Comprensoras Altas GA 250

ZE 3
APF200498
Instruction book
Atlas Copco
ZE 3
APF200498
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 - 04
www.atlascopco.com
Instruction book
Table of contents
1
Safety precautions..........................................................................................................5
1.1
SAFETY ICONS................................................................................................................................... 5
1.2
GENERAL SAFETY PRECAUTIONS............................................................................................................5
1.3
SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 6
1.4
SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 7
1.5
SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 8
General description...................................................................................................... 10
2.1
INTRODUCTION.................................................................................................................................10
2.2
AIR FLOW, OIL AND COOLING SYSTEM................................................................................................... 15
2.3
ELECTRICAL SYSTEM.........................................................................................................................23
Elektronikon Graphic Plus controller.......................................................................24
3.1
ELECTRONIC CONTROL SYSTEM...........................................................................................................24
3.2
CONTROL PANEL.............................................................................................................................. 25
3.3
DIGITAL OUTPUT CONTACTS................................................................................................................26
3.4
ICONS USED.................................................................................................................................... 28
3.5
MAIN SCREEN..................................................................................................................................32
3.6
CALLING UP MENUS.......................................................................................................................... 35
3.7
CONVERTER MENU............................................................................................................................36
3.8
SERVICE MENU................................................................................................................................ 37
3.9
PROTECTIONS MENU......................................................................................................................... 42
3.10
WEEK TIMER MENU...........................................................................................................................45
3.11
INFO MENU......................................................................................................................................55
3.12
TEST MENU..................................................................................................................................... 56
3.13
COUNTERS......................................................................................................................................57
3.14
MODIFYING THE PRESSURE BAND........................................................................................................ 59
3.15
INPUTS MENU...................................................................................................................................61
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3.16
OUTPUTS MENU............................................................................................................................... 66
3.17
SPM MENU.................................................................................................................................... 67
3.18
EVENT HISTORY MENU.......................................................................................................................69
3.19
MODIFYING SETTINGS........................................................................................................................70
3.20
PROGRAMMABLE SETTINGS.................................................................................................................77
3.21
WEB SERVER.................................................................................................................................. 77
Installation.....................................................................................................................85
4.1
DIMENSION DRAWING........................................................................................................................ 85
4.2
INSTALLATION PROPOSAL................................................................................................................... 87
4.3
ELECTRIC CABLE SIZE....................................................................................................................... 89
4.4
SETTINGS OF OVERLOAD RELAY AND FUSES...........................................................................................90
4.5
QUALITY OF SAFETY COMPONENTS.......................................................................................................90
4.6
COOLING WATER REQUIREMENTS.........................................................................................................90
4.7
PICTOGRAPHS................................................................................................................................. 94
Operating instructions................................................................................................. 97
5.1
INITIAL START-UP..............................................................................................................................97
5.2
BEFORE STARTING..........................................................................................................................100
5.3
STARTING..................................................................................................................................... 101
5.4
DURING OPERATION........................................................................................................................ 102
5.5
CHECKING THE DISPLAY...................................................................................................................103
5.6
STOPPING.....................................................................................................................................104
5.7
TAKING OUT OF OPERATION..............................................................................................................104
Maintenance................................................................................................................ 105
6.1
PREVENTIVE MAINTENANCE SCHEDULE................................................................................................105
6.2
MOTOR GREASING.......................................................................................................................... 106
6.3
OIL SPECIFICATIONS........................................................................................................................107
6.4
STORAGE AFTER INSTALLATION......................................................................................................... 107
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6.5
DISPOSAL OF USED MATERIAL........................................................................................................... 107
Servicing procedures................................................................................................. 108
7.1
AIR FILTERS.................................................................................................................................. 108
7.2
OIL AND OIL FILTER CHANGE.............................................................................................................108
7.3
SAFETY VALVES............................................................................................................................. 109
Problem solving..........................................................................................................110
8.1
PROBLEM SOLVING......................................................................................................................... 110
Technical data.............................................................................................................111
9.1
READINGS.....................................................................................................................................111
9.2
SETTINGS OF SAFETY VALVES........................................................................................................... 111
9.3
REFERENCE CONDITIONS AND LIMITATIONS.......................................................................................... 112
9.4
COMMON DATA.............................................................................................................................. 112
9.5
COMPRESSOR DATA........................................................................................................................112
10
Pressure equipment directives................................................................................. 116
10.1
PRESSURE EQUIPMENT DIRECTIVES....................................................................................................116
11
Documentation............................................................................................................117
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Safety precautions
1.1
Safety icons
Explanation
Danger for 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 compressor
Press the emergency stop button
Switch off the voltage
Depressurize the compressor
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.
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1.3
Safety precautions during installation

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

1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept
within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. In case the device is a compressor, place the machine where the ambient air is as cool and clean as
possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to
minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the
working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors and
particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people cannot
be drawn in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the electrical
isolating switch is open, locked and labelled with a temporary warning before any maintenance or
repair. As a further safeguard, persons switching on or off remotely controlled machines shall take
adequate precautions to ensure that there is no one checking or working on the machine. To this end,
a suitable notice shall be affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available
and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
12. The electrical connections must correspond to the applicable codes. The machines must be earthed
and protected against short circuits by fuses in all phases. A lockable power isolating switch must be
installed near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after voltage failure
is activated, a sign stating "This machine may start without warning" must be affixed near the
instrument panel.
14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Nonreturn valves (check valves) must not be relied upon for isolating pressure systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure relieving device or devices as required.
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Instruction book
16. Piping or other parts with a temperature in excess of 70C (158F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high temperature
piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the dryer,
safety valves must be installed in the vessels of the dryer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4
Safety precautions during operation

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

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

9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to
avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
1.5
Safety precautions during maintenance or repair

