the correct actions. Press the
Enter key to confirm.
2920 1815 04 139
Page 4016 of 6229

Instruction book
(1) Monday
(2) Are you sure?
(3) No
(4) Yes
(5) Save
(6) Modify
Press the Escape key to leave this window.

• The actions are displayed below their respective day.

(2) Monday
(3) Start
(4) Tuesday
(5) Wednesday
(6) Thursday
(7) Friday
(8) Saturday
140 2920 1815 04
Page 4017 of 6229

Instruction book
(9) Sunday
Push the Escape key on the controller to leave this screen.
Programming the week cycle

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

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

(2) Week 1
(4) Week 2
2920 1815 04 141
Page 4018 of 6229

Instruction book

(6) Week 3
(8) Off
(9) Modify
Push the Enter key twice to modify the first week.

• Following window appears. Select action e.g. Week Action Scheme 1.
(1) Week Cycle

(2) Week 1
(3) Off
(7) Modify
• Check the status of the Week Timer.

Use the Escape key to return to the main Week Timer menu. The status of the Week Timer is
displayed in the third line. Push the Enter key to adjust status.
(1) Week Timer

142 2920 1815 04
Page 4019 of 6229

Instruction book
(3) Week Cycle

(4) Status
(5) Week Timer Inactive
(7) Off
• A new window appears. Select Week 1 and push the Enter key to enable the Week Timer.
(1) Week Timer

(2) Week
(3) Week Timer Inactive
(4) Week 1
• Press the Escape key to leave the pop up window. The status shows that week 1 is active.
• In certain cases it might be necessary to keep the compressor running instead of allowing the Week
Timer to stop it. To enable this condition Remaining Running Time was developed. After scrolling to
Remaining Running Time, its setting can be modified by pushing Enter and adjusting the value
between 5 and 240 minutes in steps of 5 minutes.
(1) Week Timer

• After pushing the Enter key, the Remaining Running Time is confirmed and displayed. This timer is
prior to all Week Timer actions.
2920 1815 04 143
Page 4020 of 6229

Instruction book
6.10 Info menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Info
Function
To show the Atlas Copco internet address.
Procedure
• Move the cursor to the Menu action button and push the Enter key. Following screen appears:
• Scroll the cursor to the Info icon (see above, section Menu icon).
144 2920 1815 04
Page 4021 of 6229

Instruction book
• Push the Enter key. The Atlas Copco internet address appears on the screen. At the bottom of the
screen, the More button is displayed. Push the button to display following additional info:
• MAC address
• Expansion modules
• Boot software
• Operating system
• Application software
• PEG software
• Licence ESi
6.11 Test menu
Control panel
Menu icon, Test
Function
• To perform a safety valve test and a drain test. Both actions can only be performed by authorized
personnel and are protected by a security code.
2920 1815 04 145
Page 4022 of 6229

Instruction book
6.12 Counters
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Counters
Function
To display:
• The loaded hours (air delivery)
• The number of load cycles
• The number of hours that the controller has been powered (module hours)
Procedure
• Move the cursor to the Menu action button and press the Enter key. Following screen appears:
146 2920 1815 04
Page 4023 of 6229

Instruction book
Text on figure
(1) Menu
(2) Regulation
• Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon)
• Press the Enter key. Following screen appears:
Text on figure
(1) Counters
(2) Running hours
(3) Loaded Hours
(4) Motor starts
(5) Load relay
The screen shows a list of all counters and their current values.
2920 1815 04 147
Page 4024 of 6229

Instruction book
6.13 Modifying the pressure band
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Regulation
Function
The regulation menu allows tuning of 2 pressure bands and the selection of the current pressure band.
Procedure
• The regulation menu is accessible in two ways:
a. select Menu action key using the Scroll keys and push the Enter key. Following screen appears:
148 2920 1815 04
Page 4025 of 6229

Instruction book
Text on figure
(1) Menu
(2) Regulation
Enter the Regulation menu by pushing Enter once again while the Regulation menu icon is
highlighted.
b. Select following shortcut icon in the Main Screen and push enter
.
• Following screen appears:
Text on figure
(1) Regulation
(2) Unloading pressure 1
(3) Loading pressure 1
(4) Unloading pressure 2
(5) Loading pressure 2
(6) Modify
• The screen shows the current settings.

To modify the settings, move the cursor to the action button Modify and push the Enter key.
Following screen appears:
2920 1815 04 149
Page 4026 of 6229

Instruction book
• Unloading Pressure 1 is highlighted in grey. Use the Scroll keys (3) to highlight the setting to be
modified and push the Enter key (1). Following screen appears:
The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the
↑ or ↓ key of the Scroll keys to modify the settings as required and push the Enter key to accept.
If necessary, change the other settings as required in the same way as described above.
6.14 Inputs menu
Control panel
150 2920 1815 04
Page 4027 of 6229

Instruction book
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Inputs
Function
To display the current values and the status of a number of digital and analogue inputs.
Procedure
Starting from the main screen (see Main screen),
Move the cursor to the Menu action key and push the Enter key. Following screen appears:
Text on figure
(1) Menu
(2) Regulation
• Using the Scroll keys, move the cursor to the Inputs icon (see above, section Menu icon).
• Push the Enter key and the screen below appears:
2920 1815 04 151
Page 4028 of 6229

Instruction book
Depending on the installed optional equipment less or more icons may appear.
Text on figure
(1) Inputs
(2) Cooler
• The inputs are categorized under a number of representative icons. Push the Enter key to show the
actual inputs.
• If an input reaches a warning or shutdown level, the original icon is replaced by the warning or
shutdown icon, respectively.
Setting an input as main chart (see section Main screen)

• Navigate to the input screen as described above.
• Push the Enter key; the first input on the screen will be highlighted in grey.
• Using the arrow keys, scroll to the input to be set as main chart.
• Push the Enter key; following screen appears:
Text on figure
(1) Inputs
(2) Main chart signal
(3) Set as main chart signal
(4) Modify
152 2920 1815 04
Page 4029 of 6229

Instruction book
• Push the Enter key; the active input is now set as main chart.
Changing the main chart input

To set another input as main chart, proceed as follows:
• Using the arrow keys, scroll to the input to be set as main chart.
(1) Inputs
(3) Set as main chart signal
(4) Modify

(2) Are you sure to change the main chart signal? All current chart data will be lost!
(3) Yes
(4) No
• Select the Yes key to confirm or the No key to cancel the modification operation.
2920 1815 04 153
Page 4030 of 6229

Instruction book
Removing the main chart input

To remove the input as main chart, proceed as follows:
• Using the arrow keys, scroll to the input with the small chart icon.

(2) Remove from main chart

(2) Are you sure to change the main chart signal? All current chart data will be lost!
(3) Yes
(4) No
• Select the Yes key to confirm or the No key to cancel the modification.
154 2920 1815 04
Page 4031 of 6229

Instruction book
6.15 Outputs menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Outputs
Function
To display information regarding the current status of the digital outputs.
Procedure
2920 1815 04 155
Page 4032 of 6229

Instruction book
Text on figure
(1) Menu
(2) Regulation
• Move the cursor to the Outputs icon (see above, section Menu icon), using the Scroll keys.
• Push the Enter key.
• The outputs are categorized under a number of representative icons. Push the Enter key to show the
actual outputs.
• •
General
• Load/Unload
• Automatic operation
• General warning
• General shutdown
•
Drain(s)
• Condensate drain IC
• Condensate drain AC
• Condensate drain AC2 (AC2 = additional aftercooler for Full-Feature compressors with
energy recovery)
• Condensate drain RC in (RC = Regeneration cooler)
• Condensate drain RC out (RC = Regeneration cooler)
• Condensate drain MD (MD = MD Dryer )
•
Main Motor
• Line contactor
• Star contactor
• Delta contactor
156 2920 1815 04
Page 4033 of 6229

Instruction book
6.16 Event history menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Event History
Function
To display a list of all shutdowns, their causes and the status of counters and in/outputs at the moment of
shutdown.
Procedure
2920 1815 04 157
Page 4034 of 6229

Instruction book
• Using the Scroll keys, move the cursor to the Event History icon (see above, section Menu icon).
• A chronological shutdown list is displayed.
• Select the moment of your interest and push Enter.
• The type of event and the status data of counters and in/outputs will be displayed.
6.17 Modifying settings
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Settings
Function
To display and modify a number of settings (e.g. Time, Date, Date format, Language, units ...)
Procedure
158 2920 1815 04
Page 4035 of 6229

Instruction book
• Using the Scroll keys, move the cursor to the Settings icon (see above, section menu icon).
• Push the Enter key. A screen similar to the one below appears:
• The screen displays following icons:
Icon Function
Network settings
Regulation settings
General settings
Automatic restart after voltage failure settings
Access key
User password
2920 1815 04 159
Page 4036 of 6229

Instruction book
Icon Function
Main chart
• Move the cursor to the icon of the function that needs to be modified and push the Enter key.
Modifying network settings

• Select the network settings icon as described above and push the Enter key (1). Following screen
appears:
Text on figure
(1) Network
(2) CAN
(3) Ethernet
• Scroll to the desired network and push the Enter key. A screen similar to the one below appears:
Screen for CAN settings
160 2920 1815 04
Page 4037 of 6229

Instruction book
Screen for Ethernet settings
.
• Push the Enter key once again to modify a parameter. A network parameter can only be modified
when the network is disabled (Off).
Regulation settings
This menu allows to view and modify the regulation settings.
General settings
• Select the General settings icon as described above and push the Enter key (1). Following screen
appears:
Text on figure
(1) General
(2) Language in use
(3) Time
(4) Date
(5) Date format
• The screen displays the first 4 items of a list of all settings. Scroll through the list to display all other
items.
2920 1815 04 161
Page 4038 of 6229

Instruction book
• Push the Enter key, use the Scroll keys to select the setting to be modified and push the Enter key
again.
• A screen appears. Use the ↑ or ↓ key to select the required parameter and push the Enter key to
confirm.
Automatic restart
• Select the Automatic restart settings icon as described above and push the Enter key (2). Following
screen appears:
Text on figure
(1) Automatic restart

(2) Maximum power down time
(3) Restart delay
(4) Modify
• The screen displays 3 adjustable settings.

• Push the Enter key (1), scroll to the setting to be modified and push the Enter Key once again.
• A screen appears; the required parameter is adjustable and confirmed by pushing the Enter Key once
more.
Access key
A number of security levels are set in the controller (e.g. user, service technician, etc.). The Access key
menu item is used to change the security level.
• Scroll to the correct icon using the scroll key and push the Enter key.
• Push the Enter key twice to modify the security level code and push Enter to confirm.
User password
If the password option is enabled, it is impossible for unauthorized personnel to modify any setting.
• Using the Scroll keys, move the cursor to the Password icon.
• Push the Enter key twice to select and activate.
• Pick a 4 digit password using the Scroll keys and push the Enter key to confirm.
162 2920 1815 04
Page 4039 of 6229

Instruction book
Main chart settings
Chart ranges and bands can be modified. This can cause the current value to be out of
range and can thus cause the absence of a visible curve in the graph.
The main chart settings menu allows to adjust the scale and curves on the graph. To modify these settings,
proceed as follows:
• Select the Main chart settings icon as described above and push the Enter button (1). Following
screen appears:
Text on figure
(1) Main chart

(3) Chart range
(4) Minimum
(5) Maximum
(6) Chart band
(7) Low
(8) High
(9) Off
The screen shows the main chart signal, the current chart range and band settings. To modify these settings,
proceed as follows:
Push the Enter key, select chart range or chart band as desired and confirm.
Modifying the chart range
Select the chart range as described above and proceed as follows:
• Push the Enter key; the minimum setting becomes highlighted. Push the Enter key to modify the
minimum setting or use the arrow down key to modify the maximum setting.
• Push the Enter key to confirm the modification.
Modifying the chart band
Select the chart band as described above and proceed as follows:
2920 1815 04 163
Page 4040 of 6229

Instruction book
• Push the Enter key; the low band setting becomes highlighted. Push the Enter key to modify the
on/off setting or use the arrow down key to modify the low setting.
• Push the Enter key to confirm the modification.
• Proceed to modify the high band setting.
Service settings
Factory
setting
Service
Service level A hr 4000
Service level B hr 8000
Service level C hr 16000
Service level D hr 40000
Service level E hr 60000
Service level I hr 2000
Remark
A number of service operations are grouped (Level A, Level B, ...). Each level stands for a number of
service operations to be carried out at the programmed intervals. Consult your Atlas Copco Service Center.
Other programmable settings
Min.
Min. Max. (with
(Full-
Unit (Pack Max. Energy
Feature
version) Recovery)
version)
Pressure regulation (UN)LOAD level

mbar
7 bar (60 Hz ) 4000 5000 7005 6505
7.5 bar (50 Hz) 4000 5500 7505 7005
8.6 bar (50 Hz) 4000 6500 8605 8105
8.6 bar (60 Hz) 4000 6500 8605 8105
10 bar (50 Hz) 7000 7500 10005 9505
10.4 bar (60 Hz) 7000 7500 10405 9905
13 bar (50 Hz) 7000 9500 13005 12505
13 bar (60 Hz) 7000 9500 13005 12505
=>converted (m)bar-psi values psi
* 101.5 psi (60 Hz) 58.0 72.5 101.6 94,3
* 108.7 psi (50 Hz) 58.0 79.8 108.9 101.6
* 125 psi (50 Hz) 58.0 94.3 124.8 117.6
164 2920 1815 04
Page 4041 of 6229

Instruction book
Min.
Min. Max. (with
(Full-
Unit (Pack Max. Energy
Feature
version) Recovery)
version)
* 125 psi (60 Hz) 58.0 94.3 124.8 117.6
* 145 psi (50 Hz) 101.5 108.8 145.1 137.9
* 150.8 psi (60 Hz) 101.5 108.8 150.9 143.7
* 188.5 psi (50 Hz) 101.5 137.8 188.6 181.4
* 188.5 psi (60 Hz) 101.5 137.8 188.6 181.4
Control timers
s
Unload time 3 3 20 20
Minimum stop time 20 20 99 99
Y-D starter
s
Y-D time 10 10 30 30
Y-D time with motor voltage > or = 2.3 kV 0 0 30 30
Load delay 3 3 30 30
Load delay with motor voltage > or = 2.3 kV 13 13 30 30
Automatic Restart After Voltage Failure - ARAVF

s
Maximum power down time 20 20 3600 3600
Restart delay 0 0 255 255
Others
s
External communication timeout 10 10 60 60
6.19 Web server

All controllers have a built-in web server that allows direct connection to the company network or to a
dedicated PC via a local area network (LAN). This allows to consult certain data and settings via a PC
instead of the display of the controller.
Getting started
If the unit is equipped with a SMARTBOX, the network connection of the Elektronikon is
already in use. To allow the web server functionality, the network cable that is
connected to the SMARTBOX should be unplugged and replaced by the cable of the
company network.
If both the web server functionality and SMARTBOX are required, please contact your
local Atlas Copco Customer Center for support.
Make sure you are logged in as administrator.

