Z160-250 Instruction Manual

Z 160 200 250
Instruction book
Atlas Copco
Instruction book
Original instructions
COPYRIGHT NOTICE
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2019 - 03
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................6
1.1 SAFETY ICONS................................................................................................................................... 6
1.2 GENERAL SAFETY PRECAUTIONS.............................................................................................................6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION............................................................................................ 7
1.4 SAFETY PRECAUTIONS DURING OPERATION............................................................................................... 8
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR............................................................................. 9
1.6 DISMANTLING AND DISPOSAL............................................................................................................... 11
2 General description...................................................................................................... 12
2.1 INTRODUCTION................................................................................................................................. 12
2.2 AIR SYSTEM.....................................................................................................................................15
2.3 COOLING AND CONDENSATE DRAIN SYSTEM............................................................................................ 17
2.4 ELEKTRONIKON REGULATED DRAIN (ERD)............................................................................................. 18
2.5 OIL SYSTEM.....................................................................................................................................20
2.6 REGULATING SYSTEM.........................................................................................................................21
3 Elektronikon regulator type overview.........................................................................24
3.1 ELEKTRONIKON® CONTROLLER TYPE OVERVIEW....................................................................................... 24
4 Elektronikon regulator................................................................................................. 26
4.1 ELEKTRONIKON® REGULATOR.............................................................................................................. 26
4.2 CONTROL PANEL...............................................................................................................................28
4.3 FUNCTION KEYS................................................................................................................................29
4.4 SCROLL KEYS.................................................................................................................................. 30
4.5 EMERGENCY STOP BUTTON................................................................................................................. 30
4.6 EXTERNAL COMPRESSOR STATUS INDICATION ......................................................................................... 31
4.7 CONTROL PROGRAMS........................................................................................................................ 31
4.8 CALLING UP MENUS........................................................................................................................... 33
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4.9 MAIN SCREEN MENU.......................................................................................................................... 34
4.10 STATUS DATA MENU.......................................................................................................................... 35
4.11 MEASURED DATA MENU......................................................................................................................38
4.12 COUNTERS MENU..............................................................................................................................39
4.13 TEST MENU..................................................................................................................................... 40
4.14 MODIFY PARAMETERS MENU................................................................................................................41
4.15 MODIFYING PARAMETERS....................................................................................................................41
4.16 MODIFYING PROTECTION SETTINGS....................................................................................................... 42
4.17 MODIFYING SERVICE PLANS.................................................................................................................43
4.18 PROGRAMMING CLOCK FUNCTION......................................................................................................... 44
4.19 MODIFYING CONFIGURATION SETTINGS...................................................................................................49
4.20 SERVICE MENU.................................................................................................................................50
4.21 SAVED DATA MENU............................................................................................................................52
4.22 PROGRAMMABLE SETTINGS................................................................................................................. 53
5 Elektronikon® GraphicPlus controller....................................................................... 56
5.1 ELEKTRONIKON® GRAPHICPLUS CONTROLLER........................................................................................ 56
5.2 CONTROL PANEL...............................................................................................................................58
5.3 DIGITAL OUTPUT CONTACTS.................................................................................................................59
5.4 ICONS USED.....................................................................................................................................60
5.5 MAIN SCREEN.................................................................................................................................. 64
5.6 CALLING UP MENUS........................................................................................................................... 69
5.7 SERVICE MENU.................................................................................................................................70
5.8 PROTECTIONS MENU..........................................................................................................................75
5.9 WEEK TIMER MENU........................................................................................................................... 78
5.10 INFO MENU...................................................................................................................................... 88
5.11 TEST MENU..................................................................................................................................... 89
5.12 COUNTERS...................................................................................................................................... 90
5.13 MODIFYING THE PRESSURE BAND......................................................................................................... 92
5.14 INPUTS MENU................................................................................................................................... 95
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5.15 OUTPUTS MENU................................................................................................................................99
5.16 EVENT HISTORY MENU..................................................................................................................... 101
5.17 MODIFYING SETTINGS...................................................................................................................... 102
5.18 PROGRAMMABLE SETTINGS............................................................................................................... 108
5.19 WEB SERVER.................................................................................................................................109
6 Installation...................................................................................................................118
6.1 DIMENSION DRAWING....................................................................................................................... 118
6.2 INSTALLATION PROPOSAL.................................................................................................................. 121
6.3 INSTALLATION REQUIREMENTS FOR RUBBER COMPENSATORS.....................................................................123
6.4 ELECTRIC CABLE SIZE, FUSES AND CABLE LENGTH..................................................................................130
6.5 ELECTRIC CONNECTION.................................................................................................................... 131
6.6 QUALITY OF SAFETY COMPONENTS......................................................................................................134
6.7 COOLING WATER REQUIREMENTS........................................................................................................134
6.8 GENERAL PICTOGRAPHS................................................................................................................... 139
6.9 PICTOGRAPHS, ELEKTRONIKON CONTROL SYSTEM..................................................................................140
7 Operating instructions............................................................................................... 142
7.1 INITIAL START-UP............................................................................................................................ 142
7.2 BEFORE STARTING.......................................................................................................................... 146
7.3 ROUTINE STARTING......................................................................................................................... 148
7.4 STARTING AFTER EMERGENCY STOP OR SHUTDOWN................................................................................150
7.5 DURING OPERATION........................................................................................................................ 152
7.6 CHECKING THE DISPLAY................................................................................................................... 154
7.7 MANUAL LOADING/UNLOADING............................................................................................................155
7.8 STOPPING..................................................................................................................................... 158
7.9 TAKING OUT OF OPERATION...............................................................................................................162
8 Maintenance................................................................................................................ 163
8.1 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................. 163
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8.2 MOTOR GREASING.......................................................................................................................... 165
8.3 OIL SPECIFICATIONS........................................................................................................................ 165
8.4 STORAGE AFTER INSTALLATION.......................................................................................................... 166
9 Servicing procedures................................................................................................. 167
9.1 AIR FILTERS...................................................................................................................................167
9.2 OIL AND OIL FILTER CHANGE..............................................................................................................168
9.3 SAFETY VALVES..............................................................................................................................169
10 Problem solving..........................................................................................................170
10.1 PROBLEM SOLVING..........................................................................................................................170
11 Technical data.............................................................................................................173
11.1 READINGS.....................................................................................................................................173
11.2 SETTINGS OF SAFETY VALVES............................................................................................................ 173
11.3 SETTINGS FOR OVERLOAD RELAY........................................................................................................173
11.4 REFERENCE CONDITIONS.................................................................................................................. 174
11.5 LIMITATIONS.................................................................................................................................. 174
11.6 COMPRESSOR DATA........................................................................................................................ 175
12 Pressure equipment directives................................................................................. 176
13 Documentation............................................................................................................177
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 General safety precautions