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

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
Use only the correct tools for maintenance and repair work.
Use only genuine spare parts.
All maintenance work shall only be undertaken when the machine has cooled down.
A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the
starting equipment.
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.
Close the compressor air outlet valve before connecting or disconnecting a pipe.
Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapours of cleaning liquids.
Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
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12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly. If the coupling guard of the compressor drive shaft was removed, check
that it has been reinstalled.
17. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam-cleaning.
18. 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.
19. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas. Processing
of any other gas requires additional safety precautions typical to the application which are
not included herein.
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General description
2.1
Introduction
General views
Front view, ZA/ZE 3/4 160 kW (215 hp)
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Front view, ZE 3/4 with aftercooler and ZA/ZE 3/4 160 kW (215 hp)
Side view, ZE 3/4 with aftercooler and ZA/ZE 3/4 160 kW (215 hp)
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Side view, ZA/ZE 3/4 160 kW (215 hp)
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View of compressor element, ZE 3/4
Ref.
Name
AF
Air filter
AO
Air outlet
Ca
Aftercooler
Co
Oil cooler
Compressor element
E1
Electronic regulator
FN
Fan
M1
Compressor motor
SV
Safety valve
S2
Emergency stop button
TV
Full-load/no-load regulator
Electric cabinet
Vibration dampers
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ZE/ZA are low pressure, single-stage, electric motor driven screw compressors which deliver oil-free,
pulsation-free air. By continuously matching the speed of the drive motor to the air net pressure, the
compressors optimize energy consumption and reduce the operating pressure band.
ZE compressors are air-cooled.
The compressors include mainly:
Air filter
Compressor element
Drive motor
Drive coupling
Gear casing
Elektronikon control system
Safety valves
Oil cooler
The compressors can be equipped with a full-load/no-load regulator.
Aftercooler
The ZE 3/4 compressors can be provided with an aftercooler.
Connections
ANSI flanges
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2.2
Air flow, oil and cooling system
Flow diagram
ZE 3/4 compressor with aftercooler and with throttle valve
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ZE 3/4 compressor without aftercooler and with throttle valve
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ZA 3/4 compressor with throttle valve
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ZA 3/4 compressor without throttle valve
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ZE 3/4 compressor without aftercooler and without throttle valve
ZE 3/4 compressor with aftercooler and without throttle valve
Text on figures:
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Instruction book
Reference
Description
(1)
1 fan for ZE 3 - 2 fans for ZE 4
(2)
SI 94 only for VSD units
(3)
1 for ZE 3 and 2 for ZE 4
(4)
Extra for ZE 3-4
(5)
Only on pressure variants 1 up to 2.75 bar
(6)
Only on pressure variants 1.5 up to 2.75 bar
(7)
1 for ZE 3 and 2 for ZE 4
Component list
20
Reference
Component
005
Frame
007
Panels and doors
008
Silencing foam
012
Hydraulic hoses
100
Air inlet filter, process air
102
Expansion joint
103
Inlet throttle valve (with throttle)
104
Oil-free air compressor stage
105
Inlet silencer
106
Floating pipe
107
Safety valve
108
Flexible connection
109
Check valve
110
Compensator
111
Water separator
115
Precooler
116
Aftercooler
119
Compensator
120a
Diaphragm (with throttle)
120b
Solenoid valve
124
Drain receiver with valve
129
Blow-off silencer
130
Oil sump
131
Oil pump
132
Oil cooler
133
Oil filter
134
Valve
135
Bypass valve
150
Drive motor
151
Coupling
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Reference
Component
153
Fan and motor
154
Fan and motor
160
Electrical cubicle
169
Gear box breather with filter
Sensor list
Reference
Component
PT29
Compressor outlet pressure
PDT02
Pressure difference, air filter
PT49
Oil pressure
TT29
Compressor outlet temperature
TT11
Compressor element outlet temperature
TT44
Oil temperature
TT10
Ambient warning
Air flow
Air drawn through filter (100) is compressed in compressor element (104) and discharged through check
valve (109) towards the air net.
An aftercooler is available as an option.
Condensate drain system
If a pre-aftercooler (115) and aftercooler (116) are provided, a water separator (111) (integrated in the
aftercooler) with drain receiver and valve (124) is installed downstream of the cooler to prevent condensate
from entering the air outlet pipe.
Oil system
Oil is circulated by pump (131) from the sump of the gear casing through cooler (132), the cooling jacket
of compressor element (104) and filter (133) towards the bearings and timing gears.
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Cooling system ZE 3/4
If an aftercooler (Ca) is provided, the cooler is cooled by fans (FN3 and FN4). The oil cooler is cooled by a
fan (FN2).
Cooling system ZA 3/4
ZA compressors have a cooling water circuit for the oil cooler (Co) and the cooling jacket of compressor
element (E).
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2.3
Electrical system
Description
Arrangement E compressors are completely equipped and wired, and require only connection to the mains.
The system includes mainly:
APF200498
Compressor motor
Elektronikon control system including an electronic regulator and a control panel
Pressure and temperature sensors
On compressors with low-voltage motors, an electric cabinet including the starting equipment of the
motor is also installed.
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Instruction book
Elektronikon Graphic Plus controller
3.1
Electronic control system
Control panel
Introduction
The electronic controller has following functions:
Controlling the compressor

Protecting the compressor
Monitoring components subject to service
Automatic restart after voltage failure (made inactive)
Automatic control of the compressor operation

The 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 the display and general alarm
LED (1) will blink.
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Remedy the trouble and reset the message. See also the section Inputs menu.
Before remedying, consult the applicable safety precautions.
Shut-down warning
A shut-down warning level is a programmable level below the shut-down level.
If one of the measurements exceeds the programmed shut-down warning level, a message will appear on
the display and general alarm LED (1) 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 Service Plans). Each Service Plan has a programmed
time interval. If a time interval is exceeded, a message will appear on the display to warn the operator to
carry out the service actions belonging to that Service Plan.
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 your 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.
3.2
Control panel
Elektronikon regulator
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Parts and functions
3.3
Reference
Designation
Function
Display
Shows the compressor operating condition and a

number of icons to navigate through the menu.
Pictogram
Automatic operation
Pictogram
General alarm
General alarm LED
Blinks when operating in shutdown warning

condition.
Pictogram
Service
Service LED
Lights up when service is needed.
Automatic operation LED
Indicates that the controller runs in automatic mode.
Voltage on LED
Lights up when supply is switched on. Compressor

unit might start automatically!
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.
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).
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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
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
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Relay
Connector
Maximum 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
3.4
Icons used
Status icons
Name
Icon
Description
Stopped / Running
When the compressor is stopped, the icon is motionless.