• Use the internal network card from your computer or a USB to LAN adapter.
2920 1815 04 165
Page 4042 of 6229

Instruction book
• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).
Configuration of the network card

• Go to Network and Sharing Center (1).
• Click on Change adapter settings (1).
• Select the Local Area Connection, which is connected to the controller.
• Click with the right button and select Properties (1).
166 2920 1815 04
Page 4043 of 6229

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

• IP Address 192.168.100.200 (1)
• Subnetmask 255.255.255.0 (2)
Click OK (3) and close network connections.
Configure a company network (LAN) connection

• Ask your IT department to generate a fixed IP address in your company’s network.
• That IP address will be excluded from the DNS server, so it will be reserved for the Elektronikon
Mk5.
• Also get the correct Gateway and Subnet mask settings. For example:
• IP = 10.25.43.200
• Gateway = 10.25.42.250
2920 1815 04 167
Page 4044 of 6229

Instruction book
• Subnet mask = 255.255.254.0

• Connect your Elektronikon Mk5 to the company's network (LAN) by using a UTP cable (min. CAT
5e).
• Adapt the network settings in the Elektronikon Mk5:

• Go to Main Menu
• Go to Settings (1)
• Go to Network (1)
168 2920 1815 04
Page 4045 of 6229

Instruction book
• Go to Ethernet (1)
• Switch Off (1) the Ethernet communication to allow editing the settings
• Adapt IP Address (1)

• Adapt Gateway IP (2)
• Adapt Subnet Mask (3)
• Switch On (4) the Ethernet communication
2920 1815 04 169
Page 4046 of 6229

Instruction book
• Wait a few minutes so the LAN network can connect to the Elektronikon Mk5
Configuration of the web server

The internal web server is designed and tested for Microsoft® Internet Explorer.
Also "Opera", "Mozilla Firefox", "Safari"and "Chrome" should work.
Viewing the controller data
All screen shots are indicative. The number of displayed fields depends on the selected
options.
• Open your browser and type the IP address of the controller you want to view in your browser (in this
example http://192.168.100.100). The interface opens:
170 2920 1815 04
Page 4047 of 6229

Instruction book
Screen shot (example!)
Navigation and options

• The banner shows the unit type and the language selector. In this example, three languages are
available on the controller.
• On the left side of the interface, you can find the navigation menu.
If a license for ESi is foreseen, the menu contains 3 buttons.
• Machine: shows all generator settings.
• ES: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure unit.
2920 1815 04 171
Page 4048 of 6229

Instruction book
Unit settings
All unit settings can be displayed or hidden. Put a check mark in front of each point of interest and it will
be displayed. Only the machine status is fixed and can not be removed from the main screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference button from
the navigation menu.
Counters
Lists all current counter values from controller and unit.
Info status
Machine status is always shown on the web interface.
Digital inputs
Lists all digital inputs and their status.
172 2920 1815 04
Page 4049 of 6229

Instruction book
Digital outputs
Lists all digital outputs and their status.
Special protections
Lists all special protections of the unit.
Service plan
Displays all levels of the service plan and their status. This screen shot underneath only shows the running
hours. It is also possible to show the current status of the service interval.
2920 1815 04 173
Page 4050 of 6229

Instruction book
7 Installation
7.1 Dimension drawing
Dimensions
Dimension drawing of ZR 110 up to ZR 145
174 2920 1815 04
Page 4051 of 6229

Instruction book
Dimension drawing of ZR 110 up to ZR 145 Full-Feature, page 1
2920 1815 04 175
Page 4052 of 6229

Instruction book
Dimension drawing of ZR 110 up to ZR 145 Full-Feature, page 2
176 2920 1815 04
Page 4053 of 6229

Instruction book
Dimension drawing of ZT 110 up to ZT 145, page 1
2920 1815 04 177
Page 4054 of 6229

Instruction book
Dimension drawing of ZT 110 up to ZT 145, page 2
Reference Name
1 Right side view
2 Front view
3 Motor cooling air outlet
4 Motor cooling + compressor air inlet
5 Hot air version
6 Voltage supply entrance
178 2920 1815 04
Page 4055 of 6229

Instruction book
Reference Name
7 Center of gravity
8 Left side view of energy recovery version
9 Left side view
10 Cooling water out
11 Compressed air outlet
12 Cooling water inlet
13 ANSI flanges, optional
14 M8 for ducting on roofs; for position, see top view
15 Automatic drain, aftercooler
16 Automatic drain, intercooler
17 Rear side view
18 Top view
19 Type
20 Net mass (approx.) of units (kg)
21 ZR no motor Arr. E
22 ZR no motor Arr. 1
23 Opening for transportation
24 4 slotted holes for pulling out of container
25 Water in/out
26 Prepared for MD with ER, water out
27 Prepared for MD with ER, water in
28 Automatic drain, dryer outlet
29 Automatic drain, regeneration outlet
30 Automatic drain, prepared for MD with energy recovery
31 Manual drain, dryer inlet
32 Compressor and cooling air outlet
33 Cooling + compressor air inlet
34 Cooling air inlet
35 Standard version
36 Voltage supply entrance, possibility 2
37 Voltage supply entrance, possibility 1
38 Cooling air outlet
39 Voltage supply entrance, possibility 1 only for ZT 160 - 275
40 Hole M8
41 Voltage supply entrance, possibility 1 only for ZR 160 - 275
42 Left side view, Hot air
43 Electric cable for water shut-off valve
44 Voltage supply entrance, possibility 1 only for VSD units
45 Cold water circuit, cooling water in
46 Cold water circuit, cooling water out
47 Automatic drain, extra aftercooler
2920 1815 04 179
Page 4056 of 6229

Instruction book
Reference Name
48 Energy recovery circuit, cooling water in
49 Energy recovery circuit, cooling water out
50 Automatic drain, dryer inlet
51 Detail X
52 Detail Y
53 Cooling water
54 From FD dryer: Tropicalized integrated dryer, see detail
55 To FD dryer: Tropicalized integrated dryer, see detail
56 Service cover for regeneration cooler of dryer
57 Full-Feature with energy recovery. Fresh water in
58 Full-Feature with energy recovery. Fresh water out
59 Access for PDP sensor
60 Low load option. Connection for regeneration air, see detail
61 For connection with pipe coupling , brand Victaulic
62 Access for control cable, water shut-off valve
63 For option energy recovery: closed circuit out
64 For option energy recovery: closed circuit in
65 Low load option/blow off
66 Compressor air inlet
67 Motor cooling air inlet
68 Separated air intake
69 Standard unit
70 To external dryer
71 From external dryer
72 Use coupling
73 Grating, only separate air intake
74 Circuit A
75 Circuit B
76 Automatic drain, regeneration inlet
180 2920 1815 04
Page 4057 of 6229

Instruction book
Dimension drawing of ZR 160 up to ZR 275 Pack and ZR 250/315 VSD Pack compressors (in metric units)
2920 1815 04 181
Page 4058 of 6229

Instruction book
Dimension drawing of ZR 160 up to ZR 275 Pack and ZR 250/315 VSD Pack compressors (in imperial units)
182 2920 1815 04
Page 4059 of 6229

Instruction book
Dimension drawing of ZT 160 up to ZT 275 Pack and ZT 250/315 VSD Pack compressors (in metric units)
2920 1815 04 183
Page 4060 of 6229

Instruction book
Dimension drawing of ZT 160 up to ZT 275 Pack and ZT 250/315 VSD Pack compressors (in imperial units)
184 2920 1815 04
Page 4061 of 6229

Instruction book
Dimension drawing of ZR 160 up to ZR 275 Full-Feature and ZR 250/315 VSD Full-Feature compressors (in metric units)
2920 1815 04 185
Page 4062 of 6229

Instruction book
Dimension drawing of ZR 160 up to ZR 275 Full-Feature and ZR 250/315 VSD Full-Feature compressors (in imperial units)
186 2920 1815 04
Page 4063 of 6229

Instruction book
Dimension drawing of ZT 160 up to ZT 275 Full-Feature and ZT 250/315 VSD Full-Feature compressors (in metric units)
2920 1815 04 187
Page 4064 of 6229

Instruction book
Dimension drawing of ZT 160 up to ZT 275 Full-Feature and ZT 250/315 VSD Full-Feature compressors (in imperial units)
1 Right side view
2 Front view
3 Motor cooling air outlet
4 Compressed air inlet
5 Motor cooling air inlet (only for option: separate air intake)
188 2920 1815 04
Page 4065 of 6229

Instruction book
6 Motor cooling air inlet + compressor air inlet (for standard unit)
7 Left side view (for standard compressor)
8 Center of gravity
9 Cooling water in
10 Cooling water out
11 Circuit A
12 Compressed air outlet for standard dryer or low load dryer
13 Compressed air outlet for option: dryer bypass
14 Automatic drain of dryer with Low Load option G 1/2" (female)
15 Automatic drain of regeneration outlet G 1/2" (female)
16 Automatic drain of dryer inlet G 1/2" (female)
17 Automatic drain of intercooler G 1/2" (female)
18 Automatic drain of aftercooler G 1/2" (female)
19 Electrical cable for water shut-off valve diameter 25 mm (only for option water shut-off
valve)
20 Voltage supply: entrance for fixed speed compressors with supply ≤ 690 V
21 Voltage supply entrance:
• for fixed speed compressors with supply > 690 V
• VSD compressors (possibility 1)
• compressors with foot mounted motors
22 Top view
23 Left side view (for option: energy recovery)
24 Compressed air outlet DN 80 PN 16 acc. DIN 2633 (Scale 1:5)
25 Compressed air outlet 3" 150 Lbs acc. ANSI B16.5 (Scale 1:5)
26 Cooling water outlet of the energy recovery circuit
27 Circuit A
28 Cooling water outlet of the dryer circuit
29 Circuit B
30 Compressed air outlet
31 Cooling water inlet of the energy recovery circuit
32 Cooling water inlet of the dryer circuit
33 Automatic drain of extra aftercooler G 1/2" (female)
34 Circuit A: Water in/out DN 50 PN 16 acc. DIN 2633 (Scale 1:5)
35 Circuit B: Water in/out DN 32 PN 16 acc. DIN 2633 (Scale 1:5)
36 Rear side view
37 Grating only for option: separate air intake
38 Voltage supply: entrance for VSD compressors (possibility 2)
39 Circuit A: Water in/out 2" 150 Lbs acc ANSI B16.5 (Scale 1:5)
40 Circuit B: Water in/out 1 1/4" 150 Lbs acc ANSI B16.5 (Scale 1:5)
41 Opening for transportation
42 4 slotted holes to pull the compressor out of a container
43 Net mass of a standard compressor
2920 1815 04 189
Page 4066 of 6229

Instruction book
44 Net mass of a compressor without a motor
45 700 kg should be added in case of an oversized motor or motor with supply voltage >
690 V
1540 lb should be added in case of an oversized motor or motor with supply voltage >
690 V
46 Cooling air outlet
47 Automatic drain of dryer inlet G 1/2" (female)
48 Automatic low load drain drain for optional low load dryer feature
49 Cooling air inlet
50 Left side view
51 Center of gravity Z 160-275
52 Center of gravity Z 250/315 VSD
53 Left side view (for hot air version)
54 Hot air version
55 Standard version
56 Water in/out DN 50 PN 16 acc. DIN 2633 (Scale 1:5)
57 700 kg should be added in case of a high ambient temperature compressor or an
oversized motor or a motor with supply voltage > 690 V
1540 lb should be added in case of a high ambient temperature compressor or an
oversized motor or a motor with supply voltage > 690 V
58 Automatic drain of aftercooler G 1/2" (female) (not for hot air version)
59 Automatic drain of regeneration outlet 1, G 1/2" (female)
60 Automatic drain of regeneration outlet 2, G 1/2" (female)
7.2 DIN to JIS adaptor flanges
Application
Compressors used for the Japanese market are connected to an outlet pipe that is manufactured according
to the local JIS standard (Japanese Industrial Standard). To enable the connection between the mounted
DIN flanged compensator and the JIS outlet pipe the compressor comes with a loose DIN to JIS adaptor
flange that should be welded on the Japanese customer's installation.
190 2920 1815 04
Page 4067 of 6229

Instruction book
Drawings
DIN to JIS adaptor flange with inner pipe diameter ranging from 32 to 65 mm
2920 1815 04 191
Page 4068 of 6229

Instruction book
DIN to JIS adaptor flange with inner pipe diameter ranging from 80 to 125 mm
192 2920 1815 04
Page 4069 of 6229

Instruction book
Reference Name
1 Flange of compensator
2 Mating flange
3 Outlet pipe
4 Section X-X
5 Cooling water, quantity: 2
Applicable for range
6 O.D. = Outer Diameter
7 Bolt hole pitch
8 I.D. = Inner Diameter
9 Pipe size
10 Hole for pipe
11 Air outlet, quantity: 1
Applicable for range
12 To be ordered through Systems Wilrijk
2920 1815 04 193
Page 4070 of 6229

Instruction book
7.3 Installation proposal
Compressor room example
Installation proposal for ZR 110 up to ZR 145 and ZR 132/160 VSD
194 2920 1815 04
Page 4071 of 6229

Instruction book
Installation proposal for ZR 110 Full-Feature up to ZR 145 Full-Feature and ZR 132/160 VSD Full-Feature
2920 1815 04 195
Page 4072 of 6229

Instruction book
Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature, ZR 250 VSD Full-Feature and ZR 315 VSD Full-
Feature without Energy Recovery and without dryer by-pass option (in mm)
196 2920 1815 04
Page 4073 of 6229

Instruction book
Feature without Energy Recovery and without dryer by-pass option (in inch)
2920 1815 04 197
Page 4074 of 6229

Instruction book
Feature with Energy Recovery (in mm)
198 2920 1815 04
Page 4075 of 6229

Instruction book
Feature with Energy Recovery (in inch)
2920 1815 04 199
Page 4076 of 6229

Instruction book
Feature with dryer by-pass option (in mm)
200 2920 1815 04
Page 4077 of 6229

Instruction book
Feature with dryer by-pass (in inch)
2920 1815 04 201
Page 4078 of 6229

Instruction book
Installation proposal for ZT 110 up to ZT 145 and ZT 132/160 VSD
202 2920 1815 04
Page 4079 of 6229

Instruction book
Installation proposal for ZT 160 up to ZT 275, ZT 250 VSD and ZT 315 VSD
(1) Minimum free area to be reserved.

(2) Ventilation proposal.
(3) Rear side view.
(4) Ventilation proposal (without option separate air intake).
(5) Ventilation proposal (with option separate air intake).
(6) Common ducting for multiple units is not allowed.
2920 1815 04 203
Page 4080 of 6229

Instruction book
(7) Reverse side view.
Description
The compressor must only be moved or lifted as described in the section Initial start-up.
1. Install the compressor on a level floor suitable for taking its weight. The recommended minimum
distance between the top of the body and the ceiling is 1200 mm (47 in).
2. Remove the plastic plug (if provided) from the compressor air outlet pipe and install an air outlet
valve. Close the valve and connect it to the air net.
3. The maximum total length of the air delivery pipe can be calculated as follows:
For SI Units:
Lmax= (dp x d5 x p) / (450 x Qc1.85)
Symbol Explanation
d Inner diameter of the outlet pipe in mm
dp Pressure drop (recommended maximum = 0.1 bar)
L Length of outlet pipe in m
p Absolute pressure at the compressor outlet in bar(a)
Qc Free air delivery of the compressor in l/s
For British/American Units:

Lmax= (1470 x d5 x p x dp) / Qc1.85
Symbol Explanation
d Inner diameter of the outlet pipe in inch
dp Pressure drop (recommended maximum = 1.45 psi)
L Length of outlet pipe in ft
p Absolute pressure at the compressor outlet in psi(g)
Qc Free air delivery of the compressor in cfm
It is strongly recommended to make the connection of the compressor air outlet pipe on top of the
main air net pipe in order to minimize carry-over of possible condensate residue.
As a rule of thumb, the following formula can be used to calculate the recommended volume of the
air net:
V = (30 x C x p x Q) / dp
Symbol Explanation
C Correction factor
dp Pressure difference between unloading and loading pressures in bar (recommended
minimum = 0.6)
p Compressor inlet pressure in bar absolute
Q Free air delivery of compressor in l/s
V Recommended air net volume in l
204 2920 1815 04
Page 4081 of 6229

Instruction book
Air consumption divided by compressor free air Correction factor C

delivery
0.9 0.10
0.8 0.15
0.7 0.20
0.5 0.25
0.3 0.20
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 (16.5 ft/s).
The required ventilation capacity (per compressor installed) to limit the compressor room temperature
can be calculated as follows:
For ZR compressors:
• For SI Units: Qv = 0.1 N/dT
• For British/American Units: Qv = 284.5 N/dT
For ZT compressors:
• For SI Units: Qv = 0.92 N/dT
• For British/American Units: Qv = 2617.4 N/dT
Symbol Explanation
dT Temperature increase in compressor room
• For SI Units: in °C
• For British/American Units: in °F
N Shaft input of compressor
• For SI Units: in kW
• For British/American Units: in hp
Qv Required ventilation capacity
• For SI Units: in m3/s
• For British/American Units: in cfm
If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is 30 Pa (0.12
in wc). Common ducting for several compressors is not allowed.
5. Lay out the drain piping from the condensate outlets towards the condensate collector. The drain
pipes must not dip into the water in the collector. It is recommended to provide a funnel to allow
visual inspection of the condensate flow.
6. Elektronikon control system with control panel.
7. See Electric cable size, fuses and cable length for the recommended size of the supply cables.
Check that the electrical connections meet local codes. The installation must be earthed and protected
against short circuits by fuses in all phases. An isolating switch must be installed near the compressor.
8. Install a condensate drain valve in the lower part of the air net piping.
9. On ZR compressors, remove the plastic plugs (if fitted) from the compressor water pipes (WI and
WO) and connect the pipes to the cooling water circuit. Fit a valve in the compressor water inlet pipe
and outlet pipe.
10. Extra grating for compressors equipped with the separate air intake and/or prefilter option(s).
11. Energy recovery water supply.
2920 1815 04 205
Page 4082 of 6229

Instruction book
Hot air version
Thermal insulation should be provided to offer protection against the high temperature of
the air outlet valve and air delivery pipe.
7.4 Installation requirements for rubber compensators
Types and sizes

Atlas Copco oil-free air products with aftercooler are equipped with rubber compensators on the air outlet
and water connections.
Types of misalignments
The supplied compensators can cope with 2 types of minor misalignments when the customer pipe end is
mounted:
• Axial ΔL
• Lateral ΔR
206 2920 1815 04
Page 4083 of 6229

Instruction book
Drawing reference Description

A Atlas Copco compressor pipe end
B Customer installation pipe end
Angular misalignments Δα are NOT allowed!
2920 1815 04 207
Page 4084 of 6229

Instruction book
Misalignment tolerances
• Single direction misalignments
Axial 1: ΔL mm 20
Axial 1: ΔL in 0.8
Lateral: ΔR mm 20
Lateral: ΔR in 0.8
Δα2 ° 0
1 = stretch or compression
2 = NO angular misalignment is tolerated!
• Combined direction misalignments

(1) Compression
(2) Stretch
Do NOT operate outside of the black polygon.
Do NOT exceed the misalignment tolerances to avoid compensator damage! The piping
system of the customer should be designed to fit the misalignment tolerances both during
standstill and operation.
208 2920 1815 04
Page 4085 of 6229

Instruction book
Temperature correction factors
Medium temperature Medium temperature Correction factor for maximum working pressure of
(°C) (°F) the compensator
0 32 1
50 122 1
80 176 1
85 185 0.92
90 194 0.83
95 203 0.75
100 212 0.67
105 221 0.6
110 230 0.54
Torque values
Compensator bolts should be torqued in 3 successive steps
• Step 1: Hand-tighten each bolt.
• Step 2: Torque the bolts crosswise up to the value mentioned in the table below and allow a
stabilization period of 30 minutes before moving to step 3.
• Step 3: Torque the bolts crosswise up to the value mentioned in the table below.
• Mind the parallelism of the sealing.