1. The operator must employ safe working practices and observe all related work safety
requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter
of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel. The personnel should apply safe working practices by use of
personal protection equipment, appropriate tools and defined procedures.
4. The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to the
applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any
electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
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9. If compressed air is used in the food industry and more specifically for direct food contact, it
is recommended, for optimal safety, to use certified Class 0 compressors in combination
with appropriate filtration depending on the application. Please contact your customer center
for advice on specific filtration.
1.3 Safety precautions during installation

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

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

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

manufacturer.
Precautions during maintenance or repair

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

This equipment falls under the provisions of the European Directive 2012/19/EU on waste
electrical and electronic appliances (WEEE) and may not be disposed as unsorted waste.
The equipment is labelled in accordance with the European Directive 2012/19/EU with the
crossed-out wheelie bin symbol.
At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate
collection.
For more information check with your local waste authority, customer center or distributor.
Disposal of other 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.
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2 General description
2.1 Introduction
General views
General view of ZR 160 up to ZR 275 FF with Elektronikon controller
General view of ZR 160 up to ZR 275 FF with Elektronikon GraphicPlus controller
Ref. Name
AO Compressed air outlet
DRa Condensate drain receiver, aftercooler
DRi Condensate drain receiver, intercooler
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Ref. Name
MK4 Elektronikon regulator
MK5 Elektronikon GraphicPlus regulator
SVh Safety valve, high pressure
SVl Safety valve, low pressure
S2 Emergency stop button
WI Cooling water inlet
WO Cooling water outlet
These units are two-stage, electric motor driven screw compressors which deliver oil-free,
pulsation-free air.
ZR compressors are water-cooled.
The compressor is enclosed in a sound-insulated bodywork and includes mainly:
• Air filter
• Low-pressure compressor element
• Intercooler
• High-pressure compressor element
• Aftercooler
• Water separators
• Electronic water drain
• Electric motor
• Drive coupling
• Gear casing
• Elektronikon® control system
• Safety valves
Drive arrangement
On ARR E, the motor is flanged to the gear casing by means of a coupling housing. The motor/
gear casing unit is supported on the frame by vibration dampers.
Elektronikon control system