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

Remote start / stop
Network control
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Automatic restart after voltage

failure
Automatic restart after voltage failure is enabled
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.
Menu icons
Icon
Description
Service
Alarms (warnings, shutdowns)

Week timer
Info
Test
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Icon
Description
Counters
Regulation setpoints
Inputs
Outputs
ESi
Event history (saved data)

Settings
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)
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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
General alarm
Oil circuit
Regulation
General settings
Access key / User password
Navigation arrows
Icon
Description
Up
Down
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3.5
Main screen
Control panel
Control panel
(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.
2.
3.
4.
5.
Two value lines

Four value lines
Chart (High resolution)
Chart (Medium resolution)
Chart (Low resolution)
Value views
Text on figures
(1)
Compressor Outlet
(2)
32
(3)
Text varies upon the compressor's actual condition
(4)
Menu
(5)
Running hours
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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:
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:
Designation
Function
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.
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Chart views
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.
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3.6
Calling up menus
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:
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.
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3.7
Converter menu
Control panel
(1)
Enter key
(2)
Escape key
(3)
Scroll keys
Menu icon
Function
To call-up the speed of the fan motor
Procedure
Starting from the Main screen (see Main screen):
Move the cursor to the action button Menu and press the enter key (2). Following screen appears:
Using the scroll keys (1), move the cursor to the converter icon (see above, section Menu icon)
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Press the enter key (2). Following screen appears:
A red selection bar is covering the item Fan (2). Press the enter key. A screen showing the speed of
the fan motor appears.
To return to the menu screen, press the Escape button (2).
3.8
Service menu
Control panel
(1)
Enter key
(2)
Escape key
(3)
Scroll keys
Menu icon, Service
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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:
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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.
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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:
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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.
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3.9
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 press the enter key (2). Following screen appears:
Using the scroll keys (1), move the cursor to the protections icon.
Press the enter key (2). Following screen appears:
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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
A number of icons is shown, allowing to display and reset following protections:
Depending on the machine type and the installed optional equipment less/more/different
icons and/or relevant underlying menus are displayed.
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
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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 Closed: monitors position of the delta contactor
Expansion Module Communication

Not triggered: if Triggered the communication between the Elektronikon and the
expansion module failed.
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
Converter(s)
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Main motor converter alarm

Fan motor converter alarm
Dryer motor converter alarm
3.10 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.
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),
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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.
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.
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(1)
Week Action Schemes
(2)
Week Action Scheme 1
(3)
(4)
(5)
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.
(1)
(2)
Monday
(3)
Tuesday
(4)
Wednesday
(5)
Thursday
(6)
Friday
(7)
Saturday
(8)
Sunday
A new window opens. The Modify action button is selected. Push the Enter key on the controller
twice to create the first action.
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(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.
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(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.
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(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.
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(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.
(1)
(2)
Monday
(3)
Start
(4)
Tuesday
(5)
Wednesday
(6)
Thursday
(7)
Friday
(8)
Saturday
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(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
(2)
Week Action Schemes
(3)
Week Cycle
(4)
Status
(5)
Week 1
(6)
A list of 10 weeks is displayed.
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(1)
Week Cycle
(2)
Week 1
(3)
(4)
Week 2
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(5)
(6)
Week 3
(7)
(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
(4)
(5)
(6)
(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
(2)
Week Action Schemes
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(3)
Week Cycle
(4)
Status
(5)
Week Timer Inactive
(6)
(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
(2)
After pushing the Enter key, the Remaining Running Time is confirmed and displayed. This timer is
prior to all Week Timer actions.
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3.11 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).
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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
Licence ESi
3.12 Test menu

Control panel
Menu icon, Test
Function
To perform a safety valve test. This action can only be performed by authorized personnel and is
protected by a security code.
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3.13 Counters
Control panel
(1)
Enter key
(2)
Escape key
(3)
Scroll keys
Menu icon, Counters
Function
To display:
The running hours

The loaded hours (air delivery)
The number of motor starts
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:
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Text on figure
(1)
Menu
(2)
Regulation
Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon)
Press the Enter key. Following screen appears:
Text on figure
(1)
Counters
(2)
Running hours
(3)
Loaded Hours
(4)
Motor starts
(5)
Load relay
The screen shows a list of all counters and their current values.
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3.14 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:
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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:
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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.
3.15 Inputs menu

Control panel
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(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:
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Text on figure
(1)
Inputs
(2)
Compressor outlet
(3)
Dp Air filter
(4)
Oil pressure
(5)
Compressor outlet
(6)
Modify
The screen displays a list of all inputs with their corresponding icons and readings.
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)
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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:
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Text on figure
(1)
Inputs
(2)
Main chart signal
(3)
Set as main chart signal
(4)
Modify
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
(2)
Main chart signal
(3)
Set as main chart signal
(4)
Modify
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(1)
Main chart signal
(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.
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.
(1)
Main chart signal
(2)
Remove from main chart
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(1)
Main chart signal
(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.
3.16 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
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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.
Depending on the installed optional equipment less or more icons may appear.
Line contactor
Star contactor
Delta contactor
Load/Unload
3.17 SPM menu

Control panel
(1)
Enter key
(2)
Escape key
(3)
Scroll keys
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Menu icon, Event History
Function
To call up the SPM data.
Procedure
Move the cursor to the Menu action button and press the Enter key. Following screen appears:
Using the Scroll keys, move the cursor to the SPM icon (see above, section Menu icon).
The list of measured SPM data is shown.
SPM values are only measured when the machine is running in load.
For VSD compressors, the SPM values are only displayed when the measurement was done on a
stable speed (not during ramping up or ramping down).
Before each SPM value a time stamp shows when this value was measured.
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3.18 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
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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.
3.19 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
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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:
Depending on the installed optional equipment less or more icons may appear.
The screen displays following icons:
Icon
Function
Network settings
Regulation settings
General settings
Fan settings
Automatic restart after voltage failure settings
Access key
User password
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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
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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.
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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.
Fan settings
Select the Fan settings icon as described above and push the Enter key (1). Following screen appears:
Text on figure
(1)
Fan
(2)
Temperature setpoint offset select
(3)
Temperature setpoint offset outlet
(4)
Temperature setpoint offset approach
(5)
Reaction delay
The screen shows the first items of a list of all settings. Use the scroll button to see the other items in
the list.
Push the Enter key (1); a red selection bar is covering the first programmable item (Temperature
setpoint offset outlet).
Use the key of the Scroll keys to select the setting to be modified and push the Enter key.
A pop-up 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:
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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.
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:
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Text on figure
(1)
Main chart
(2)
Main chart signal
(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:
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.
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3.20 Programmable settings

Service settings
Minimum
setting
Factory
setting
Maximum
setting
Service
Service level A
hr
4000
Service level B
hr
8000
Service level C
hr
16000
Service level D
hr
40000
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 Centre.
3.21 Web server