• Excessive torque will damage the sealing.
DN DN Step 1 Step 2 Step 2 Step 3 Step 3

(mm) (inch) (Nm) (lbfin) (Nm) (lbfin)
20 – 80 2–3 hand tight 50 443 80 708
100 – 300 4 – 12 hand tight 50 443 100 885
350 – 500 14 – 20 hand tight 50 443 130 1551
Do's and don'ts

The supplied compensators are NOT designed:
• to carry the weight of the mounted customer pipe end.
• to work as a damper for unanchored pipe ends.
• to carry the thrust forces of the compressed air.
Therefore, adequate supporting and anchoring of the customer pipe end should be foreseen to avoid
compensator damage.
2920 1815 04 209
Page 4086 of 6229

Instruction book
The compensator loads (Fg and Ft) that are mentioned on the drawing are strictly forbidden:
• Weight loads Fg
• Thrust forces Ft
For the design of piping and supporting structures, use an approved standard code (e.g. EN 13480 or
ASME 16.5/B31.3).
Mind that the connected pipe at customer side does not create any flow restriction
caused by e.g. section reduction.
While installing the compensator, please mind the following check points to avoid sealing damage.
210 2920 1815 04
Page 4087 of 6229

Instruction book
Situation Description
A Flat DIN flanges prevent damage of the rubber sealings.
B Collared flanges prevent premature wear.
C Add a flat sealing or if necessary a metal disc with flat seal in case of damage risk.
D Avoid excessive torque to prevent damage to the bended pipes or the sealings.
Rubber sealings will get damaged when the inner pipe diameter exceeds the inner sealing
E diameter.
F Rough pipe ends will damage the rubber sealing.
G Avoid contact between the pipe end and the rubber sealing.
Refer to the pictures below for a visual overview of 5 do's and don'ts when installing rubber compensators:
• WRONG installation!
2920 1815 04 211
Page 4088 of 6229

Instruction book
• CORRECT installation!
212 2920 1815 04
Page 4089 of 6229

Instruction book

(1) Larger than maximum allowed installation length.
(2) Less than or equal to maximum allowed installation length
(3) Minimum 1 mm of free space
Do NOT:
• Paint the rubber bellows of the expansion joint since:
• Solvents can damage the rubber cover.
• The colored coating avoids decent visual inspection of the rubber condition.
• Weld, cut or grind without protecting the rubber bellows
• Expose the compensator to permanent radiation heat above 90 °C (194 °F)
7.5 Electric cable size, fuses and cable length
General
Local regulations remain applicable if they are stricter than the values proposed below.
The voltage drop must not exceed 10 % of the nominal voltage. It may be necessary to
use cables with a larger size than those stated to comply with this requirement.
IEC compressors
• Cables calculated according to IEC 60364-5-52
• Mounting type: E (Multicore cables in free air)
• Multiple circuit arrangement:
• 4 (Single layer on a perforated horizontal or vertical tray system)
• Use 90 °C (194 °F) cables (Type H07V2-K)
• Cables have to be recalculated if the fuses that are used are bigger than the fuses that are proposed.
CSA/UL compressors
• Cables calculated according to CEC C22.1/NFPA 70
• Multicore cables on perforated tray or ladder system.
• Use 90 °C (194 °F) cables (Type R90, RW90, T90)
• 2 sets of fuses to be placed in series in order to meet the SCCR rating of 65kA (before model year
2014)
• Cables have to be recalculated if the fuses that are used are bigger than the fuses that are proposed.
Abbreviation Description
FLA Full Load Ampacity
MCA Minimum Circuit Ampacity
Icc Rated conditional short circuit current
SCCR Short Circuit Current Rating
2920 1815 04 213
Page 4090 of 6229

Instruction book
380 V - 50 Hz IEC
Compressors designed for a maximum ambient temperature of 40 °C (104 °F) with IE2 motors
Type Cables (H07V2-K) IEC 60364-5-52: Maximum cable

E&4 Fuses gL/gG length
mm2 (A) (m)
ZR/ZT 110 2 x (3x 120 + 70) 2X (3X 250) 247
ZR/ZT 132 2 x (3x 120 + 70) 2X (3X 250) 247
ZR/ZT 145 4 x (3x 95 + 50) 2X (3X 315) 179
ZR/ZT 160 4 x (3x 120 + 70) 2X (3X 400) 175
ZR/ZT 200 4 x (3x 120 + 70) 2X (3X 400) 175
ZR/ZT 250 4 x (3x 150 + 95) 2X (3X 500) 179
ZR/ZT 275 4 x (3x 150 + 95) 2X (3X 500) 179
Type FLA MCA Proposed cable Maximum Proposed Maximum Icc

(mm²) cable fuses (A) fuse (A)
length (m) (gL/gG) (gL/gG)
ZT/ZR 110 239 263 4 X (3 X35+16) 106 2 x(3 X 200) 315 50 kA
ZT/ZR 132 285 314 4 X (3 X70+35) 177 2 x(3 X 250) 315 50 kA
ZT/ZR 145 308 339 2 X (3 X120+70) 245 2 x(3 X 250) 400 50 kA
ZT/ZR 160 371 408 4 X (3 X95+50) 177 2 x(3 X 315) 400 50 kA
ZT/ZR 200 451 496 4 X (3 X 95+50) 177 2 x(3 X 315) 400 50 kA
ZT/ZR 250 566 623 4 X (3 X 120+70) 176 2 x(3 X 400) 500 50 kA
ZT/ZR 275 (7.5 593 652 4 X (3 X 120+70) 176 2 x(3 X 400) 800 50 kA
bar)
ZT/ZR 275 (8.6 703 773 4 X (3 X 150+95) 179 2 x(3 X 500) 500 50 kA
and 10 bar)
FLA and MCA based on an air-cooled full option compressor.

Icc only achieved with recommended fuses.
Type Cables (H07V2-K) IEC 60364-5-52:

E&4 Fuses gL/gG Maximum cable length
mm2 (A) (m)
ZR/ZT 110 2 x (3x 150 + 95) 2X (3X 250) 319
ZR/ZT 132 2 x (3x 150 + 95) 2X (3X 250) 319
ZR/ZT 145 4 x (3x 95 + 50) 2X (3X 315) 179
ZR/ZT 160 4 x (3x 150 + 95) 2X (3X 400) 175
ZR/ZT 200 4 x (3x 150 + 95) 2X (3X 400) 175
ZR/ZT 250 4 x (3x 185 + 95) 2X (3X 500) 179
214 2920 1815 04
Page 4091 of 6229

Instruction book
Compressors designed for a maximum ambient temperature of 50 °C (122 °F) with IE3 motors or
with oversized motors

ZT/ZR 110 264 291 4 X (3 X50+25) 156 2 x(3 X 200) 315 50 kA
ZT/ZR 132 285 314 2 X (3 X150+95) 318 2 x(3 X 250) 400 50 kA
ZT/ZR 145 285 314 2 X (3 X150+95) 318 2 x(3 X 250) 400 50 kA
ZT/ZR 160 409 450 4 X (3 X 95+50) 177 2 x(3 X 315) 400 50 kA
ZT/ZR 200 515 567 4 X (3 X 150+95) 226 2 x(3 X 400) 500 50 kA
ZT/ZR 250 623 686 4 X (3 X 185+95) 207 2 x(3 X 500) 500 50 kA

400 V - 50 Hz IEC

mm2 (A) (m)
ZR/ZT 110 2 x (3x 120 + 70) 2X (3X 250) 260
ZR/ZT 132 2 x (3x 120 + 70) 2X (3X 250) 260
ZR/ZT 145 2 x (3x 120 + 70) 2X (3X 250) 260
ZR/ZT 160 4 x (3x 95 + 50) 2X (3X 315) 188
ZR/ZT 200 4 x (3x 120 + 70) 2X (3X 400) 184
ZR/ZT 250 4 x (3x 120 + 70) 2X (3X 400) 184
ZR/ZT 275 4 x (3x 150 + 95) 2X (3X 500) 188

ZT/ZR 110 228 250 4 X (3 X35+16) 112 2 x(3 X 200) 315 50 kA
ZT/ZR 132 268 295 2 X (3 X95+50) 241 2 x(3 X 200) 315 50 kA
ZT/ZR 145 291 320 2 X (3 X120+70) 258 2 x(3 X 250) 400 50 kA
ZT/ZR 160 353 388 2 X (3 X120+70) 258 2 x(3 X 250) 400 50 kA
ZT/ZR 200 433 477 4 X (3 X 95+50) 187 2 x(3 X 315) 400 50 kA
ZT/ZR 250 531 584 4 X (3 X 120+70) 186 2 x(3 X 400) 500 50 kA
ZT/ZR 275 (7.5 566 622 4 X (3 X 120+70) 186 2 x(3 X 400) 800 50 kA
bar)
ZT/ZR 275 (8.6 659 725 4 X (3 X 150+95) 188 2 x(3 X 500) 500 50 kA
and 10 bar)
2920 1815 04 215
Page 4092 of 6229

Instruction book


mm2 (A) (m)
ZR/ZT 110 2 x (3x 150 + 95) 2X (3X 250) 336
ZR/ZT 132 2 x (3x 150 + 95) 2X (3X 250) 336
ZR/ZT 145 2 x (3x 150 + 95) 2X (3X 250) 336
ZR/ZT 160 4 x (3x 95 + 50) 2X (3X 315) 188
ZR/ZT 200 4 x (3x 150 + 95) 2X (3X 400) 184
ZR/ZT 250 4 x (3x 150 + 95) 2X (3X 400) 184

ZT/ZR 110 248 273 4 X (3 X50+25) 165 2 x(3 X 200) 315 50 kA
ZT/ZR 132 269 296 2 X (3 X120+70) 319 2 x(3 X 200) 400 50 kA
ZT/ZR 145 269 296 2 X (3 X120+70) 319 2 x(3 X 200) 400 50 kA
ZT/ZR 160 393 432 4 X (3 X 95+50) 187 2 x(3 X 315) 400 50 kA
ZT/ZR 200 483 531 4 X (3 X 150+95) 238 2 x(3 X 400) 500 50 kA
ZT/ZR 250 582 640 4 X (3 X 150+95) 238 2 x(3 X 400) 500 50 kA

500 V - 50 Hz IEC

mm2 (A) (m)
ZR/ZT 110 2 x (3x 120 + 70) 2X (3X 250) 325
ZR/ZT 132 2 x (3x 120 + 70) 2X (3X 250) 325
ZR/ZT 145 2 x (3x 120 + 70) 2X (3X 250) 325
ZR/ZT 160 2 x (3x 120 + 70) 2X (3X 250) 325
ZR/ZT 200 4 x (3x 95 + 50) 2X (3X 315) 235
ZR/ZT 250 4 x (3x 120 + 70) 2X (3X 400) 230
ZR/ZT 275 4 x (3x 120 + 70) 2X (3X 400) 230
216 2920 1815 04
Page 4093 of 6229

Instruction book

ZT/ZR 110 184 202 2 X (3 X70+35) 306 2 x(3 X 160) 315 50 kA
ZT/ZR 132 219 240 2 X (3 X70+35) 306 2 x(3 X 160) 315 50 kA
ZT/ZR 145 236 259 4 X (3 X35+16) 140 2 x(3 X 200) 315 50 kA
ZT/ZR 160 285 313 4 X (3 X70+35) 233 2 x(3 X 250) 315 50 kA
ZT/ZR 200 348 383 2 X (3 X120+70) 323 2 x(3 X 250) 400 50 kA
ZT/ZR 250 428 471 4 X (3 X 95+50) 233 2 x(3 X 315) 400 50 kA
ZT/ZR 275 (7.5 469 515 4 X (3 X 95+50) 233 2 x(3 X 315) 500 50 kA
bar)
ZT/ZR 275 (8.6 524 576 4 X (3 X 120+70) 232 2 x(3 X 400) 400 50 kA
and 10 bar)


mm2 (A) (m)
ZR/ZT 110 2 x (3x 150 + 95) 2X (3X 250) 420
ZR/ZT 132 2 x (3x 150 + 95) 2X (3X 250) 420
ZR/ZT 145 2 x (3x 150 + 95) 2X (3X 250) 420
ZR/ZT 160 2 x (3x 150 + 95) 2X (3X 250) 420
ZR/ZT 200 4 x (3x 95 + 50) 2X (3X 315) 235
ZR/ZT 250 4 x (3x 150 + 95) 2X (3X 400) 230

ZT/ZR 110 203 223 2 X (3 X70+35) 306 2 x(3 X 160) 315 50 kA
ZT/ZR 132 218 240 2 X (3 X70+35) 306 2 x(3 X 160) 315 50 kA
ZT/ZR 145 218 240 2 X (3 X70+35) 306 2 x(3 X 160) 315 50 kA
ZT/ZR 160 315 347 2 X (3 X150+95) 419 2 x(3 X 250) 400 50 kA
ZT/ZR 200 389 428 4 X (3 X 95+50) 233 2 x(3 X 315) 400 50 kA
ZT/ZR 250 463 509 4 X (3 X150+95) 297 2 x(3 X 400) 400 50 kA

2920 1815 04 217
Page 4094 of 6229

Instruction book
690 V - 50 Hz IEC

mm2 (A) (m)
ZR/ZT 110 2 x (3x 70 + 35) 2X (3X 160) 421
ZR/ZT 132 2 x (3x 70 + 35) 2X (3X 160) 421
ZR/ZT 145 2 x (3x 120 + 70) 2X (3X 250) 449
ZR/ZT 160 2 x (3x 120 + 70) 2X (3X 250) 449
ZR/ZT 200 4 x (3x 95 + 50) 2X (3X 315) 324
ZR/ZT 250 4 x (3x 95 + 50) 2X (3X 315) 324
ZR/ZT 275 4 x (3x 95 + 50) 2X (3X 315) 324

(mm²) cable fuses (A) fuse(A)
ZT/ZR 110 133 147 2 X (3 X35+16) 292 2 x(3 X 100) 315 50 kA
ZT/ZR 132 159 174 2 X (3 X50+25) 359 2 x(3 X 125) 315 50 kA
ZT/ZR 145 171 188 2 X (3 X50+25) 359 2 x(3 X 125) 315 50 kA
ZT/ZR 160 198 218 2 X (3 X70+35) 423 2 x(3 X 160) 315 50 kA
ZT/ZR 200 245 270 4 X (3 X35+16) 193 2 x(3 X 200) 315 50 kA
ZT/ZR 250 303 333 2 X (3 X120+70) 446 2 x(3 X 250) 400 50 kA
ZT/ZR 275 (7.5 327 360 2 X (3 X120+70) 446 2 x(3 X 250) 500 50 kA
bar)
ZT/ZR 275 (8.6 388 427 4 X (3 X 95+50) 322 2 x(3 X 315) 400 50 kA
and 10 bar)


mm2 (A) (m)
ZR/ZT 110 2 x (3x 70 + 35) 2X (3X 160) 421
ZR/ZT 132 2 x (3x 70 + 35) 2X (3X 160) 421
ZR/ZT 145 2 x (3x 150 + 95) 2X (3X 250) 580
ZR/ZT 160 2 x (3x 150 + 95) 2X (3X 250) 580
ZR/ZT 200 4 x (3x 95 + 50) 2X (3X 315) 324
ZR/ZT 250 4 x (3x 95 + 50) 2X (3X 315) 324
218 2920 1815 04
Page 4095 of 6229

Instruction book

ZT/ZR 110 147 162 2 X (3 X50+25) 359 2 x(3 X 125) 315 50 kA
ZT/ZR 132 159 174 2 X (3 X50+25) 359 2 x(3 X 125) 315 50 kA
ZT/ZR 145 159 174 2 X (3 X50+25) 359 2 x(3 X 125) 315 50 kA
ZT/ZR 160 227 249 2 X (3 X70+35) 423 2 x(3 X 160) 315 50 kA
ZT/ZR 200 280 308 2 X (3 X120+70) 551 2 x(3 X 200) 400 50 kA
ZT/ZR 250 343 377 2 X (3 X150+95) 578 2 x(3 X 250) 400 50 kA

Compressors without starter IEC

Compressors designed for a maximum ambient temperature of 40 °C (104 °F)

mm2 (A) (m)
ZR/ZT 110 3x 16 + 10 3X 80 80
ZR/ZT 132 3x 16 + 10 3X 80 80
ZR/ZT 145 3x 16 + 10 3X 80 80
ZR/ZT 160 3x 16 + 10 3X 80 80
ZR/ZT 200 3x 16 + 10 3X 80 80
ZR/ZT 250 3x 16 + 10 3X 80 80
ZR/ZT 275 3x 16 + 10 3X 80 80
Compressors designed for a maximum ambient temperature of 50 °C (122 °F)

mm2 (A) (m)
ZR/ZT 110 3x 25 + 16 3X 80 125
ZR/ZT 132 3x 25 + 16 3X 80 125
ZR/ZT 145 3x 25 + 16 3X 80 125
ZR/ZT 160 3x 25 + 16 3X 80 125
ZR/ZT 200 3x 25 + 16 3X 80 125
ZR/ZT 250 3x 25 + 16 3X 80 125
2920 1815 04 219
Page 4096 of 6229