All Elektronikon controllers have a built-in web server that allows direct connection to the company
network or to a dedicated PC via a local area network (LAN). This allows to consult certain data and
settings via a PC instead of the display of the controller.
Getting started
If the compressor 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 (see picture below).
USB to LAN adapter
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Use a UTP cable (CAT 5e) to connect to the controller (see picture below).
Configuration of the network card (in Windows XP)

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

IP Address 192.168.100.200
Subnetmask 255.255.255.0
Click OK and close network connections.
Configuration of the web server
Configure the web interface (for Internet Explorer)
Open Internet Explorer and click on Tools - Internet options (2).
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Click on the Connections tab (1) and then click on the LAN settings button (2).
In the Proxy server Group box, click on the Advanced button (1).
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In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be
given but they must be separated with semicolons (;).
Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now
you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1)
(see picture).
Click OK (2) to close the window.
Viewing the controller data
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All screen shots are indicative. The number of displayed fields depends on the selected
options.
Open your browser and type the IP address of the controller you want to view in your browser (in this
example http://192.168.100.100). The interface opens:
Screen shot (example!)
Navigation and options

The banner shows the compressor type and the language selector. In this example, three languages are
available on the controller.
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Compressor settings
All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and
it will be displayed. Only the machine status is fixed and can not be removed from the main screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference button from
the navigation menu.
Counters
Lists all current counter values from controller and compressor.
Info status
Machine status is always shown on the web interface.
Digital inputs
Lists all Digital inputs and their status.
Digital outputs
Lists all Digital outputs and their status.
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Special protections
Lists all special protections of the compressor.
Service plan
Displays all levels of the service plan and their status. This screen shot underneath only shows the running
hours. It is also possible to show the current status of the service interval.
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Installation
4.1
Dimension drawing
Dimensions
Dimension drawing, ZE 3-4 with aftercooler and with ANSI connections
Text on figures:
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Reference
Name
(1)
Compressed air outlet
(2)
Centre of gravity
(3)
Electric cable entry
(4)
Cooling air
(5)
Cooling air outlet
(6)
Air inlet
(7)
Cooling water In - Out
(8)
Only for ZA units
(9)
Type
(10)
Net mass approximately
(11)
Automatic drain, aftercooler
(12)
Manual drain, aftercooler
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4.2
Installation proposal
Compressor room example
ZE 3-4 with aftercooler and ANSI connections
Reference
Name
(1)
Minimum free area to be reserved for the compressor installation
(2)
Ventilation proposals
(3)
Common ducting for multiple units is not allowed
(4)
Compressor cooling
(5)
Process air
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Warning
Working with machinery controlled by a frequency converter requires special safety
precautions which depend on the type of network (TN, TT or IT). Consult Atlas Copco.
The unit complies with class A limits for radiated emission according to EN 55011 (1998).
Beware of possible electro-magnetic interferences in case stricter limitations are valid.
The unit complies with limits according to standards EN61000-4-2:1995,
EN61000-4-3:1996, EN61000-4-4:1995, EN61000-4-6:1996 for immunity of the equipment.
Environmental conditions : Class 3K3, 3C2 according to EN 60721-3-3.
Oil mist, formation of ice, moisture condensation, water drops, water spray, water splashes
and water jets are not permissible (EN 60204 Part 1).
Thermal insulation should be provided on compressors without aftercooler to protect
against the high temperature of the air outlet valve and air delivery pipe.
Description
1. Install the compressor on a level floor with a maximum allowable deviation of 3 mm on 1 m (0.118 in
on 3.28 ft), suitable for taking the weight of the compressor. Recommended minimum distance
between the top of the bodywork and the ceiling is 500 mm (1200 mm for compressors equipped with
an aftercooler), ventilation proposal alternative 2 excepted. Distances between unit and walls stated
are minimum.
2. Remove the plastic plug (if provided) from the compressor air outlet pipe and install an air outlet
valve. See section Dimension drawings for the dimensions. Close the air outlet valve and connect the
air net to the compressor.
3. The maximum pressure drop over the delivery pipe can be calculated as follows:
dp = (L x 450 x Qc1.85) / (d5 x P)
dp = pressure drop (recommended maximum = 0.1 bar)
L = length of delivery pipe in m
d = inner diameter of the delivery pipe in mm
P = absolute pressure at the compressor outlet in bar(a)
Qc = free air delivery of the compressor in l/s
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 air velocity to the grids should be limited to 5 m/s.
For alternative 2 the maximum allowable pressure drop over the cooling air ducts is 30 Pa. If the
pressure drop exceeds 30 Pa, a ventilation fan is required. Consult Atlas Copco. Common ducting for
several compressors is not allowed.
For alternative 1, the required ventilation capacity (per compressor installed) to limit the compressor
room temperature can be calculated as follows:
Qv
Ducted
Not ducted
With aftercooler
0.04 N/dT
0.96 N/dT
Qv = required ventilation capacity in m3/s

N = shaft input of the compressor in kW
dT = temperature rise of the compressor room in degrees Celsius
5. On compressors with aftercooler, fit the manual drain valve. Lay out the drain piping from the valve
and the automatic condensate outlet towards the open condensate collector. The drain pipes must not
dip into the water of the collector.
6. Elektronikon control system with control panel.
7. See section Electric cables for the recommended cable size of the supply cables. Check that the
electrical connections correspond to the 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.
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4.3
Electric cable size
General
Local regulations remain applicable if they are stricter than the values proposed below.
The voltage drop must not exceed 5 % of the nominal voltage. It may be necessary to
use cables with a larger size than those stated to comply with this requirement.
The size is valid for cable PVC 70 C (158 F), at ambient temperature 40 C (104 F)
according to EN60204.
Electrical connections
(1)
Customer's installation
(2)
Main drive motor
(3)
With 6 fuses type 2
(4)
With 3 fuses type 1
ZE/ZA 3/4 60 Hz compressors

Mains + earth cable
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ZE Compressors with aftercooler

Motor power
Supply voltage
Cable size
100 hp
440
2x(3xAWG1+AWG8)
4.4
Settings of overload relay and fuses
60 Hz compressors
ZE compressors with aftercooler
Motor power
Supply voltage
100 hp
440 V
4.5
Circuit breaker (F21)