Instruction book
380 V - 60 Hz IEC
Compressors designed for a maximum ambient temperature of 104 °F (40 °C) with IE2 motors

mm2 (A) (m)
ZR/ZT 110 2 x (3x 120 + 70) 2X (3X 250) 247
ZR/ZT 145 4 x (3x 95 + 50) 2X (3X 315) 179
ZR/ZT 160 4 x (3x 120 + 70) 2X (3X 400) 175
ZR/ZT 200 4 x (3x 120 + 70) 2X (3X 400) 175
ZR/ZT 250 4 x (3x 120 + 70) 2X (3X 400) 175
ZR/ZT 275 4 x (3x 150 + 95) 2X (3X 500) 179

ZT/ZR 110 259 285 4 X (3 X 35+16) 106 2 x(3 X 200) 315 50 kA
ZT/ZR 145 339 373 2 X (3 X 120+70) 245 2 x(3 X 250) 400 50 kA
ZT/ZR 160 363 399 4 X (3 X 95+50) 177 2 x(3 X 315) 400 50 kA
ZT/ZR 200 441 485 2 X (3 X 185+95) 258 2 x(3 X 315) 500 50 kA
ZT/ZR 250 513 564 4 X (3 X 120+70) 176 2 x(3 X 400) 500 50 kA
ZT/ZR 275 655 720 4 X (3 X 150+95) 179 2 x(3 X 500) 500 50 kA


mm2 (A) (m)
ZR/ZT 110 2 x (3x 150 + 95) 2X (3X 250) 319
ZR/ZT 145 4 x (3x 95 + 50) 2X (3X 315) 179
ZR/ZT 160 4 x (3x 150 + 95) 2X (3X 400) 175
ZR/ZT 200 4 x (3x 150 + 95) 2X (3X 400) 175
ZR/ZT 250 4 x (3x 150 + 95) 2X (3X 400) 175
220 2920 1815 04
Page 4097 of 6229

Instruction book
Compressors designed for a maximum ambient temperature of 122 °F (50 °C) with IE3 motors or

ZT/ZR 110 312 344 2 X (3 X150+95) 318 2 x(3 X 250) 400 50 kA
ZT/ZR 145 312 344 2X (3 X150+95) 318 2 x(3 X 250) 400 50 kA
ZT/ZR 160 398 438 4 X (3 X 95+50) 177 2 x(3 X 315) 500 50 kA
ZT/ZR 200 464 511 4 X (3 X 150+95) 226 2 x(3 X 400) 500 50 kA
ZT/ZR 250 574 632 4 X (3 X 150+95) 226 2 x(3 X 400) 500 50 kA

440 V - 60 Hz IEC

mm2 (A) (m)
ZR/ZT 110 2 x (3x 120 + 70) 2X (3X 250) 286
ZR/ZT 145 2 x (3x 120 + 70) 2X (3X 250) 286
ZR/ZT 160 4 x (3x 95 + 50) 2X (3X 315) 207
ZR/ZT 200 4 x (3x 120 + 70) 2X (3X 400) 202
ZR/ZT 250 4 x (3x 120 + 70) 2X (3X 400) 202
ZR/ZT 275 4 x (3x 120 + 70) 2X (3X 400) 202

ZT/ZR 110 221 243 2 X (3 X70+35) 269 2 x(3 X 160) 315 50 kA
ZT/ZR 145 285 313 4 X (3 X70+35) 205 2 x(3 X 250) 315 50 kA
ZT/ZR 160 311 342 4 X (3 X70+35) 205 2 x(3 X 250) 315 50 kA
ZT/ZR 200 377 414 4 X (3 X95+50) 205 2 x(3 X 315) 400 50 kA
ZT/ZR 250 437 480 2 X (3 X185+95) 299 2 x(3 X 315) 500 50 kA
ZT/ZR 275 564 620 4 X (3 X 120+70) 204 2 x(3 X 400) 500 50 kA

2920 1815 04 221
Page 4098 of 6229

Instruction book

mm2 (A) (m)
ZR/ZT 110 2 x (3x 150 + 95) 2X (3X 250) 370
ZR/ZT 145 2 x (3x 150 + 95) 2X (3X 250) 370
ZR/ZT 160 4 x (3x 95 + 50) 2X (3X 315) 207
ZR/ZT 200 4 x (3x 150 + 95) 2X (3X 400) 202
ZR/ZT 250 4 x (3x 150 + 95) 2X (3X 400) 202

ZT/ZR 110 262 289 4 X (3 X 50+25) 181 2 x(3 X 200) 315 50 kA
ZT/ZR 145 262 289 4 X (3 X 50+25) 181 2 x(3 X 200) 315 50 kA
ZT/ZR 160 340 374 4 X (3 X 70+35) 205 2 x(3 X 250) 400 50 kA
ZT/ZR 200 395 434 4 X (3 X 95+50) 205 2 x(3 X 315) 500 50 kA
ZT/ZR 250 495 545 4 X (3 X 150+95) 261 2 x(3 X 400) 500 50 kA

460 V - 60 Hz CSA/UL
Type Fuses LPJ Maximum cable

Cables (90° cable) CEC Fuses RK5 (A) length
C22.1 (A) (m)
2 x (3x MCM 250 + AWG
ZR/ZT 110 3) 2X (3X 175) 2X (3X 600) 193
ZR/ZT 145 4 x (3xAWG 000 + AWG 2) 2X (3X 250) 2X (3X 600) 120
Type FLA MCA Proposed cable Maximum Proposed Maximum SCCR

length (m) (LPJ) (LPJ)
ZT/ZR 110 211 233 2 X (3 X00+4AWG) 180 2 x(3 X 600 65 kA
150)
222 2920 1815 04
Page 4099 of 6229

Instruction book

ZT/ZR 145 273 300 2 X (3 X0000+2AWG) 208 2 x(3 X 600 65 kA
200)
ZT/ZR 160 305 336 2 X (3 X0000+2AWG) 183 2 x(3 X 600 65 kA
225)
ZT/ZR 200 365 402 2 X (3 X 300MCM 149 2 x(3 X 600 65 kA
+2AWG) 300)
ZT/ZR 250 425 468 4 X (3 X 00+4AWG) 121 2 x(3 X 600 65 kA
300)
ZT/ZR 275 502 552 4 X (3 X 000+4AWG) 114 2 x(3 X 600 65 kA
350)

SCCR only achieved with recommended fuses.

C22.1 (A) (m)
2 x (3x MCM 300 + AWG
ZR/ZT 110 3) 2X (3X 175) 2X (3X 600) 202
4 x (3x AWG 0000 + AWG
ZR/ZT 145 2) 2X (3X 250) 2X (3X 600) 133
4 x (3x AWG 0000 + AWG
ZR/ZT 160 2) 2X (3X 250) 2X (3X 600) 133
4 x (3x MCM 300 + AWG
ZR/ZT 200 0) 2X (3X 300) 2X (3X 600) 207
4 x (3x MCM 350 + AWG
ZR/ZT 250 0) 2X (3X 350) 2X (3X 600) 152

ZT/ZR 110 252 277 2 X (3 X250MCM 256 2 x(3 X 175) 600 65 kA
+2AWG)
ZT/ZR 145 252 277 2 X (3 X250MCM 256 2 x(3 X 175) 600 65 kA
+2AWG)
ZT/ZR 160 329 362 4 X (3 X 0+6AWG) 114 2 x(3 X 225) 600 65 kA
ZT/ZR 200 384 423 4 X (3 X 00+4AWG) 121 2 x(3 X 300) 600 65 kA
ZT/ZR 250 440 484 4 X (3 X 158 2 x(3 X 350) 600 65 kA
0000+2AWG)
2920 1815 04 223
Page 4100 of 6229

Instruction book
575 V - 60 Hz CSA/UL

C22.1 (A) (m)
2 x (3x MCM 300 + AWG
ZR/ZT 145 3) 2X (3X 200) 2X (3X 600) 253
2 x (3x MCM 300 + AWG
ZR/ZT 160 3) 2X (3X 200) 2X (3X 600) 253

ZT/ZR 110 170 187 2 X (3 X1AWG 161 2 x(3 X 600 65 kA
+6AWG) 125)
ZT/ZR 145 221 243 2 X (3 X000+4AWG) 208 2 x(3 X 600 65 kA
175)
ZT/ZR 160 245 269 4 X (3 X3AWG 108 2 x(3 X 600 65 kA
+8AWG) 175)
ZT/ZR 200 294 323 2 X (3 X0000+2AWG) 260 2 x(3 X 600 65 kA
200)
ZT/ZR 250 336 369 2 X (3 X 250MCM 243 2 x(3 X 600 65 kA
+2AWG) 225)
ZT/ZR 275 401 441 2 X (3 X 300MCM 186 2 x(3 X 600 65 kA
+2AWG) 300)

224 2920 1815 04
Page 4101 of 6229

Instruction book
Compressors designed for a maximum ambient temperature of 122 °F (50 °C) for IE2 motors

C22.1 (A) (m)
2 x (3x AWG 0000 + AWG
ZR/ZT 110 4) 2X (3X 150) 2X (3X 600) 190
2 x (3x MCM 350 + AWG
ZR/ZT 145 3) 2X (3X 200) 2X (3X 600) 265
2 x (3x MCM 350 + AWG
ZR/ZT 160 3) 2X (3X 200) 2X (3X 600) 265
4 x (3x AWG 0000 + AWG
ZR/ZT 200 2) 2X (3X 250) 2X (3X 600) 167
4 x (3x MCM 300 + AWG
ZR/ZT 250 0) 2X (3X 300) 2X (3X 600) 259

ZT/ZR 110 203 224 4 X (3 X3AWG 128 2 x(3 X 150) 600 65 kA
+8AWG)
ZT/ZR 145 203 224 4 X (3 X3AWG 128 2 x(3 X 150) 600 65 kA
+8AWG)
ZT/ZR 160 265 291 2 X (3 X250CM 277 2 x(3 X 200) 600 65 kA
+2AWG)
ZT/ZR 200 303 334 2 X (3 X 300MCM 259 2 x(3 X 225) 600 65 kA
+2AWG)
ZT/ZR 250 351 386 4 X (3 X 00+4AWG) 151 2 x(3 X 300) 600 65 kA

Compressors without starter CSA/UL

Compressors designed for a maximum ambient temperature of 104 °F (40 °C)

C22.1 (A) (m)
ZR/ZT 110 3x AWG 4 + AWG8 2X (3X 60) 2X (3X 175) 156
2920 1815 04 225
Page 4102 of 6229

Instruction book
Compressors designed for a maximum ambient temperature of 122 °F (50 °C)

C22.1 (A) (m)
Compressors with medium-voltage and high-voltage motors

When the compressor is equipped with a medium- or high-voltage motor, the electrical cubicle should be
supplied separately with cable sections mentioned below.
• ZT-ZR 110-275 (except ZT 275 FF + Low Load option): 2.5 mm2
• ZT 275 FF with Low Load option: 4 mm2
For compressors with a medium-voltage or high-voltage motor, take into account the information on the
motor data plate and the ambient temperature plus 5 K to select the cable size of the drive motor supply.
Apply the local regulations for the cable size and cable specifications.
Compressors delivered without drive motor

When the compressor is delivered without a drive motor, the electrical cubicle should be supplied
separately with cable sections mentioned below.
• ZT-ZR 110-275 (except ZT 275 FF + Low Load option): 2.5 mm2
• ZT 275 FF with Low Load option: 4 mm2
When selecting the cable size of the drive motor supply, take into account the information on the customer
motor data plate and the ambient temperature plus 5 K. Apply the local regulations for the cable size and
cable specifications.
7.6 Electric connection
Attention
For the selection of the correct cables, refer to: Electric cable size, fuses and cable
length .
226 2920 1815 04
Page 4103 of 6229

Instruction book
Electric connections
Electric connections for compressors with star-delta starter (Model year 2003)
2920 1815 04 227
Page 4104 of 6229

Instruction book
Electric connections for compressors with star-delta starter (Model year 2014)
228 2920 1815 04
Page 4105 of 6229

Instruction book
Electric connections for compressors without a starter (Model year 2003)
2920 1815 04 229
Page 4106 of 6229

Instruction book
Electric connections for compressors without a starter (Model year 2014)
Text on figures
Reference Text on figure

(1) Customer’s installation
(2) K21, K23 larger than or equal to 56 with 6 type “2” fuses
(3) K21, K23 larger than or equal to 56 with 3 type “1” fuses
(4) K21, K23 smaller than 56 with 3 type “2” fuses
(5) Compressor motor
(6) Fan motor, dryer, not for ZR compressors
(7) Fan motor, not for ZR compressors
(8) Fan motor, only for units without compressor motor
(9) To be installed by the customer
(10) Dryer heater
(11) Connection only to be made for CSA/UL
(12) Fan motor in motor hood of ZR/ZT without a motor
(13) Wound anti-clockwise low-pressure side
(14) Wound anti-clockwise high-pressure side
(15) Main motor
230 2920 1815 04
Page 4107 of 6229

Instruction book
Reference Text on figure

(16) Extra set of fuses for CSA/UL certified compressors
(17) Customer's motor starter
(18) Separate low voltage supply or transformer
(19) For compressors with motor supply voltage > 690 V
7.7 Quality of safety components

When installing a remote emergency button or a motor contactor, the following B10d values are advised:
• Emergency stop button: 500 000
• Main contactor: 933 333
7.8 Cooling water requirements
Recommendations
The cooling water quality must meet certain minimum requirements.
No general recommendation can encompass the effects of all combinations of the various compounds,
solids and gases typically found in cooling water in interaction with different materials.
Only non-treated water must be used.
This recommendation is a general guide line for acceptable coolant quality.
Type of system
It is important to define the used cooling water system:
• an open system
• a closed system
In a closed system, the same cooling water circulates through a system without contact with air.
An open system is a pass-through system, or a circulating system with a cooling tower. In the latter case,
the composition of the water that enters the compressor must be considered, and not the composition of the
make-up water. Due to the evaporative effect in the cooling tower, much higher concentrations of ions can
be obtained in the circulating water than in the make-up water.
Ryznar Stability Index (RSI)

The Ryznar Stability Index (RSI) is a parameter for predicting whether water will tend to dissolve or
precipitate calcium carbonate. The adhesion of scaling deposits and their effect are different on different
materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value
and by the saturation pH value (pHs).
The saturation pH value is determined by the relationship between the calcium hardness, the total
alkalinity, the total solids concentration and the temperature.
The Ryznar Stability Index is calculated as follows :
RSI = 2*pHs - pH
2920 1815 04 231
Page 4108 of 6229

Instruction book
Symbol Explanation
pH Measured pH (at room temperature) of water sample
pHs pH at saturation
The pHs is calculated by using :

pHs = (9.3 + A + B) - (C + D)
Symbol Explanation
A Depends on the total solids concentration (mg/l)
B Depends on the highest cooling water temperature (˚C/˚F), (T=65 ˚C/149 ˚F)
C Depends on the calcium hardness (ppm CaCO3)
D Depends on the HCO3- concentration or M-alkalinity (mval/l)
The values of A, B, C and D can be found in the following table.
Total dissolved A Temperature B Ca-hardness (ppm C M-alkalinity (mval/l) D

solids (mg/l) (˚C) CaCO3)
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
Interpretation of the value obtained
RSI Water condition Action

RSI<3.9 Very high scale formation Water cannot be used.
232 2920 1815 04
Page 4109 of 6229

Instruction book
RSI Water condition Action

4.0<RSI<5.5 High boiler scale formation Regular inspection 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 Water treatment not necessary.
temperature Occasional inspection recommended.
7.6<RSI<9.0 Strong corrosion Regular inspection necessary, use of corrosion
inhibitor recommended.
9.1<RSI<11 Very strong corrosion Regular inspection necessary, use of corrosion
inhibitor required.
RSI>11 Very strong corrosion in Water should not be used.
complete water system
The table indicates that distilled or demineralized water should never be used, as their RSI is > 11.
The RSI only indicates the equilibrium of scaling - descaling. A cooling water showing good RSI
conditions can still be unsuitable due to other factors.
From the table above, the RSI index should be between 5.6 and 7.5; if not, consult your local Atlas Copco
Customer Centre.
pH
The effect of pH is already calculated in the Ryznar index, but the pH itself has some additional
limitations : 6.8 < pH < 8.5
Total Dissolved Solids (TDS)

This is the sum of all the ions in the water. It can be derived from the dry residue after evaporation (but not
including suspended solids), or it can be estimated from the electrical conductivity.
In a closed system, the following limits apply : TDS < 3000 mg/l (< 3800 microS/cm)
For an open system, the following limits apply : TDS < 750 mg/l ( < 960 microS/cm)
Chlorides (Cl-)
Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited:
Closed cooling system : chlorides < 500 ppm
Open cooling system : chlorides < 150 ppm
However, if the water is scaling, lower limits should be used. (See The Ryznar stability index (RSI)).
Free chlorine (Cl2)

A level of 0.5 ppm should not be exceeded for long periods.
For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies.
2920 1815 04 233
Page 4110 of 6229

Instruction book
Sulphates (SO4--)
Closed cooling system : sulphates < 400 ppm
Open cooling system : sulphates < 150 ppm
Carbonate hardness
Closed cooling system : 50-1000 ppm CaCO3
Open cooling system : 50-500 ppm CaCO3
HCO3- / SO42- should be > 1
Ammonia
< 0.5 ppm
Copper
< 1 ppm
Iron and manganese

< 1 ppm
Organics
No algae
No oil
Suspended solids
Non-soluble particles, size < 1 mm.
< 10 ppm
7.9 General pictographs
Pictographs
Reference Name
1 Condensate valve, intercooler
2 Automatic condensate outlet, intercooler
3 Automatic condensate outlet, aftercooler
234 2920 1815 04
Page 4111 of 6229

Instruction book
Reference Name
4 Condensate valve, aftercooler
5 Warning: under tension
6 Read Instruction manual before starting the compressor
7 Switch off the voltage and depressurize the compressor before maintenance or repair
8 Before connecting the compressor electrically, consult the Instruction manual for the
motor rotation direction
9 Torques for steel (Fe) or brass (CuZn) bolts
10 Consult the Instruction manual before greasing
11 Switch off the voltage before removing the protecting cover inside the electric cabinet
12 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)
13 Consult the Instruction manual before maintenance or repair
14 Cooling water outlet
15 Cooling water inlet
7.10 Pictographs, Elektronikon control system
Control panel of Elektronikon Controller
Reference Name
1 Start
2 Stop
3 Automatic operation
4 Alarm
5 Voltage on
6 Emergency stop
7 Key to go to next field on display
8 Keys to scroll through display
2920 1815 04 235
Page 4112 of 6229

Instruction book
Control panel of Elektronikon GraphicPlus Controller
Reference Name
1 Alarm
2 Service
3 Automatic operation
4 Voltage on
5 Enter
6 Escape
7 Scroll keys
8 Stop
9 Start
236 2920 1815 04
Page 4113 of 6229

Instruction book
8 Operating instructions
8.1 Initial start-up
Safety precautions
The operator must apply all relevant Safety precautions.
Ambient conditions / altitude opeartion

Refer to Limitations for the limits of ambient conditions and altitude operation. If the compressor is
operated beyond these limits, precautions must be taken. If this is the case, consult your Atlas Copco
Customer Center.
Moving/lifting
In order not to damage the frame, the compressor must be moved either by a lift truck or by using lifting
equipment as described below.
When moving the compressor with a lift truck, use the slots in the frame. Make sure that the forks protrude
from the other side of the frame. When moving the compressor with a lifting device, insert beams in the
slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The chains
must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. The
lifting equipment must be placed in such a way that the compressor is lifted perpendicularly. Lift gently
and avoid twisting.
General preparation
Make sure that the compressor is installed correctly.
See Dimension drawing, Installation proposal and Electric cable size, fuses and cable length.
A sticker summarizing the operating instructions is delivered with the compressor. Affix the sticker next to
the control panel.
A number of VCI (Volatile Corrosion Inhibitor) plates are available inside the bodywork to protect the
compressor against corrosion during transport. Remove these plates.
Protection during transport

The compressor and motor are secured to the frame, immobilizing the vibration dampers during transport.
All transport fixtures are painted red and must be removed.
2920 1815 04 237
Page 4114 of 6229

Instruction book
Transport fixtures on the motor side in ZR/ZT 110 up to ZR/ZT 275
On the motor side, the dampers are secured by means of bolts/spacers. Remove the bolts and spacers (1 and
2).
Transport fixtures on the gear casing side in ZR/ZT 110 up to ZR/ZT 275
On ZR/ZT 110 up to ZR/ZT 275, a transport support (1) is fitted to the gear casing. Remove the support.
238 2920 1815 04
Page 4115 of 6229

Instruction book
Transport fixtures on subframe of Arr. 1
Transport fixtures on subframe of Arr. 1
The subframe (2) of Arr. 1 units is secured by means of bolts/spacers (1). These must be removed.
2920 1815 04 239
Page 4116 of 6229

Instruction book
Silica gel bags
Position of silica gel bags on ZR 110 up to ZR 145
Position of silica gel bags on ZT 110 up to ZT 145
240 2920 1815 04
Page 4117 of 6229

Instruction book
Position of silica gel bags on ZT 160 up to ZT 275
Position of silica gel bags on ZR 160 up to ZR 275
Remove flange (1) and take out the silica gel bags. Refit the flange.
2920 1815 04 241
Page 4118 of 6229

Instruction book
Tightening the tie rods on ZT compressors
Before initial start-up, the tie rods must be tightened. Proceed as follows:
• Check that all transport fixtures are removed
• Check that the compressor is pressureless
• Tighten the nuts of tie rods (1) by hand
• Tighten the check nuts
Water circuit of ZR compressors
Water drain plug, HP element of ZR 110 up to 275
242 2920 1815 04
Page 4119 of 6229

Instruction book
Water drain plug, LP element of ZR 110 up to 275
Water drain plugs, coolers of ZR 110 up to 275
Water drain plugs, cooler block of ZR 110 up to 275
2920 1815 04 243
Page 4120 of 6229

Instruction book
Step Action
1 Fit the water drain plugs (DP2 up to DP6) that are attached to the water pipe of one of
the compressor elements (El and Eh) in a plastic bag. The plugs are painted green and
their positions are shown on the illustrations above.
2 Check that the cooling water drain valves (customer's installation) in the inlet and outlet
lines are closed.
3 Open the water inlet valve and outlet valve (customer's installation) and check for water
flow.
4 Check the water flow.
Oil circuit
Position of oil level sight-glass on ZR 110 up to ZR 275
244 2920 1815 04
Page 4121 of 6229

Instruction book
Position of oil level sight-glass on ZT 110 up to ZT 275
Check that oil is visible in sight-glass (SG).
2920 1815 04 245
Page 4122 of 6229

Instruction book
Start-up
Electric cabinet of compressor with starter (Model year 2003)
246 2920 1815 04
Page 4123 of 6229

Instruction book
Electric cabinet of compressor with starter (Model year 2014)
2920 1815 04 247
Page 4124 of 6229

Instruction book
Electric cabinet of compressor without starter(Model year 2003)
248 2920 1815 04
Page 4125 of 6229

Instruction book
Electric cabinet of compressor without starter(Model year 2014)
1. Check that the voltage selecting wires on transformer T1 are connected correctly. An instruction label
is provided.
2. Check that the electrical installation meets local regulations.
3. On compressors with a starter, check the overload relay setting (F21) and check that the relay is set
for automatic resetting.
See Settings for overload relay.
Switch on the voltage.
4. Check that the gear casing is filled with oil.
5. Start the motor and stop it immediately.
6. Check that the direction of rotation is correct (as indicated by the arrow): anti-clockwise looking at
the motor drive shaft (there may also be an arrow on the coupling housing). A grating through which
the coupling can be observed is fitted. If the direction of rotation is wrong, switch off the voltage and
reverse two electric inlet connections.
7. Run the compressor for a few minutes.
8. Stop the compressor and check the oil level.
On ZR/ZT 110 up to ZR/ZT 275, the oil level after stopping must be in the middle of the sight-glass
(in the case of longer standstill, the oil level in the sight-glass may increase).
2920 1815 04 249
Page 4126 of 6229

Instruction book
Top up, if necessary, with the correct type of oil.
Adjustment of mix-air (for ZR/ZT 110 up to ZR/ZT 145 Full-Feature compressors)
Only for 13 bar (190 psi) Full-Feature compressors or 10 bar (145 psi) and 10.4 bar (150
psi) Full-Feature compressors designed for an ambient temperature of up to 50 ˚C (122 ˚F)
If, due to changes of the ambient temperature, the Elektronikon regulator shows a warning
for the regeneration air temperature, the mix-air must be readjusted.
On most ZT compressors, the shut-off valve (1) is located in the cooler compartment and
the regulating valve (2) is located in the compressor compartment. The safety grating must
be fitted again and the door of the cooler compartment must be closed before starting the
compressor.
The operator must wear heat-resistant gloves and shirts with long sleeves before executing
below adjustments.
Mix-air regulation valves, ZR compressors
250 2920 1815 04
Page 4127 of 6229

Instruction book
Mix-air regulation valves, ZT compressors
1. On ZR compressors, open shut-off valve (1) completely and close regulation valve (2).
2. On ZT compressors, remove the safety grating. Open shut-off valve (1) completely, mount the safety
grating again and close the door of the cooler compartment. Close regulation valve (2).
3. Start and load the compressor.
4. Adjust the pressure difference of the dryer compartments as described below.
5. Call up the regeneration air inlet temperature in the Inputs menu of the Elektronikon regulator. Open
regulating valve (2) until the display of the Elektronikon regulator shows a value between 180 ˚C
(356 ˚F) and 190 ˚C (374 ˚F).
6. Check the pressure difference between the dryer compartments again. If necessary, repeat the
previous steps.
Adjustment of the pressure difference of the dryer compartments on Full-Feature

compressors(for ZR/ZT 110 up to ZR/ZT 145)
Always wear heat-resistant gloves and long-sleeved shirts when carrying out the
instructions below.
2920 1815 04 251
Page 4128 of 6229

Instruction book
Dryer components, ZR Full-Feature
Position of throttle valve on the regeneration air inlet of the dryer on ZT Full-Feature
252 2920 1815 04
Page 4129 of 6229

Instruction book
Position of dryer inlet, outlet and by-pass valves on ZT Full-Feature
Step Action
1 Close valves (1, Vd- and Vd+).
2920 1815 04 253
Page 4130 of 6229

Instruction book
Step Action
2 On compressors equipped with a PDP sensor, close the valve to this sensor. If the
compressor runs with the dryer by-passed without closing the valve to the PDP sensor,
the sensor will be damaged.
Close the dryer inlet and outlet valves (Vdi and Vdo) and open the dryer by-pass valve
(Vdb).
3 Start and load the compressor.
4 Open the dryer inlet valve (Vdi) slightly to pressurize the dryer.
5 Open the regeneration air valve (Vr) fully. Open the air outlet valve (Vdo) and close the
by-pass valve (Vdb).
6 Open valves (1 and Vd-). Open valve (Vd+) slightly, while monitoring the water levels in
the U-tube.
There are two possible conditions:
• The water level in the leg marked (+) rises. Close valve (Vd+) at once, decrease
the regeneration air inlet pressure (see step 7). Do this as often as necessary until
the water level drops.
• The water level in the leg marked (-) rises, which should normally be the case. If
the level in this leg rises 30 mm above the level in the leg marked (+), close valve
(Vd+) at once, as there is a risk that the water will escape the U-tube and
disappear into the pressure vessel. Increase the regeneration air inlet pressure
(see step 7) and open valve (Vd+) again.
7 Once the water column has stabilized, adjust the pressure differential as follows:
• Remove the protective cap from the adjusting screw of throttle valve (Rf).
• Loosen its check nut and turn the screw inwards to increase or outwards to
decrease the pressure differential.
• The water level in the leg marked (-) must be between 20 and 40 mm above that in
the leg marked (+).
• Monitor the water level for about 10 minutes.
• Tighten the check nut and reinstall the protective cap.
• Check that the moisture indicator is blue after approximately 30 minutes of
operation. If the moisture indicator is still pink after 2 hours of operation, the
pressure dewpoint is too high.
8 Stop the compressor.
Adjustments for Full-Feature compressors for ZR/ZT 160 up 275
Always wear heat-resistant gloves and long-sleeved shirts when carrying out the
instructions below.
254 2920 1815 04
Page 4131 of 6229

Instruction book
Regulation valves for ZR Full-Feature compressors without dryer by-pass
2920 1815 04 255
Page 4132 of 6229

Instruction book
Regulation valves for ZR Full-Feature compressors with dryer by-pass
256 2920 1815 04
Page 4133 of 6229

Instruction book
Regulation valves for ZR Full-Feature compressors without dryer by-pass
2920 1815 04 257
Page 4134 of 6229

Instruction book
Regulation valves for ZR Full-Feature compressors with dryer by-pass
258 2920 1815 04
Page 4135 of 6229

Instruction book
Regulation valves for ZT Full-Feature compressors without dryer by-pass
2920 1815 04 259
Page 4136 of 6229

Instruction book
Regulation valves for ZT Full-Feature compressors with dryer by-pass
1. On Full-Feature compressors without dryer by-pass, close regulation valve (1). On Full-Feature
compressors with dryer by-pass, open shut-off valve (2) and close regulation valve (1). Open the
dryer inlet and outlet valves (Vdi and Vdo) and close the dryer by-pass valve (Vdb).
2. Start the compressor and wait (for at least 5 minutes) until the compressor temperatures are stable
(after running loaded at maximum speed).
3. Adjust the Nozzle Fraction (the ratio of dried air and regeneration air):
• Scrolling to the Test screen of the Elektronikon.
• Select Modify - Enter - Tuning Throttle Valve - Enter.
260 2920 1815 04
Page 4137 of 6229

Instruction book
• Adjust the regulation valve setting at nominal pressure of the compressor (e.g. 7.0 bar) so that
the value of Nozzle Fraction is equal to the value between brackets for at least 5 minutes: NF =
40% +/-1%.
4. Lock the regulation valve.
5. Go to the main Elektronikon screen by pushing X repeatedly.
8.2 Before starting
The operator must apply all relevant Safety precautions.

If the water system has been drained, close the drain valves and fit the drain plugs or
pipe.
See section Stopping
The number of motor starts is programmed at maximum 3 per day.
To modify this setting, consult sections Modify parameters.
Oil level
Oil system components, ZR 110 up to ZR 275
2920 1815 04 261
Page 4138 of 6229

Instruction book
Oil system components, ZT 110 up to ZT 275
On ZR/ZT 110 up to ZR/ZT 275, the oil level must be in the middle of the sight-glass (SG) after stopping
(in the case of longer standstill, the oil level may increase in the sight-glass).
Top up, if necessary, with the correct type of oil.
262 2920 1815 04
Page 4139 of 6229

Instruction book
Condensate drains
Drain connections on ZR 110 up to ZR 145
Drain connections on ZR 160 Pack up to ZR 275 Pack
2920 1815 04 263
Page 4140 of 6229

Instruction book
Drain connections on ZR 160 Full-Feature up to ZR 275 Full-Feature
264 2920 1815 04
Page 4141 of 6229

Instruction book
Drain connections on ZT 110 up to ZT 275
AO Compressed air outlet
Daa Automatic drain, aftercooler
Dad Automatic drain, dryer inlet
Daea Automatic drain, extra aftercooler (for Energy Recovery option only)
Dai Automatic drain, intercooler
Dall Automatic drain, optional low load dryer
Dar1 Automatic drain, regeneration outlet
Dar2 Automatic drain, regeneration outlet
E Electrical cable for optional water shut-off valve
WI Water inlet
WO Water outlet
Open the water inlet valve and outlet valve (customer's installation).
On ZR compressors, opening of the water outlet valve can be overlooked if, after
previous operation, the setting of this valve has not been disturbed.
2920 1815 04 265
Page 4142 of 6229

Instruction book
8.3 Routine starting
Control panel
Control panel of Elektronikon controller
Procedure
Step Action
1 Open the air outlet valve (customer's installation).
2 Switch on the voltage and check that voltage on LED (6) lights up.
3 Press start button (1). The compressor starts running in unloaded condition and
automatic operation LED (8) lights up.
4 Approx. 25 seconds later (programmable), the compressor starts running loaded. The
message on display (2) changes from “Automatically unloaded” to “Automatically
loaded”.
5 On ZR compressors, regulate the water flow with the compressor running loaded.
See section Readings for the cooling water temperature.

See section Compressor data for the cooling water consumption.
If the motor is stopped and automatic operation LED (8) is alight, the motor may start
automatically.
If the start/stop timer is active, the compressor can start automatically, even if it was
stopped manually.
266 2920 1815 04
Page 4143 of 6229

Instruction book
Control panel
Control panel of Elektronikon GraphicPlus controller
2920 1815 04 267
Page 4144 of 6229

Instruction book
Procedure
Step Action
1 Open the air outlet valve (customer's installation).
2 Switch on the voltage and check that voltage on LED (8) lights up.
3 Press start button (14). The compressor starts running in unloaded condition and
automatic operation LED (7) lights up.
4 Approx. 25 seconds later (programmable), the compressor starts running loaded.
5 On ZR compressors, regulate the water flow with the compressor running loaded and
the thermostatic valve completely open (the latter is valid for energy recovery units). The
aim is to obtain a cooling water temperature rise over the complete compressor unit of
15 K (in case of Pack compressors) and 10 K (in case of Full-Feature compressors). In
case of Full-Feature compressors, also the water flow over the integrated dryer is to be
regulated: a cooling water temperature rise over the dryer of 5 K is to be achieved. For
compressors without energy recovery, this is done by using the ball valve (1) inside the
compressor.
For compressors with energy recovery, a separate fresh cooling water circuit over the
dryer is foreseen and to be regulated to 5 K.
268 2920 1815 04
Page 4145 of 6229

Instruction book
See section Readings for the cooling water temperature.

See section Compressor data for the cooling water consumption.
The operator must apply all relevant safety precautions.