70 A
Maximum fuses (RK5)

2x(3x125A)
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: 1 333 333
4.6
Cooling water requirements
General
Cooling water needs to fulfill certain requirements in order to avoid problems of scaling,
fouling, corrosion or bacterial growth.
In open circuit cooling towers, protective measures must be taken to avoid the growth of
harmful bacteria such as legionella pneumophila when there is a risk of inhalation of the
water droplets.
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. Therefore the
recommendations formulated in our Cooling Water Specifications are a general guide line for acceptable
coolant quality. However, where strict limits apply, a statement is made in the specification.
The water requirements refer to untreated water. When water is treated, some parameters will change.
Water treatments should be carried out by a specialized water treatment company, taking the responsibility
for the performance of the treated cooling water and the compatibility with the materials in the cooling
circuit. This includes not only the selection of the appropriate additives, but also the correct application,
monitoring of concentrations and properties, prevention of sludge formation and maintenance of the
system. This applies also to treatment with antifreeze products. They must be provided with suitable
stabilizers and inhibitors. Specifications are also depending on the type of cooling circuit (open, once
through / recirculating with tower / closed) and on the application (Standard max 65 C cooling water
temperature at the outlet) or Energy Recovery (water temperature up to 95 C).
In case water is not in line with recommended values or if any doubt, consult the manufacturer.
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Cooling water parameters

1. pH
The effect of pH is already included in the Ryznar Stability Index (RSI - see item 4 below), but also
the pH itself is subject to limitations:
pH
Type of cooling system
Materials
Standard
Energy recovery
Single pass
Containing copper
6.8 - 9.3
6.8 - 9.3
Stainless steel with carbon 6.8 - 9.3

steel and / or cast iron
6.8 - 9.3
Stainless steel only
6 - 9.3
6 - 9.3
Containing copper
6.8 - 9.3
not applicable
Recirculating (with tower)

Closed loop
6 - 9.3
Containing copper
7.5 - 9.3
7.5 - 9.3

7.5 - 9.3
6 - 9.3
6 - 9.3
The values in bold are rejection limits.

When the system contains Zn or Al, the pH must be < 8.5.
2. Total dissolved solids (TDS) and conductivity
The conductivity is expressed in S/cm, the TDS in ppm.
Both parameters are related with each other. The conductivity is convenient for quick monitoring of
general water quality, but the TDS is required for calculating the RSI. If only one of both parameters
is measured, an estimation can be obtained by using a theoretical conversion factor (0.67):
TDS = conductivity x 0.67
3. Hardness
Different types of hardness are in relation with each other and together with the pH and the alkalinity
of the water they determine the equilibrium situation of the water, determined and specified by the
RSI.
In addition, the calcium hardness must be limited to:
Ca (ppm Ca CO3)
Standard
Energy recovery
Single pass
< 500
<2
< 500
not applicable
Closed loop
< 1000
< 50
4. The Ryznar Stability Index (RSI)

The Ryznar Stability Index is a parameter for predicting whether water will tend to dissolve or
precipitate calcium carbonate. The adhesion of scaling depositions 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:
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RSI = 2*pHs - pH,

in which
pH = measured pH (at room temp) of the water sample
pHs= pH at saturation
pHs is calculated from:
pHs = (9.3 + A + B) - (C + D),
in which
A : depends on the total solids concentration
B : depends on the water temperature at the outlet of the heat exchanger
C : depends on the calcium hardness (CaCO3)
D : depends on the HCO3- concentration or M-alkalinity
The values of A, B, C and D can be found in below table:
Total
dissolved
solids
(mg/l)
Temperature
(C)
Ca hardness
(ppm CaCO3)
MD
Alkalinity
(ppm
CaCO3)
< 30
0.1
0-1
2.3
9 - 11
0.6
10 - 11
1.0
30 - 320
0.2
2-6
2.2
12 - 14
0.7
12 - 14
1.1
> 320
0.3
7 - 11
2.1
15 - 17
0.8
15 - 17
1.2
12 - 16
2.0
18 - 22
0.9
18 - 22
1.3
17 - 22
1.9
23 - 28
1.0
23 - 28
1.4
23 - 27
1.8
29 - 35
1.1
29 - 35
1.5
28 - 32
1.7
36 - 44
1.2
36 - 44
1.6
33 - 38
1.6
45 - 56
1.3
45 - 56
1.7
39 - 43
1.5
57 - 70
1.4
57 - 70
1.8
44 - 49
1.4
71 - 89
1.5
71 - 89
1.9
50 - 55
1.3
90 - 112
1.6
90 - 112
2.0
56 - 61
1.2
113 - 141
1.7
113 - 141
2.1
62 - 67
1.1
142 - 177
1.8
142 - 177
2.2
68 - 73
1.0
178 - 223
1.9
178 - 223
2.3
74 - 79
0.9
224 - 281
2.0
224 - 281
2.4
80 - 85
0.8
282 - 355
2.1
282 - 355
2.5
86 - 91
0.7
356 - 446
2.2
356 - 446
2.6
92 - 95
0.6
447 - 563
2.3
447 - 563
2.7
564 - 707
2.4
564 - 707
2.8
708 - 892
2.5
708 - 892
2.9
893 - 1000
2.6
893 - 1000 3.0
Interpretation of the values obtained:

RSI < 6: boiler scale formation
6 < RSI < 7: neutral water
RSI > 7: corrosive water
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As a general rule, the RSI index should be between 5.6 and 7.5. If that is not the case,
contact a specialist.
5. Free chlorine (Cl2)

Disinfecting with chlorine is not done in closed systems, neither in energy recovery systems.
A continuous level of 0.5 ppm should not be exceeded. For shock treatments, a maximum limit of 2
ppm for maximum 30 minutes/day applies.
6. Chlorides (Cl-)
Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited,
depending from the RSI value.
Cl- (ppm)
RSI < 5.5
5.6 < RSI < 6.2
6.3 < RSI < 6.8
6.9 < RSI < 7.5
7.6 < RSI
200
350
500
350
200
For energy recovery systems, the limit is 100 ppm.

7. Sulphates (SO42-)
Sulphate (ppm)
Standard
Energy recovery
Single pass
< 1000
< 200
< 1000
not applicable
Closed loop
< 400
< 200
8. Iron and Manganese

Dissolved iron (ppm)
Dissolved manganese (ppm)
Type of cooling
system
Standard
Energy recovery
Standard
Energy recovery
Single pass
<1
< 0.2
< 0.2
< 0.05
Recirculating (with
tower)
<1
not applicable
< 0.2
not applicable
Closed loop
<1
< 0.2
< 0.2
< 0.05
The values in bold are rejection limits.

9. Copper
Copper (ppm)
Standard
Energy recovery
Single pass
<1
< 0.2
<1
not applicable
Closed loop
<1
< 0.2
10. Ammonium
The limit of 0.5 ppm is a rejection limit.
The limitation only applies for copper containing systems.
11. Suspended solids
Large particles (size > 10 m) should not be present as they can be filtered out.
Small particles (< 0.5 m) are not taken into account.
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For particles between 0.5 m and 10 m, the following limits apply:

Suspended solids (ppm)
Standard
Energy recovery
Single pass
< 10
<1
< 10
not applicable
Closed loop
< 10
<1
12. Oil or grease

< 1 ppm (rejection value)
13. Biology
If biology is present, it must be aerobic. Anaerobic biology (in closed systems) must be avoided.
Biology (CFU/ml)
Standard
Energy recovery
Single pass
< 105 / < 107
< 103 / < 105
< 105 / < 107
not applicable
Closed loop
< 103 / < 105
< 103 / < 105
The table shows the recommended values. The values in bold are rejection limits.
If additives are used in the cooling water, take into account that the cooling capacity will
change.
m = ((Cpw - Cpa) * X) / (Cpw *(1-X) + X*Cpa) * 100 %
with
m: change of mass flow of the coolant
Cpw: specific heat capacity of water
Cpa: specific heat capacity of the additives
X: the percentage of additives
4.7
Pictographs
Pictographs on control panel
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Reference
Name
Alarm
Service
Automatic operation
Voltage on
Enter
Escape
Scroll keys
Stop
Start
Pictographs at other locations
Reference
Name
10
Pictograph, earthing
11
Warning: under tension
12
Switch off the voltage and depressurize the compressor before maintenance or repair
13
Before connecting the compressor electrically, consult the Instruction book for the motor
rotation direction
14
Torques for steel (Fe) or brass (CuZn) bolts
15
Read Instruction book before starting the compressor
16
Consult the Instruction book before greasing
17
Switch off the voltage before removing the protecting cover inside the electric cabinet
18
Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)
19
Stop the compressor before maintenance or repair
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Reference
Name
20
Automatic condensate drain
21
Manual condensate drain
22
Pictograph, warning: blow off
23
Pictograph, warning: hot surface
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Operating instructions
5.1
Initial start-up
Safety precautions
The operator must apply all relevant Safety precautions.
Ambient conditions
If the compressor is being operated at high altitudes, consult the Atlas Copco Customer Centre.
Moving/lifting
The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude
from the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Make
sure that the beams cannot slide and that they protrude from the frame equally. The chains must be held
parallel to the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment
must be placed in such a way that the compressor will be lifted perpendicularly. Lift smoothly and avoid
twisting.
General preparation
Make sure that the compressor is installed correctly.
See sections Dimension drawings, Installation proposal and Electric cables.
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.
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Remove both transport supports (Ts1) (one at each side of the gear casing) which fix the gear casing
to the frame.
Loosen nut (4) and unscrew bolt (5) until the thread of the bolt between bolt head and nut is
noticeable over a distance of 50 mm. Tighten the nut (maximum torque = 100 Nm).
Silica gel bags
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To protect the compressor against corrosion during transport, silica gel bags are installed in the silencer.
Remove flange (1), take out the silica gel bags and reinstall the flange.
Oil circuit
Check that the compressor is filled with oil; oil must be visible in oil level sight-glass (SG).
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Start-up
1. Check the voltage selecting wires at transformer (T1) for correct connection. Check the settings of the
circuit breakers.
2. Switch on the voltage. Start the motor and stop it immediately. Check for correct direction of rotation
while the motor is coasting to a stop. The correct rotation direction is indicated by the arrow on the
coupling housing or on the gear casing. If the rotation direction is wrong, consult Atlas Copco.
Also check the rotation direction of the oil cooler fan motor (M2) and, if provided, fan motors (M3
and M4); arrows indicating the correct direction are stuck on all the motors.
3. Run the compressor for a few minutes; stop the compressor and check the oil level, which must be in
the middle of sight-glass (SG). Top up, if necessary.
5.2
Before starting
Safety precautions
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Procedure
Check the oil level, which must be in the middle of sight-glass (SG). Top up, if necessary, with the
correct type of oil.
If an aftercooler is installed, close the condensate drain valve.
Open the air outlet valve (customer's installation).
Switch on the voltage and check that voltage on LED (4) lights up.
5.3
Starting
Warnings
When the compressor is stopped and automatic operation LED (3) is alight, the
compressor may start automatically.
If the start/stop timer is active, the compressor may start automatically, even if it was
stopped manually.
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Description
Press start button (6). The compressor starts running and automatic operation LED (3) lights up.
5.4
During operation
Warning
Control panel
When automatic operation LED (3) is alight, the Elektronikon regulator is automatically controlling the
compressor: the speed will continuously vary to match the air delivery to the air consumption; the
compressor will start and stop whenever necessary.
Keep all doors closed during operation.
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5.5
Checking the display
Warnings
Before starting any maintenance or repairs, stop the compressor and open the isolating
switch (customer's installation) to switch off the voltage to the compressor.
Repairs inside the start and speed regulation cabinet may 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 start and speed regulation unit for 6 minutes after
switching off the voltage.
Close the air outlet valve.
Control panel
Description
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 (1) 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.
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5.6
Stopping
Control panel
Description
1.
2.
3.
4.
Press stop button (5). The compressor will stop and LED (3) will go out.
To stop the compressor in case of emergency, press the emergency stop button.
If an aftercooler is installed, open the condensate drain valve.
Emergency stopping
To stop the compressor immediately, press emergency stop button. Alarm LED (1) starts blinking.
After remedying the trouble, unlock the emergency stop button by pulling it out.
After stopping, close the air outlet valve. If an aftercooler is installed, open the drain valve of the
aftercooler drain receiver.
5.7
Taking out of operation
Description
At the end of the service life of the compressor, proceed as follows:
1.
2.
3.
4.
Close the air outlet valve and stop the compressor.

Switch off the voltage and disconnect the compressor from the mains.
Depressurize the compressor as described in section Depressurizing the compressor.
Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the
compressor air outlet pipe from the air net.
5. Drain the oil and condensate circuits.
6. Disconnect the condensate drain piping from the compressor.
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Maintenance
6.1
Preventive maintenance schedule
Safety precautions
Before starting any maintenance or repairs, stop the compressor and open the
isolating switch (customer's installation) to switch off the voltage to the
compressor.
Repairs inside the start and speed regulation cabinet may 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 start and speed regulation unit for 6
minutes after switching off the voltage.
The operator must apply all relevant Safety precautions, including those
mentioned in this book.
Service agreements
Atlas Copco Customer Centres have a range of service agreements to suit your needs:
An Inspection plan
A Preventive maintenance plan
A Total responsibility plan
Contact your Customer Centre to agree on a tailor-made service agreement. It will ensure optimum
operational efficiency, minimize downtime and reduce the total life cycle costs.
Warranty-Product Liability
Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability.
Service kits
Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits. Service kits
comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts
while keeping the maintenance budget low.
Regular checks
The following checks should be carried out regularly to ensure safe operation and long service life.
Period
Running hours
Operation
Daily
Check the readings.
Daily
On compressors with aftercooler, check that condensate is

discharged during loading.
Daily
--
Check the oil level.