If the motor is stopped and automatic operation LED (7) is alight, the motor may start
automatically.
If the start/stop timer is active, the compressor can start automatically, even if it was
stopped manually.
8.4 Starting after emergency stop or shutdown
Control panel
Procedure
Step Action
1 Press the emergency stop button (S2) (if not yet done so).
2 Switch off the voltage and then depressurize the compressor.
3 Remedy the fault.
4 Unlock the emergency stop button by pulling it out.
5 Restart the compressor. See Routine starting.
If the automatic restart function after voltage failure is activated and the duration of
repair is shorter than the programmed power recovery time, reset the display after
remedying the fault. Press the key “Reset”; the message “All protection functions are
OK” will appear, whereupon the compressor can be restarted. Press the keys “Menu”
and “Main Screen” to return to the main display.
2920 1815 04 269
Page 4146 of 6229

Instruction book
Control panel
Procedure
Step Action
1 Press the emergency stop button (if not yet done).
2 Switch off the voltage and then depressurize the compressor.
3 Remedy the fault.
4 Unlock the emergency stop button by pulling it back.
5 Reset the protection warning in the Elektronikon controller.
6 Restart the compressor. Check the section Routine starting.
If the automatic restart function after voltage failure is activated and the duration of
repair is shorter than the programmed power recovery time, reset the display after
remedying the fault. Press the key “Reset”; the message “All protection functions are
OK” will appear, whereupon the compressor can be restarted. Press the keys “Menu”
and “Main Screen” to return to the main display.
Minimum stop time

The compressor will not be allowed to restart within a programmed time (20 s) after a stop for any reason
at all. A start command given during the minimum stop time will be memorized; automatic operation LED
(8) lights up. The compressor will start when the minimum stop time has run out.
Manual restart
In automatic operation, the regulator limits the number of motor starts.
270 2920 1815 04
Page 4147 of 6229

Instruction book
On compressors with a low-voltage motor, observe a minimum interval of 20 minutes between two manual
starts.
On compressors with a medium-voltage or high-voltage motor, the number of motor starts is limited to 3
starts per day.
8.5 During operation
Control panel
Procedure
When automatic operation LED (8) is alight, starting and stopping of the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
Step Action
1 Check the readings on display (2).
2 When reaching the preset unloading pressure, shown on display (2), the compressor will
start running unloaded. From now on, the electronic control module will calculate the
optimum moment to stop and restart the compressor motor automatically, depending on
the maximum permissible number of motor starts and on the air consumption.
3 To unload the compressor manually, press the key “Unload” (5).
To put the compressor back into automatic operation, press the key “Load” (5).
If the “Load” or “Unload” function is not indicated on the bottom line of the display (2),
press key “Menu” (5) until the function “Main Screen” appears above key (F1). Then
press the key “Main Screen”.
2920 1815 04 271
Page 4148 of 6229

Instruction book
Control panel
Procedure

When automatic operation LED (7) is alight, starting and stopping of the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
Step Action
1 Check the readings on display (1).
2 When reaching the preset unloading pressure, shown on display (1), the compressor will
start running unloaded. From now on, the electronic control module will calculate the
optimum moment to stop and restart the compressor motor automatically, depending on
the maximum permissible number of motor starts and on the air consumption.
3 To unload the compressor manually, select Unload on the display using the cursor keys
and press the Enter key.
To put the compressor back into automatic operation, select Load on the display using
the cursor keys and press the Enter key.
272 2920 1815 04
Page 4149 of 6229

Instruction book
8.6 Checking the display
Control panel
Procedure
Before carrying out any maintenance, repair or adjustment work, stop the compressor,
press emergency stop button (S2), switch off the voltage and depressurize the
compressor.
Step Action
1 Regularly check the display for readings and messages. Normally, the main display 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 flashing.
3 The display will show a service message if one of the monitored components is to be
serviced. Replace the component, change the oil or grease the drive motor as required.
Reset the relevant timer.
4 Check:
• The compressor control status (automatic or manual, local or remote)
• The status of the compressor start/stop timer (active or not). The compressor is
automatically started/stopped if these start/stop commands are programmed and
activated.
• The maximum working pressure
• The outlet pressure
• The pressure drop over the air filters
• The oil pressure
• The intercooler pressure
• The outlet temperature
• The temperatures of the compressor elements
• The cooling water temperatures
• The oil temperature
• The status of the drive motor overload protection (normal or not)
• The total running and loading hours
2920 1815 04 273
Page 4150 of 6229

Instruction book
Whenever a warning, service request, sensor error or motor overload message is

displayed, the free spaces on the display between the function keys (5) are filled with
flashing indicators (**).
When more than one message needs to be displayed (e.g. both warning and service),
the messages are continuously displayed for 3 seconds each.
Control panel
Before carrying out any maintenance, repair or adjustment work, stop the compressor,
press emergency stop button (S2), switch off the voltage and depressurize the
compressor.
Procedure
1. Regularly check the display for readings and messages. Normally, the main display is shown.
2. Always check the display and remedy the trouble if alarm LED (4) is alight or blinks.
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.
Regularly check the Inputs and Outputs menus for a quick look at the compressor status.
8.7 Manual loading/unloading

274 2920 1815 04
Page 4151 of 6229

Instruction book
Control panel
General
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.
If required, the compressor can be unloaded manually. In this case, the compressor is switched out of
automatic operation, i.e. the compressor remains running unloaded unless it is loaded again manually.
Manual unloading
Press the key “Unload” (5). LED (8) fades. The message “Manually Unloaded” appears on the display.
Manual loading
Press the key “Load” (5). LED (8) lights up. The “Load” command does not force the compressor in loaded
condition, but it will switch the compressor to automatic operation again, i.e. the compressor will be loaded
if the air net pressure drops below the programmed level.
If the “Load” or “Unload” function is not indicated on the bottom line of display (2), press
“Menu” (5) until “Main Screen” appears above key (F1), then press “Main Screen”.
2920 1815 04 275
Page 4152 of 6229

Instruction book
Control panel
General
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and
restarts the compressor automatically. LED (7) is then alight.
If required, the compressor can be unloaded manually. In this case, the compressor is switched out of
automatic operation i.e. the compressor remains running unloaded unless it is loaded again manually.
Manual unloading
Starting from the main screen, move the cursor so that Unload is highlighted in grey. When the Enter key is
pressed, the compressor starts running unloaded and LED (7) fades. The message Manual Unload appears
on the display.
Manual loading
Starting from the main screen, move the cursor so that Load is highlighted in grey. When the Enter key is
pressed, LED (7) lights up and the compressor starts running loaded in case the air net pressure drops
below the programmed level. The message Load appears on the display.
If the Load or Unload buttons are not displayed on the bottom line of the screen, make
sure to return to the Main screen first.
276 2920 1815 04
Page 4153 of 6229

Instruction book
8.8 Stopping
Control panel
Procedure
Frequently stopping the compressor using the emergency stop button may damage the
compressor. Only use the emergency stop button in case of emergency.
Step Action
1 Close the air outlet valve.
2 Press stop button (9). The compressor will run unloaded for 3 seconds and then stop.
3 To stop the compressor in case of emergency, press the emergency stop button (S2).
Alarm LED (7) starts flashing. After remedying the trouble, unlock the emergency stop
button by pulling it out.
2920 1815 04 277
Page 4154 of 6229

Instruction book
Control panel
Procedure

Frequently stopping the compressor using the emergency stop button may damage the
compressor. Only use the emergency stop button in case of emergency.
Step Action
1 Close the air outlet valve.
2 Press stop button (13). The compressor will run unloaded for 3 seconds and then stop.
3 To stop the compressor in case of emergency, press the emergency stop button. Alarm
LED (4) starts flashing. After remedying the trouble, unlock the emergency stop button
by pulling it back.
Cooling water system on ZR compressors

Close the cooling water inlet valve after stopping.
If the compressor is installed in a room where freezing temperatures are expected, drain the cooling
system completely:
• By opening the main drain valves in the water inlet and outlet pipes (customer's installation)
• By removing the drain plugs. The following plugs (painted green) are provided:
• DP7 and DP8 underneath the cooler casing (for ZR 110 up to ZR 145)
• On ZR 160 up to ZR 275, drain plug (DP9) underneath the cooler casing
• DP2 and DP5 underneath the compressor elements
• DP6 on the oil cooler
278 2920 1815 04
Page 4155 of 6229

Instruction book
Water drain plugs underneath cooler casing of ZR 110 up to ZR 145
Cooler casing on ZR 160 up to ZR 275
Cooler casing on ZR 160 up to ZR 275
2920 1815 04 279
Page 4156 of 6229

Instruction book
Drain plugs on high-pressure compressor element
Drain plugs on low-pressure compressor element
280 2920 1815 04
Page 4157 of 6229

Instruction book
Water drain plug on oil cooler on ZR 110 up to ZR 275
8.9 Taking out of operation
Procedure
At the end of the service life of the compressor, proceed as follows:
Step Action
1 Close the air outlet valve and stop the compressor.
On compressors with an Elektronikon regulator, press the emergency stop button.
2 Switch off the voltage and disconnect the compressor from the mains.
3 Shut off and depressurize the part of the air net which is connected to the outlet valve.
4 Disconnect the compressor air outlet pipe from the air net.
5 Drain the oil and condensate circuits. Catch the oil in a receptacle.
6 Disconnect the compressor condensate piping from the condensate drain net.
7 On ZR compressors, drain the cooling water system and disconnect the cooling water
pipes from the compressor.
2920 1815 04 281
Page 4158 of 6229

Instruction book
9 Maintenance
9.1 Preventive maintenance schedule
Safety precautions
• Before starting any maintenance or repairs, stop the compressor.

• Depressurize the air system as follows:
• Close the air outlet valve.
• Press the emergency stop button.
• On compressors equipped with Electronic Water Drains (EWD), press the
test buttons on top of the electronic water drains.
• Open the isolating switch (customer's installation) to switch off the voltage to the
compressor, and lock it (Lock Out - Tag Out procedure, LOTO).
• Repairs inside the speed regulation cabinet must only be carried out by Atlas
Copco.
• Wait at least 6 minutes before starting any electrical repairs as hazardous high
voltage remains on the condensers of the variable speed drive for 6 minutes after
switching off the voltage.
• The operator must apply all relevant safety precautions.
Service agreements
Atlas Copco Customer Centers have a range of service agreements to suit your needs:
• An Inspection plan
• A Preventive maintenance plan
• A Total responsibility plan
Contact your Customer Center to agree on a tailor-made service agreement. It will ensure optimum
operational efficiency, minimize downtime and reduce the total life cycle costs and ensure that all
warranties are validated.
Warranty-Product Liability
Use only authorized parts at the correct intervals (check with your local Atlas Copco Service center). Any
damage or malfunction caused by the use of unauthorized parts or unqualified personnel is not covered by
Warranty or Product Liability. In the event of any extended warranty, the end user must ensure that all
required maintenance actions are performed when indicated on the Elektronikon display (see table below)
or, alternatively, use an Atlas Copco Service agreement.
Service kits
Atlas Copco Customer Centers 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.
282 2920 1815 04
Page 4159 of 6229

Instruction book
Regular checks
The following checks should be carried out regularly to ensure safe operation and long service life.
Depending on the environmental and working conditions of the compressor, the local Atlas Copco Service
center may overrule the standard maintenance schedule; always check if in doubt.
Please keep following checks in mind:
• Keep the dryer clean. (if applicable)
• Regularly brush and blow off the finned surface of the air cooler(s) (if applicable)
• Regularly test the water drains
Period Running hours Operation

-- At initial start Check the dryer adjustment as specified in Initial start-up .
Daily 8 Check the Elektronikon display for warnings.
Check that condensate is discharged from the drain receivers
Daily 8
during loading.
Before stopping:
• Drain the aftercooler drain receiver
• Drain the intercooler drain receiver
Daily --
• On Full-Feature compressors, drain the drain receivers of
the internal dryer, and additional aftercooler for energy
recovery units.
Weekly -- Check the oil level. Refer to Before starting .
Weekly -- Drain condensate from the air receiver, if installed.
Check for leaks. Tighten leaking connections and replace
Weekly --
damaged/leaking parts.
3-monthly -- Clean compressor.
3-monthly 500 Check coolers, clean if necessary.
2-yearly 16000 Replace the demister sponge of the integrated dryer.
2-yearly 16000 Inspect the dryer heater
2-yearly 16000 Inspect the dryer rotor
Carry out service actions according to the displayed service
When displayed --
warnings or service plans as shown below.
• When operating in a dusty atmosphere, inspect the air filters more frequently. Always
use Atlas Copco filters to guarantee the performance of your compressor.
• Grease the motor bearings at the correct interval and with the correct grease type and
quantity as mentioned on the motor data plate. If in doubt, consult your Atlas Copco
Service center.
Service plan
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 a level is reached, a message will appear on the screen. After carrying out all service actions, reset
the interval timers using the "Reset" key in the "Service" menu.
2920 1815 04 283
Page 4160 of 6229

Instruction book
Activities Level A Level B Level C

Take service readings (air, oil, water temperature and X X X
pressure)
Check cooler functions (approach temperature) and clean if X X X
necessary
Change intercooler condensate check valve X X X
Check intercooler blowdown valve X X X
Check for air, water and oil leakage X X X
Check critical bolt/coupling connections X X X
Check operation of safety valves X X X
Check for presence of water in lube oil X X X
Change Roto Z oil (16000 hrs or 2-yearly) - - X
Inspect/change air filter element(s) X X X
Check condition of air intake chamber X X X
Change compressor oil filter (8000 hrs or annually) - X X
Replace filter element of gear case breather X X X
Check cycle of air intake throttle valve X X X
Replace diaphragm of air throttle valve X X
Overhaul air intake valve X
Check functioning of check valve (8000 hrs or annually) X X X
Overhaul check valve X
Check condition of balance piston diaphragm X X -
Change balance piston diaphragm - X X
Check/Service condensate drain(s) X X X
Overhaul drain(s) - X X
Grease main drive motor bearings (according to motor data X X X
plate)
Clean fan cowl of electric motor X X X
Check rubber inserts of drive coupling (arr. E) X X
Replace inserts of drive coupling (arr. E) X
Check condition of drive gear teeth X X
Take and record all S.P.M. readings. On VSD compressors X X X
also register the motor speed
Inspect electrical contactors X X X
Check all electrical connections X X
On VSD compressors, if applicable, replace motor carbon X
brush
On VSD compressors, if necessary, clean electrical cabinet X X X
with vacuum cleaner
Check oil quantity X X X
Replace shaft seal - - X
Replace the demister sponge of the integrated dryer - - X
Inspect the dryer heater - - X
Inspect the dryer rotor - - X
284 2920 1815 04
Page 4161 of 6229

Instruction book
Activities Level A Level B Level C

Inspect and operate the dryer bypass valves (open/close X X X
position)
9.2 Motor greasing
General
Stop the compressor and follow the LOTO procedure (Lock Out - Tag Out) (refer to
General Safety Precautions) before greasing.
Never mix greases of different brands or types.
Main motor bearings

Refer to the motor re-greasing data plate for the recommended grease type, the greasing quantity and
interval for the motor bearings.
Fan motor bearings of ZT compressors

The bearings of the fan motor are greased for life.
9.3 Oil specifications
Roto-Z lubricating oil

Use Atlas Copco Roto-Z oil which is specially developed for oil-free rotary compressors. This oil has a
long service life and ensures optimum lubrication.
Atlas Copco Roto-Z oil can be ordered in following quantities:
Quantity (l) Quantity (US gal) Quantity (Imp gal) Quantity (cu.ft) Ordering number
5 l can 1.32 US gal can 1.10 Imp gal can 0.18 cu.ft can 2908 8503 00
20 l can 5.28 US gal can 4.40 Imp gal can 0.70 cu.ft can 2908 8501 01
209 l drum 55.18 US gal drum 45.98 Imp gal drum 7.32 cu.ft drum 2908 8500 00
9.4 Storage after installation
Run the compressor, e.g. twice a week, until warm.

If the compressor is going to be stored without running from time to time, protective measures must be
taken. Consult Atlas Copco.
2920 1815 04 285
Page 4162 of 6229

Instruction book
10 Servicing procedures
10.1 Air filters
Location of the air filters
Air filter of ZR/ZT 110 up to ZR/ZT 275
Procedure
The filters must be serviced regularly; consult section Preventive maintenance schedule.
Never install damaged or clogged filters.
Procedure for ZR/ZT 110 up to ZR/ZT 275 and ZR/ZT 132 VSD up to ZR/ZT 315 VSD
Step Action
1 Stop the compressor and press the emergency stop button.
2 Switch off the voltage and follow the LOTO procedure. (Refer to the Safety Precautions
before acting.)
3 Remove nuts (1).
4 Loosen clamps (2).
5 Take out filter housing (3) with filter element (4).
6 Replace the dirty filter element with a new one.
7 Put the filter housing with the filter element back into place.
8 Tighten clamps (2) and nuts (1).
9 Switch on the voltage.
10 Unlock the emergency stop button and reset the air filter service warning.
286 2920 1815 04
Page 4163 of 6229

Instruction book
10.2 Oil and oil filter change
Oil system
Oil system components, ZR 110 up to ZR 275
2920 1815 04 287
Page 4164 of 6229

Instruction book
Oil system components, ZT 110 up to ZT 275
Procedure
Step Action
1 Run the compressor until warm.
Press the emergency stop button.
3 Switch off the voltage and follow the LOTO procedure. (Refer to the Safety Precautions
before acting.)
4 The filler plug and drain points are painted yellow.
Remove filler plug (FC). Drain the compressor sump by opening drain valve (Dmo).
On ZR compressors, drain the oil cooler by opening drain valve (Dmc).
On ZT compressors, fit a proper flexible over the extension of drain plugs (Dmc). Drain
the oil system by loosening the drain plugs.
Close the drain valves and tighten the drain plugs after draining.
5 Remove the oil filters (OF). Clean the filter seats, oil the gaskets of the new filters and
screw the filters into place until the gaskets contact the seats. Then tighten by hand.
6 On ZR 110 up to ZR 275, fill the compressor sump to the middle of the oil level sight-
glass (SG).
On ZT 110 up to ZT 275, fill the compressor sump to the maximum mark of the oil level
sight-glass.
See Oil specifications for the correct type of oil.
7 Reinstall the filler plug.
288 2920 1815 04
Page 4165 of 6229

Instruction book
Step Action
8 Switch on the voltage.
Unlock the emergency stop button and reset the oil and oil filter service warnings.
9 Run the compressor for a few minutes.
11 On ZR 110 up to ZR 275 and ZT 110 up to ZT 275, check that the oil level is in the
middle of sight-glass (SG) after stopping (at longer standstill the level may rise in the
sight-glass).
Top up, if necessary.
10.3 Safety valves
Testing
The valves can be tested on a separate compressed air line. If a valve does not open at the pressure
specified in Settings of safety valves, consult Atlas Copco.
Never run the compressor without safety valves.

No adjustments are allowed.
10.4 Coolers
Testing
The coolers must be serviced regularly; refer to Preventive maintenance schedule .

Never install damaged or clogged coolers.
2920 1815 04 289
Page 4166 of 6229

Instruction book
Cooler block (CB) of air-cooled Full-Feature compressors
Coolers of water-cooled Full-Feature compressors
290 2920 1815 04
Page 4167 of 6229

Instruction book

AC Aftercooler
AC (ER) Extra aftercooler in case of the energy recovery option
IC Intercooler
OC Oil cooler
RC Regeneration cooler (only on Full-Feature compressors)
Keep the coolers clean to ensure cooling efficiency.

On air-cooled compressors proceed as follows:
Cooler block (CB) of air-cooled Full-Feature compressors
Step Action
2 Depressurize the air system as follows:
3 Remove the compressor roof.
4 Remove any dirt form the coolers with a fibre brush in the direction of the fins.
5 Remove dirt from the fans.
6 Clean the coolers with an air jet in the reverse direction to normal flow (i.e. from the
outside to the inside of the compressor). Use low pressure air. If required, the pressure
may be increased up to 6 bar(e) (87 psig).
2920 1815 04 291
Page 4168 of 6229

Instruction book
Step Action
7 If it is required to clean the coolers with a cleaning agent, consult your Atlas Copco
Customer Center.
8 Re-install the compressor roof.
292 2920 1815 04
Page 4169 of 6229

Instruction book
11 Problem solving
11.1 Problem solving
• Before starting any maintenance or repairs, stop the compressor.

• Depressurize the air system as follows:
• On compressors equipped with Electronic Water Drains (EWD), press the
test buttons on top of the electronic water drains.
• Repairs inside the speed regulation cabinet must only be carried out by Atlas
Copco.
• Apply all relevant safety precautions.
• Wait at least 6 minutes before starting any electrical repairs as hazardous high
voltage remains on the condensers of the variable speed drive for 6 minutes after
switching off the voltage.
Control panel
2920 1815 04 293
Page 4170 of 6229

Instruction book
Faults and remedies
Condition Fault Remedy

Compressor starts running,
Pressure in air net is above Compressor will load when pressure in air
but does not load after a delay
pre-set loading pressure net drops to pre-set loading pressure
time
Loading solenoid valve
Check and replace the valve as necessary
inoperative
Full-load/no-load valve
Have the valve inspected
malfunctioning
Compressor capacity or
Air consumption exceeds
working pressure lower than Check pneumatic plant
capacity of compressor
normal
Check for leaks. Tighten leaking
Leaking connections and
connections and replace damaged/leaking
damaged/leaking parts
parts.
Top up level as described in section Before
Oil pressure too low Oil level too low
starting.
Oil filters clogged Replace filters
Inlet temperature too high due
Improve ventilation in compressor room
Air temperature above normal to bad room ventilation or
and prevent recirculation of cooling air
recirculation of cooling air
On ZR compressors, Check water temperature and increase
insufficient cooling water flow cooling water flow
On ZR compressors,
restriction in cooling water
Consult the Atlas Copco Customer Center
system due to formation of
scale or dirt deposits
On ZT compressors, coolers
Refer to the Coolers section.
clogged
294 2920 1815 04
Page 4171 of 6229

Instruction book

Unloading pressure incorrectly
Check the controller setting.
set
On ZT compressors,
insufficient cooling air or
Check and correct.
cooling air temperature too
high
Condensate is not discharged
from condensate traps during Drain/pipe clogged Check and correct
operation
Frozen drain piping Check and correct
Venting lines not/badly
Check and correct
assembled
Only on IC drain : intercooler
condensate check valve
Check and correct
defect/dirty/wrongly
assembled
Solenoid valve defect/dirty Check and correct
Manual operated solenoid
Set valve to automatic operation
valve
Level sensor defect/dirty Clean sensor or replace as necessary
Damaged/poor assembled
Drain continuously discharges
condensate drain (housing/ Check and correct
air
seals/valve/…)
Solenoid valve defect/dirty Check and correct
Level sensor defect/dirty Clean sensor or replace as necessary
For Full-Feature compressors

Compressor loading periods Take necessary action to increase duration
Pressure dewpoint too high
repeatedly too short of loading periods
Adjust the dryer as specified in Initial start-
up . Never operate the dryer with a
Incorrect dryer adjustment
pressure difference/nozzle fraction beyond
the specified range.
Do not operate the dryer at a pressure
Operating pressure too low lower than the one specified in Compressor
data
Dryer rotor/motor does not
Consult Atlas Copco Customer Center
turn
Rotor compartment sealing
ring, sealing sectors and rotor Consult Atlas Copco Customer Center
need inspection
2920 1815 04 295
Page 4172 of 6229

Instruction book

On ZR compressors :
• Check cooling water temperature and
regulate cooling water flow (Refer to
the Starting section.)
• Consult Atlas Copco Customer
Center in case of restriction in cooling
Dryer inlet temperature too water system due to formation of
high (due to increased scale or dirt deposits
aftercooler air outlet On ZT compressors :
temperature or regeneration • Check clogging of coolers, and solve
cooler air outlet temperature as described in section Coolers.
• Check for insufficient cooling air or
too high cooling air temperature, and
correct it
If temperature cannot be decreased
sufficiently, consult Atlas Copco Customer
Center.
Regeneration air outlet
temperature too low
Inspect system and replace parts where
Drain system malfunctioning
necessary
Dryer in normal operation, but Heater function desactivated, or possibly in
without any functioning of the protection state. Consult Atlas Copco
low load heater Customer Center
Regeneration air inlet Shut-off valve closed for dryer
Open the valve
temperature too low by-pass
Do not operate the dryer at a pressure
Operating pressure too low lower than the one specified in Compressor
data
Compressor loading periods Take necessary action to increase duration
too short of loading periods
Nozzle of ejector partly Remove and clean nozzle. Investigate
obstructed cause
Warning on heater outlet
sensor
Dryer rotation warnings for Full-Feature compressors
Fault/warning Action
Check that the fan of the dryer motor is rotating during load of the
Dryer rotation direction
compressor.
Check that the rotation direction of the dryer motor fan corresponds with the
arrow on the motor:
• OK: Check all connections of the rotation sensor following the
electrical diagram. Consult your Atlas Copco Customer Center.
• NOK: Switch off the voltage and reverse two of the input line
connections. Consult your Atlas Copco Customer Center.
Dryer rotation too slow Consult your Atlas Copco Customer Center.
Check that the fan of the dryer motor is rotating during load of the
Rotor standstill
compressor.
296 2920 1815 04
Page 4173 of 6229

Instruction book
Fault/warning Action
Check that the circuit breaker in the dryer control box is switched on.
Check that the gear motor cable is correctly connected to the terminals of
the dryer control box
Consult your Atlas Copco Customer Center.
2920 1815 04 297
Page 4174 of 6229

Instruction book
12 Technical data
12.1 Readings
Important
The readings below are indicative values when operating at reference conditions. Check
the section Reference conditions. These values are no rejection limits. In case of doubt,
consult your Atlas Copco Customer Center.
For the maximum working pressure and the outlet pressure, consult the section Compressor data.
Pressure readings
Item Reading Reading

dp of air filter Below 0.044 bar Below 0.64 psi
Intercooler pressure (loaded condition) 1.7-3 bar(e) 24.6-43.5 psig
Intercooler pressure (unloaded condition) (-0.65)-(-0.70) bar(e) (-9.43)-(-10.15) psig
Oil pressure (depends on climatic conditions) 1.8-3.5 bar(e) 26.1-50.8 psig
Temperature readings for ZR compressors

Oil temperature Approx. 40 ˚C Approx 104 ˚F
Air outlet temperature Approx. 25 ˚C Approx. 77 ˚F
Cooling water inlet temperature Below 40 ˚C Below 104 ˚F
Cooling water outlet temperature Below 50 ˚C Below 122 ˚F
Temperature readings for ZT compressors

Oil temperature Approx. 50 ˚C Approx 122 ˚F
Air outlet temperature Approx. 27 ˚C Approx. 81 ˚F
298 2920 1815 04
Page 4175 of 6229

Instruction book
12.2 Settings of safety valves
Item Opening Opening pressure

pressure
Low-pressure safety valve(s) for 7 up to 10.4 bar (101.5 up to 3.7 bar(e) 54 psig
151 psi) compressors
Low-pressure safety valve(s) for 13 bar (190 psi) compressors 4.5 bar(e) 65 psig
High-pressure safety valve(s) for 7 and 8.6 bar (101.5 and 125 9.3 bar(e) 135 psig
psi) compressors
High-pressure safety valve(s) for 10 and 10.4 bar (145 and 11 bar(e) 160 psig
151 psi) compressors
High-pressure safety valve(s) for 13 bar (190 psi) compressors 13.7 bar(e) 200 psig
12.3 Settings for overload relay
50 Hz compressors
ZT/ZR 110 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor
Supply voltage Recommended overload setting F21

(V) (A)
380 128.8
400 122.2
500 97.6
690 70.4

(V) (A)
380 129
400 123
500 98
690 71

(V) (A)
380 153.8
400 146.1
500 116.9
690 83.7
2920 1815 04 299
Page 4176 of 6229

Instruction book

(V) (A)
380 144
400 135
500 109
690 79
ZT/ZR 110 compressors with oversized IE2 motor

(V) (A)
380 153.8
400 146.1
500 116.9
690 83.7

(V) (A)
380 144
400 135
500 109
690 79

(V) (A)
380 153.8
400 146.1
500 116.9
690 83.7

(V) (A)
380 156
400 146
500 118
690 86
300 2920 1815 04
Page 4177 of 6229

Instruction book

(V) (A)
380 166.0
400 159.3
500 127.5
690 92.3

(V) (A)
380 156
400 147
500 118
690 86

(V) (A)
380 169.3
400 159.3
500 127.5
690 92.3

(V) (A)
380 156
400 147
500 118
690 86

(V) (A)
380 169.3
400 159.3
500 127.5
690 92.3
2920 1815 04 301
Page 4178 of 6229

Instruction book

(V) (A)
380 169
400 159
500 128
690 93

(V) (A)
380 166.0
400 159.3
500 127.5
690 92.3

(V) (A)
380 156
400 147
500 118
690 86
ZR/ZT 160 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor

(V) (A)
380 189
400 183
500 146
690 106

(V) (A)
380 199
400 189
500 153
690 109
or equipped with oversized IE2 motor
302 2920 1815 04
Page 4179 of 6229

Instruction book

(V) (A)
380 242
400 229
500 183
690 133

(V) (A)
380 226
400 217
500 174
690 125

(V) (A)
380 242
400 229
500 183
690 133

(V) (A)
380 246
400 236
500 189
690 136

(V) (A)
380 322
400 295
500 236
690 169
2920 1815 04 303
Page 4180 of 6229

Instruction book

(V) (A)
380 288
400 269
500 217
690 156

(V) (A)
380 322
400 295
500 236
690 169

(V) (A)
380 281
400 239
500 232
690 184

(V) (A)
380 341
400 312
500 254
690 182

(V) (A)
380 321
400 277
500 245
690 196
ZR/ZT 275 7.5 bar (110 psi) designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2
motor
304 2920 1815 04
Page 4181 of 6229

Instruction book

(V) (A)
380 305
400 292
500 229
690 168
ZR/ZT 275 7.5 bar (110 psi) designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3
motor

(V) (A)
380 318
400 302
500 251
690 175
ZR/ZT 275 8.6 up to 13 bar (125 up to 190 psi) designed for a maximum inlet temperature of 40
˚C/104 ˚F with IE2 motor

(V) (A)
380 341
400 312
500 254
690 182
ZR/ZT 275 8.6 up to 13 bar (125 up to 190 psi) designed for a maximum inlet temperature of 40
˚C/104 ˚F with IE3 motor

(V) (A)
380 381
400 356
500 283
690 210
60 Hz compressors
2920 1815 04 305
Page 4182 of 6229

Instruction book

(V) (A)
380 138.6
440 120.6
460 110.2
575 88.0

(V) (A)
380 137
440 119
460 113
575 91

(V) (A)
380 180.1
440 155.9
460 149.6
575 119.9

(V) (A)
380 168
440 143
460 137
575 110

(V) (A)
380 180.1
440 155.9
460 149.6
575 119.9
306 2920 1815 04
Page 4183 of 6229

Instruction book

(V) (A)
380 168
440 143
460 137
575 110

(V) (A)
380 180.1
440 155.9
460 149.6
575 119.9

(V) (A)
380 184
440 156
460 149
575 120

(V) (A)
380 172.6
440 149.8
460 140.7
575 112.7

(V) (A)
380 168
440 143
460 137
575 110
2920 1815 04 307
Page 4184 of 6229

Instruction book

(V) (A)
380 187
440 163
460 161
575 127

(V) (A)
380 194
440 166
460 163
575 131

(V) (A)
380 236
440 204
460 209
575 167

(V) (A)
380 219
440 187
460 181
575 146

(V) (A)
380 236
440 204
460 209
575 167
308 2920 1815 04
Page 4185 of 6229

Instruction book

(V) (A)
380 239
440 204
460 197
575 159

(V) (A)
380 288
440 249
460 234
575 187

(V) (A)
380 257
440 219
460 213
575 168

(V) (A)
380 288
440 249
460 234
575 187

(V) (A)
380 281
440 239
460 232
575 184
2920 1815 04 309
Page 4186 of 6229

Instruction book

(V) (A)
380 312
440 269
460 272
575 217

(V) (A)
380 321
440 277
460 249
575 196
ZR/ZT 275 designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor

(V) (A)
380 312
440 269
460 272
575 217
ZR/ZT 275 designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor

(V) (A)
380 349
440 302
460 266
575 212
Compressors with medium-voltage and high-voltage motors

For compressors with a medium-voltage or high-voltage motor, apply the local regulations.
12.4 Reference conditions
Absolute inlet pressure 1 bar(a)

14.5 psi(a)
Ambient temperature 20 °C
68 °F
310 2920 1815 04
Page 4187 of 6229

Instruction book
Air inlet temperature 20 °C

68 °F
Effective working pressure 9 bar(g) for 10/10.4 bar compressors
131 psi(g) for 145/151 psi compressors
7 bar(g) for 7/7.5/8.6 bar compressors
102 psi(g) for 102/109/125 psi compressors
12 bar(g) for 13 bar compressors
174 psi(g) for 188 psi compressors
Temperature of cooling medium (water or air) inlet 20 °C
68 °F
Temperature rise of cooling water of ZR Pack 15 °C
compressors 27 °F
Temperature rise of cooling water of ZR Full-Feature 10 °C
compressors 18 °F
Temperature rise of cooling water in the Energy Recovery 5 °C
circuit of ZR Full-Feature compressors 9 °F
ZR / ZT 110-145
Motor shaft speed for 50 Hz fixed speed compressors 2980
(rpm)
(rpm)
ZR / ZT 160-275
(rpm) - except for ZR / ZT 275 7.5 bar (109 psi)
Motor shaft speed for 50 Hz fixed speed unit ZR / ZT 275 2980
7.5 bar (109 psi) (rpm)
(rpm)
12.5 Limitations
Minimum - maximum ambient temperature (for 0 - 40 °C
standard compressors) 32- 104 °F
Minimum - maximum ambient temperature (for 0 - 50 °C
High Ambient Temperature compressors) 32- 122 °F
Minimum - maximum temperature of air inlet (for 0 - 40 °C
standard compressors) 32- 104 °F
Minimum - maximum temperature of air inlet (for 0 - 50 °C
High Ambient Temperature compressors) 32- 122 °F
Maximum altitude 1000 m
3281 ft
Minimum temperature of cooling medium (water or 0 °C
air) inlet 32 °F
Maximum temperature of cooling air inlet (for 40 °C
standard compressors) 104 °F
Maximum temperature of cooling air inlet (for High 50 °C
Ambient Temperature compressors) 122 °F
2920 1815 04 311
Page 4188 of 6229