Before starting, the level should be in the middle of the sight-glass.
Weekly
--
Drain condensate from the air receiver, if installed
APF200498
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Instruction book
Period
Running hours
Operation
Every 3 months
--
Clean compressor.
Every 3 months
--
Check for possible leaks.
Every 3 months
500
Check the coolers; clean them if necessary.
Every 3 months
500
Remove air filter and inspect. Replace if dirty or damaged.
When displayed
--
Carry out service actions according to the displayed service plans
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. Consult your Atlas Copco Customer
Centre.
Service plan
Running hours
4000
8000
16000
40000
2000
6.2
Motor greasing
General
Stop the compressor before greasing.
Never mix greases of different brands or types.
Motor greasing
Motor Type
Interval
Quantity
Grease
WEG W22 250 S/M

WEG W22 404/5TSD
WEG W22 280 S/M
4000 hrs
27 gr
Roto Glide Blue
4000 hrs
30 gr
Roto Glide Green
WEG W22 444/5TSD

SIEMENS 315L
Atlas Copco grease can be ordered with following ordening numbers:
106
Roto Glide Blue
2908 8521 00
Roto Glide Green
2908 8514 00
APF200498
Instruction book
6.3
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:
6.4
Quantity (l)
Ordering number
5 l can
2908 8503 00
20 l can
2908 8501 01
209 l drum
2908 8500 00
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.
6.5
Disposal of used material

Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must
be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations
and environmental legislation.
Electronic components are subject to the EU Directive 2002/96/EC for Waste Electrical and Electronic
Equipment (WEEE). As such, these parts must not be disposed of at a municipal waste collection point.
Refer to local regulations for directions on how to dispose of this product in an environmental friendly
manner.
APF200498
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Instruction book
Servicing procedures
7.1
Air filters
Procedure
1. In dusty operating conditions where it will be necessary to replace the filter too frequently, an
appropriate pre-filter of the dry type should be installed.
2. The filter must be serviced as soon as the service warning appears on the display.
3. Stop the compressor and switch off the voltage to the compressor.
4. Remove the air filter, never remove the filter while the compressor is running.
5. Install the new filter. Never install damaged or clogged filters.
6. Switch on the voltage and reset the air filter service warning.
7.2
Oil and oil filter change
Oil system
Procedure
1. Run the compressor until warm.
2. Stop the compressor and switch off the voltage.
3. Remove filler plug (FC). Drain the compressor sump and oil cooler while the compressor is still
warm.
Remove the drain plugs (Dp1 and Dp2) and open the drain valves (Dv1 and Dv2). Close the valves
and reinstall the plugs after draining.
4. Remove the oil filter. Clean the filter seat, oil the gasket of the new filter and screw it into place until
the gasket contacts the seat. Then tighten by hand.
5. Fill the compressor sump to the middle of the oil level sight-glass (SG) with oil as specified in section
Oil specifications. Reinstall the filler plug.
108
APF200498
Instruction book
6. Run the compressor for a few minutes; stop the compressor and check the oil level. Top up if
necessary to the middle of sight-glass.
7. After carrying out all the service actions of the related service plan, reset the service warning.
7.3
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.
APF200498
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Instruction book
Problem solving
8.1
Problem solving
Before carrying out any maintenance, repair or adjustment work, stop the
compressor and open the isolator switch to switch off the voltage to the
compressor.
Repairs inside the start and speed regulation cabinet may 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 start and speed regulation unit for 6
minutes after switching off the voltage.
Control panel
Faults and remedies
If the alarm LED is lit or flashes, consult sections Event history menu or Service menu.
Condition
Fault
Remedy
Compressor starts running,

Pressure in air net is above
but does not load after a delay pre-set loading pressure
time
Compressor will load when pressure in air

net drops to pre-set loading pressure
Compressor capacity or
working pressure lower than
normal
Air consumption exceeds

capacity of compressor
Check pneumatic plant
Safety valves leaking
Have valves inspected
Oil level too low
Top up level to the middle of the oil level

sight-glass
Oil filter clogged
Replace filter
Oil pressure too low
Air temperature above normal Inlet temperature too high due Improve ventilation of compressor room
to bad room ventilation or
and avoid cooling air recirculation
recirculation of cooling air
Air filter clogged
Oil temperature above normal Oil shut-down temperature
incorrectly set
110
Replace filter
Correct setting to trip at the specified
temperature
On ZE, insufficient cooling air

flow
Check the cooling fan
On ZA, insufficient cooling

water flow
Check cooling water
APF200498
Instruction book
Technical data
9.1
Readings
Important
The readings below are valid when operating at reference conditions. See the section
Reference conditions.
Readings on display
For the maximum working pressure and the outlet pressure, consult sections Compressor data.
Item
Reading
Outlet pressure
Depends on compressor type
dp of air filter
Below -0.044 bar
Oil pressure
2-2.2 bar(e)
Air outlet temperature
See below
Air temperature element 1 out
115-180 C
Oil temperature
Approx. 30-40 C
Cooling water temperature
Max. 8 C above cooling water inlet

temperature
The air temperature at the outlet valve depends on the compressor type. The temperatures given below are
average values and may differ depending on the compressor type.
9.2
Maximum working pressure
Unit
ZE/ZA 3
1.5 bar
132
Settings of safety valves
Opening pressure of safety valve

Opening pressure(e): 4.5 bar(e) (65 psig)
APF200498
111
Instruction book
9.3
Reference conditions and limitations
Reference conditions
Item
Condition
Absolute inlet pressure
1 bar(a) (14.5 psi)
Relative air humidity
0%
Air inlet temperature
20 C (68 F)
Motor shaft speed
See Compressor data.
Nominal effective working pressure
Limitations
Item
Limit
Maximum air inlet temperature
40 C (104 F)
Minimum ambient temperature
0 C (32 F)
Maximum effective working pressure
Nominal effective working pressure
Minimum effective working pressure
9.4
Common data
9.5
Compressor data
Specific data for ZE 3 60 Hz compressors with aftercooler