Instruction book
Maximum temperature of cooling water inlet - open 40 °C

circuit 104 °F
Maximum temperature of cooling water outlet 50 °C
122 °F
Maximum temperature of cooling water outlet of 90 °C
compressors with Energy Recovery- closed circuit 194 °F
Maximum rise of cooling water temperature (for up to 35 °C
compressors without Energy Recovery) up to 63 °F
Maximum rise of cooling water temperature (for up to 70 °C
compressors with Energy Recovery) up to 126 °F
Maximum rise of cooling water temperature in the up to 10 °C
Energy Recovery circuit of Full-Feature up to 18 °F
compressors
Maximum pressure of cooling water inlet 10 bar(g)
145 psi(g)
Minimum - maximum oil pressure 1.2–4.5 bar(g)
17.4–65.3 psi(g)
Minimum - maximum oil temperature (for standard 0-70 °C
compressors) 32- 158 °F
Minimum - maximum oil temperature (for High 0 - 80 °C
Ambient Temperature compressors) 32- 176 °F
Working pressure: Minimum- Pack Full-Feature

Maximum (bar(g))
7 bar - 60 Hz 4–7.5 5–7.5
7.5 bar - 50 Hz 4–7.5 5–7.5
8.6 bar - 50/60 Hz 4–8.6 6–8.6
10 bar - 50 Hz 4–10 7–10
10.4 bar - 60 Hz 4–10.4 8–10
13 bar - 50/60 Hz 9–13 -
Working pressure: Minimum- Pack Full-Feature

Maximum (psi(g))
101 psi - 60 Hz 58–73 73–102
109 psi - 50 Hz 58–73 73–109
125 psi - 50/60 Hz 58–125 87–125
145 psi - 50 Hz 58–145 102–145
150 psi - 60 Hz 58–151 116–145
188 psi - 50/60 Hz 131–189 -
312 2920 1815 04
Page 4189 of 6229

Instruction book
Item Reading in bar(g) Reading in psi(g)

Pressure drop over air filter Below 0.044 Below 0.64
Intercooler pressure (loaded condition) 1.7-3 24.6-43.5
Intercooler pressure (unloaded condition) (-0.65)-(-0.70) (-9.43)-(-10.15)
Oil pressure (depends on climatic conditions) 1.2-4.5 17.4-65.3
12.6 Compressor data

ZR compressors
Temperature Reading
Oil Approx. 40 ˚C
120-220 °C for 7/7.5/8.6 bar standard compressors
120-235 °C for 7/7.5/8.6 bar High Ambient Temperature
compressors
120-235 °C for 10/10.4 bar standard compressors
120-260 °C for 10/10.4 bar High Ambient Temperature
compressors
Outlet of low pressure stage 120-260 °C for 13 bar compressors
compressors
100-235 °C for 10/10.4 bar compressors
Outlet of high pressure stage 100-235 °C for 13 bar compressors
Air outlet Approx. 25 ˚C
Inlet of cooling water Below 40 ˚C
Outlet of cooling water Below 50 ˚C
Temperature Reading
Oil Approx. 104 ˚F
248-428 °F for 7/7.5/8.6 bar standard compressors
248-455 °F for 7/7.5/8.6 bar High Ambient Temperature
compressors
248-455 °F for 10/10.4 bar standard compressors
248-500 °F for 10/10.4 bar High Ambient Temperature
compressors
Outlet of low pressure stage 248-500 °F for 13 bar compressors
212-455 °F for 7/7.5/8.6 bar High Ambient Temperature
compressors
212-455 °F °C for 10/10.4 bar compressors
Outlet of high pressure stage 212-455 °F for 13 bar compressors
Air outlet Approx. 77 ˚F
Inlet of cooling water Below 104 ˚F
Outlet of cooling water Below 122 ˚F
ZT compressors
2920 1815 04 313
Page 4190 of 6229

Instruction book
Temperature Reading
Oil Approx. 50 ˚C
compressors
Outlet of low pressure stage compressors
compressors
Outlet of high pressure stage compressors
Air outlet for compressors with
aftercooler Approx. 27 ˚C
Air outlet for Hot Air variants Outlet of high pressure stage
Temperature Reading
Oil Approx. 122 ˚F
248-455°F for 7/7.5/8.6 bar High Ambient Temperature
compressors
Outlet of low pressure stage compressors
212-455°F for 7/7.5/8.6 bar High Ambient Temperature
compressors
Outlet of high pressure stage compressors
Air outlet for compressors with
aftercooler Approx. 81 ˚F
Air outlet for Hot Air variants Outlet of high pressure stage
Oil quantity in the lubrication system of the compressor
Compressor type l cu.ft Imp gal US gal

ZR 110, ZR 132, ZR 145 29 1.02 6.38 7.66
ZT 110, ZT 132, ZT 145 55 1.94 12.10 14.53
ZR 160, ZR 200, ZR 250, ZR 275 60 2.12 13.20 15.85
ZT 160, ZT 200, ZT 250, ZT 275 88 3.11 19.36 23.25
314 2920 1815 04
Page 4191 of 6229

Instruction book
12.7 Dryer data

Temperature Reading
Dryer inlet for ZR compressors Approx. 5 °C (9 °F) above inlet temperature of cooling water
Dryer inlet for ZT 110-145, ZT 132/160 VSD
compressors Approx. 7 °C (12.6 °F) above ambient temperature
Dryer inlet for ZT 160-275, ZT 250/315 VSD
compressors Approx. 10 °C (18 °F) above ambient temperature
Approx. 2 °C (3.6 °F) till 4 °C (7.2 °F) above dryer inlet
Dryer mixed air temperature
Approx. 5 °C ( 9 °F) till 25 °C (45 °F) above dryer mixed air
Dryer outlet temperature
Difference between inlet and outlet of
regeneration air Should not exceed 60 °C (108 °F)
2920 1815 04 315
Page 4192 of 6229

Instruction book
13 Pressure equipment directives
PED instructions
ZR 110 Pack up to ZR 145 Pack compressors are a pressure assembly of cat. I according to 97/23/EC.
ZR 160 Pack up to ZR 275 Pack compressors are a pressure assembly of cat. II according to 97/23/EC.
ZT 110 Pack up to ZT 275 Pack compressors are a pressure assembly of cat. I according to 97/23/EC.
ZR/ZT 110 Full-Feature up to ZR/ZT 145 Full-Feature compressors are a pressure assembly of cat. III
according to 97/23/EC.
ZR/ZT 160 Full-Feature up to ZR/ZT 275 Full-Feature compressors are a pressure assembly of cat. IV
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 2009/105/IEC are excluded from 97/23/EC according
to article I, section 3.3.
The following pressure bearing parts are of category higher than I :
Compressor type Pressure bearing part

ZR/ZT 110 up to ZR/ZT 275 Safety valve: Category IV
• Design code: AD-Merkblätter, A2
ZR/ZT 110 up to ZR/ZT 145 IMD 300
Compressed air dryer vessel
• Category III
• Design pressure 13.7 bar(e)
• Design code: ASME BPVC section VIII div. 1.
• Material (Cover, housing and bottom): SA-395.
• When pressurized, vessel remains under pressure.
Safety valve (only for option dryer bypass)
• Category IV
• Design code: ISO 4126.
ZR 160 up to ZR 275 Compressor
Heat exchanger at compressed air side (aftercooler)
• Design pressure 13.7 bar(e)
• Volume 17.6 l.
ZR/ZT 160 up to ZR/ZT 275 IMD 600
Compressed air dryer vessel
• Category IV
• Design pressure 11 bar(e)
• Material (housing and cover): SA-395.
• When pressurized, vessel remains under pressure.
Safety valve (only for option low load and dryer bypass)
• Category IV
• Design code: ISO 4126.
316 2920 1815 04
Page 4193 of 6229

Instruction book
Vessel for MD dryers on ZR/ZT 110 up to ZR/ZT 145

Instruction for use (vessel)
Reference Name
1 Cover
2 Bottom
3 Bolt
4 Washer
5 Nut
6 Housing
• This vessel can contain pressurized air; please be aware of its potential danger in case of misuse.
• This vessel shall only be used as an air dryer to a compressor and operated within the specified limits
as given on the data plate.
• Original bolts have to be used after opening for inspection. Specified torque has to be taken into
consideration.
• This vessel has been designed and built to guarantee an operational lifetime in excess of 20 years.
Therefore there is no intrinsic need for in-service inspection of the vessel when used within its design
limits and in its intended application. National legislation however may require in-service inspection.
2920 1815 04 317
Page 4194 of 6229

Instruction book
Part number V in liter MWT in mm CA in mm H in D CF

(US gal/Imp gal/ mm in
cu.ft) mm
Water-cooled: 199 Cover: Cover: 1.0 1023 528 Cover: 0.8
1617 5966 99 (52.57/443.77/7.0 • Torispherical part: Housing: 1.0 Housing: 0.8
Air-cooled: 3) 13.0 Bottom: 1.0 Bottom: 0.8
1617 5968 99 Housing:
• Cylindrical part: 10.0
Bottom:
• Cylindrical part: 10.0
• Torispherical part:
10.0
Used abbreviations
V: Internal volume (Liter)
MWT: Minimum wall thickness as manufactured (mm)
CA: Corrosion allowance (mm)
H: Height of the vessel (mm)
D: Diameter of the vessel (mm)
CF: Casting factor (according ASME BPVC section VIII div 1)
Vessel for MD dryers on ZR/ZT 160 up to ZR/ZT 275

Instruction for use (vessel)
318 2920 1815 04
Page 4195 of 6229

Instruction book
Reference Name
1 Cover
2 Bottom
3 Bolt
4 Washer
5 Nut
• This vessel can contain pressurized air; please be aware of its potential danger in case of misuse.
• This vessel shall only be used as an air dryer to a compressor and operated within the specified limits
as given on the data plate.
• Original bolts have to be used after opening for inspection. Specified torque has to be taken into
consideration.
• This vessel has been designed and built to guarantee an operational lifetime in excess of 20 years.
Therefore there is no intrinsic need for in-service inspection of the vessel when used within its design
limits and in its intended application. National legislation however may require in-service inspection.
2920 1815 04 319
Page 4196 of 6229

Instruction book
Part number V in liter MWT in mm CA in H D in CF

(US gal/Imp gal/ mm in mm
cu.ft) mm
1627 2472 99 270 Cover: Cover: 898 713 Cover: 0.8
(71.33/59.40/9.53) • Cylindrical part: 1.0 Bottom: 0.8
10.0 Bottom:
• Torispherical part: 1.0
13.5
Bottom:
• Cylindrical part:
10.0
• Torispherical part:
12.0
• Cylindrical cooler:
16.5
Used abbreviations
V: Internal volume (Liter)
MWT: Minimum wall thickness as manufactured (mm)
CA: Corrosion allowance (mm)
H: Height of the vessel (mm)
D: Diameter of the vessel (mm)
CF: Casting factor (according ASME BPVC section VIII div 1)
Heat exchanger ZR 160 up to ZR 275
Reference Name
1 Intercooler
2 Aftercooler
3 Position of data plate
320 2920 1815 04
Page 4197 of 6229

Instruction book
Heat exchanger ZR 160-275

PED Category CAT II
Design code ASME BPVC Section VIII, div 1
Material SA-395
Bolts 8.8
Interval of periodic 5 years or the frequency as given in national legislation
inspection by 3rd
party (1)
Intercooler Aftercooler
Casting factor 0.8 0.8
Minimum wall Covers : 8 mm Covers : 8 mm
thickness after Shell : 10 mm Shell : 10 mm
corrosion
Shellside Tubeside Shellside Tubeside
Medium Water, group 2 Air, group 2 Water, group 2 Air, group 2
Volume 92 l 21.4 l See intercooler 17.6 l
Design pressure 15 bar 4.5 bar 15 bar 13.7 bar
Design temperature 95 °C 240 °C 95°C 240 °C
(1) The maintenance instructions given in the user manual must be applied by the user.
2920 1815 04 321
Page 4198 of 6229

Instruction book
14 Documentation
Declaration of conformity
Typical example of a Declaration of Conformity document
(1): Contact address:

(2): Applicable directives
(3): Standards used
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this device.
322 2920 1815 04
Page 4199 of 6229

Instruction book
Declaration of incorporation
Typical example of a Declaration of Incorporation document
(1): Contact address:

(2): Applicable directives
(3): Standards used
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this device.
2920 1815 04 323
Page 4200 of 6229

Page 4201 of 6229
Page 4202 of 6229
What sets Atlas Copco apart as a company is our conviction
that we can only excel in what we do if we provide the best
possible know-how and technology to really help our customers
produce, grow and succeed.
There is a unique way of achieving that - we simply call it the
Atlas Copco way. It builds on interaction, on long-term
relationships and involvement in the customers’ process, needs
and objectives. It means having the flexibility to adapt to the
diverse demands of the people we cater for.
It’s the commitment to our customers’ business that drives our
effort towards increasing their productivity through better
solutions. It starts with fully supporting existing products and
continuously doing things better, but it goes much further,
creating advances in technology through innovation. Not for
the sake of technology, but for the sake of our customer’s
bottom line and peace-of-mind.
That is how Atlas Copco will strive to remain the first choice, to
succeed in attracting new business and to maintain our position
as the industry leader.
No. 2920 1815 04 / 2015 - 09 - Printed in Belgium
Page 4203 of 6229

Atlas ZR275 Instructions Books PDF

Uploaded by

Copyright:

Available Formats

Atlas ZR275 Instructions Books PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Atlas ZR275 Instructions Books PDF

Uploaded by

Copyright:

Available Formats

Atlas Copco

ZR 110, ZR 132, ZR 145, ZR 160, ZR 200, ZR 250, ZR 275,

Page 3878 of 6229

1.1 SAFETY ICONS................................................................................................................................... 7

1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................7

1.3 SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 8

1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 9

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR......................................................................... 10

2.2 AIR SYSTEM.................................................................................................................................... 20

2.3 COOLING AND CONDENSATE DRAIN SYSTEM........................................................................................... 25

2.4 ELEKTRONIKON REGULATED DRAIN (ERD)............................................................................................27

2.5 OIL SYSTEM.................................................................................................................................... 31

2.6 REGULATING SYSTEM........................................................................................................................ 33

2.7 ENERGY RECOVERY.......................................................................................................................... 36

2.8 LOW LOAD COMPENSATOR FOR IMD DRYER..........................................................................................39

2.9 SMARTBOX AND SMARTLINK.................................................................................................... 41

3.1 ELEKTRONIKON® REGULATOR............................................................................................................. 44

3.2 CONTROL PANEL.............................................................................................................................. 46

3.3 FUNCTION KEYS............................................................................................................................... 47

3.4 SCROLL KEYS.................................................................................................................................. 48

3.5 EMERGENCY STOP BUTTON................................................................................................................ 48

3.6 CONTROL MODE SWITCH.................................................................................................................... 49

3.7 EXTERNAL COMPRESSOR STATUS INDICATION ........................................................................................50

3.8 EXTERNAL COMMUNICATION................................................................................................................50

3.9 CONTROL PROGRAMS........................................................................................................................52

Page 3879 of 6229

3.10 CALLING UP MENUS.......................................................................................................................... 53

3.11 MAIN SCREEN MENU......................................................................................................................... 53

3.12 STATUS DATA MENU..........................................................................................................................54

3.13 MEASURED DATA MENU..................................................................................................................... 56

3.14 HOURS MENU.................................................................................................................................. 56

3.15 SERVICE MENU................................................................................................................................ 57

3.16 TEST MENU..................................................................................................................................... 59

3.17 MODIFY SETTINGS MENU....................................................................................................................60

3.18 MODIFYING REGULATION SETTINGS...................................................................................................... 60

3.19 MODIFYING PROTECTION SETTINGS ..................................................................................................... 61

3.20 MODIFYING SERVICE SETTINGS............................................................................................................63

3.21 TIMERS MENU.................................................................................................................................. 64

3.22 CONFIGURATION MENU...................................................................................................................... 67

3.23 SAVED DATA MENU........................................................................................................................... 68

3.24 SHOW MORE MENU........................................................................................................................... 69

3.25 UNLOAD-LOAD MENU.........................................................................................................................70

3.26 PROGRAMMABLE SETTINGS.................................................................................................................70

4 Elektronikon regulator type overview.........................................................................75

4.1 ELEKTRONIKON® CONTROLLER TYPE OVERVIEW......................................................................................75

5.1 ELEKTRONIKON® REGULATOR............................................................................................................. 77

5.2 CONTROL PANEL.............................................................................................................................. 79

5.3 FUNCTION KEYS............................................................................................................................... 80

5.4 SCROLL KEYS.................................................................................................................................. 81

5.5 EMERGENCY STOP BUTTON................................................................................................................ 81

5.6 EXTERNAL COMPRESSOR STATUS INDICATION ........................................................................................82

5.7 CONTROL PROGRAMS........................................................................................................................82

5.8 CALLING UP MENUS.......................................................................................................................... 84

Page 3880 of 6229

5.9 MAIN SCREEN MENU......................................................................................................................... 85

5.10 STATUS DATA MENU..........................................................................................................................86

5.11 MEASURED DATA MENU..................................................................................................................... 89

5.12 COUNTERS MENU............................................................................................................................. 90

5.13 TEST MENU..................................................................................................................................... 91