Unit
ZE 3 F
- At maximum working pressure of 1.5 bar
bar
1.5
- At maximum working pressure of 21.76 psi
psi
21.76
bar
1.75
psi
25.38
- At maximum working pressure of 2 bar
bar
psi
29.01
bar
2.25
psi
32.63
bar
2.5
psi
36.26
bar
2.75
psi
39.89
bar
Effective working pressure
112
APF200498
Instruction book
Unit
ZE 3 F
psi
43.51
bar
3.25
psi
47.14
bar
3.5
psi
50.76
bar
3.75
psi
54.39
bar
psi
58.02
bar
1.75
psi
25.38
bar
psi
29.01
bar
2.25
psi
32.63
bar
2.5
psi
36.26
bar
2.75
psi
39.89
bar
psi
43.51
bar
3.25
psi
47.14
bar
3.5
psi
50.76
bar
3.75
psi
54.39
bar
psi
58.02
bar
4.25
psi
61.64
bar
psi
14.50
-At effective working pressure of 1 bar
kW
52.6
-At effective working pressure of 14.5 psi
hp
70.49
-At effective working pressure of 1.25 bar
kW
53.8
hp
72.20
kW
56.2
hp
75.37
Maximum effective working pressure
Total electrical power input
APF200498
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Instruction book
Unit
ZE 3 F
kW
59.4
hp
79.65
kW
63.2
hp
84.71
kW
67.4
hp
90.34
kW
71.8
hp
96.30
kW
76.3
hp
102.31
kW
80.6
hp
108.02
kW
84.3
hp
113.02
kW
87.2
hp
116.94
kW
90.9
hp
121.95
kW
95.6
hp
128.18
Total electrical power input at unload
kW
28
Total electrical power input at unload
hp
37.76
Compressed air temperature at outlet valve
40
Compressed air temperature at outlet valve
104
Electrical power input of fan(s)
kW
4.8
Electrical power input of fan(s)
hp
6.44
- For maximum working pressure of 1.5 bar
kW
--
- For maximum working pressure of 21.76 psi
hp
--
kW
--
hp
--
- For maximum working pressure of 2 bar
kW
--
hp
--
kW
93
hp
124.71
kW
93
hp
124.71
kW
93
hp
124.71
kW
93
hp
124.71
Power of installed drive motor
114
APF200498
Instruction book
Unit
ZE 3 F
kW
112
hp
150.19
kW
112
hp
150.19
kW
112
hp
150.19
kW
112
hp
150.19
APF200498
115
Instruction book
10
Pressure equipment directives
10.1 Pressure equipment directives

PED instructions
Product:
ZE 3
This is a pressure assembly of cat I according to 97/23/EC
Parts of article 3.3 of 97/23/EC are subject to good engineering practice.
Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion of
article I, section 3.6.
Parts subject to the Simple Pressure Vessel Directive 87/404/EEC are excluded from 97/23/EC according
to article I, section 3.3.
The following pressure bearing parts are of category higher than I :
Safety valve: Category IV
Design code: AD-Merkbltter, A2
116
APF200498
Instruction book
11
Documentation
Declaration of conformity
Typical example of a Declaration of Conformity document
APF200498
117
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.
Its 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 customers
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.

Comprensoras Altas GA 250

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ZE 3

GENERAL SAFETY PRECAUTIONS............................................................................................................5

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

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

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

AIR FLOW, OIL AND COOLING SYSTEM................................................................................................... 15

Elektronikon Graphic Plus controller.......................................................................24

ELECTRONIC CONTROL SYSTEM...........................................................................................................24

DIGITAL OUTPUT CONTACTS................................................................................................................26

WEEK TIMER MENU...........................................................................................................................45

MODIFYING THE PRESSURE BAND........................................................................................................ 59

EVENT HISTORY MENU.......................................................................................................................69

ELECTRIC CABLE SIZE....................................................................................................................... 89

SETTINGS OF OVERLOAD RELAY AND FUSES...........................................................................................90

QUALITY OF SAFETY COMPONENTS.......................................................................................................90

COOLING WATER REQUIREMENTS.........................................................................................................90

DURING OPERATION........................................................................................................................ 102

CHECKING THE DISPLAY...................................................................................................................103

TAKING OUT OF OPERATION..............................................................................................................104

PREVENTIVE MAINTENANCE SCHEDULE................................................................................................105

MOTOR GREASING.......................................................................................................................... 106

STORAGE AFTER INSTALLATION......................................................................................................... 107

DISPOSAL OF USED MATERIAL........................................................................................................... 107

Servicing procedures................................................................................................. 108

AIR FILTERS.................................................................................................................................. 108

OIL AND OIL FILTER CHANGE.............................................................................................................108

SAFETY VALVES............................................................................................................................. 109

PROBLEM SOLVING......................................................................................................................... 110

SETTINGS OF SAFETY VALVES........................................................................................................... 111

REFERENCE CONDITIONS AND LIMITATIONS.......................................................................................... 112

COMMON DATA.............................................................................................................................. 112

Pressure equipment directives................................................................................. 116

PRESSURE EQUIPMENT DIRECTIVES....................................................................................................116

General safety precautions

Safety precautions during installation

Precautions during installation

Safety precautions during operation

Precautions during operation

Air cooling filters of the electrical cabinet are not clogged

Safety precautions during maintenance or repair

Precautions during maintenance or repair

Front view, ZA/ZE 3/4 160 kW (215 hp)

Side view, ZA/ZE 3/4 160 kW (215 hp)

View of compressor element, ZE 3/4

Emergency stop button

Air flow, oil and cooling system

ZE 3/4 compressor with aftercooler and with throttle valve

ZE 3/4 compressor without aftercooler and with throttle valve

ZA 3/4 compressor with throttle valve

ZA 3/4 compressor without throttle valve

ZE 3/4 compressor without aftercooler and without throttle valve

ZE 3/4 compressor with aftercooler and without throttle valve

1 fan for ZE 3 - 2 fans for ZE 4

SI 94 only for VSD units

1 for ZE 3 and 2 for ZE 4

Extra for ZE 3-4

Only on pressure variants 1 up to 2.75 bar

Only on pressure variants 1.5 up to 2.75 bar

1 for ZE 3 and 2 for ZE 4

Panels and doors

Air inlet filter, process air

Inlet throttle valve (with throttle)

Oil-free air compressor stage

Diaphragm (with throttle)