The compressor is controlled by an electronic regulator which:
• Controls the operation of the compressor
• Reduces the power consumption
• Warns the operator in case of an abnormal operating condition
• Protects the compressor
• Monitors components subject to service
• If activated, the regulator can automatically restart the compressor after voltage failure
Optional equipment
Following equipment is available as an option:
Connections
DIN flanges
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Motor temperature protection

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

Temperature sensors (PT1000) are embedded in the drive motor to warn the operator if the
temperature of the bearings becomes too high and to shut down the compressor, thereby
protecting the motor bearings from overheating.
Automatic water shut-off

A water shut-off valve is provided in the cooling water system to shut off the system when the
compressor is not in operation.
SPM monitoring
A number of vibration sensors are provided on the drive motor and compressor elements. The
readings can be called up on the display of the Elektronikon regulator.
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2.2 Air system
Flow diagram
Flow diagram of ZR 110 up to ZR 275 and ZR 132 VSD up to ZR 315 VSD compressors
Reference Name
AF Air filter
AO Air outlet
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Reference Name
AS Silencer
BV By-pass valve
Ca Aftercooler
Ci Intercooler
Co Oil cooler
CV Check valve
Eh High-pressure compressor element
El Low-pressure compressor element
MTa Moisture trap, aftercooler
MTi Moisture trap, intercooler
OF Oil filter
OP Oil pump
Description
Air drawn through the filter (AF) is compressed in the low-pressure compressor element (El).
On ZR compressors, the compressed air is discharged to the intercooler (Ci).
The cooled air is further compressed in the high-pressure compressor element (Eh) and
discharged through the silencer (AS) and aftercooler (Ca).
On ZR/ZT 110 up to ZR/ZT 275, a check valve (CV) is fitted downstream of the silencer.
The compressed air leaves the compressor via the air outlet (AO).
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2.3 Cooling and condensate drain system
Flow diagram
Flow diagram of ZR 110 up to ZR 275 compressors
Reference Name
AF Air filter
AO Air outlet
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Reference Name
AS Silencer
BV By-pass valve
Ca Aftercooler
Ci Intercooler
Co Oil cooler
CV Check valve
OF Oil filter
OP Oil pump
Cooling system for ZR compressors

The cooling water flows through oil cooler (Co), the cooling jackets of high-pressure compressor
element (Eh) and low-pressure compressor element (El), as well as through intercooler (Ci) and
aftercooler (Ca).
Condensate drain
Two moisture traps are installed: one downstream of the intercooler (MTi) to prevent condensate
from entering compressor element (Eh) and one downstream of the aftercooler (MTa) to prevent
condensate from entering the air outlet pipe.
On ZR/ZT 110 up to ZR/ZT 275, the moisture traps are connected to an ERD, see section
Elektronikon Regulated Drain.
2.4 Elektronikon regulated drain (ERD)
Description
The drain consists of a capacitive sensor which is incorporated in the drain collector and of a pilot
valve which is placed outside the drain collector. A drain opening delay timer is started when the
collector is filled up to the level of the capacitive sensor. As long as the delay timer is running,
extra condensate will be collected and the level will rise even higher than the position of the
sensor. As soon as the delay timer has expired, the pilot valve (normally open) is deactivated and
the diaphragm opens the outlet, discharging the condensate. From the moment that the sensor is
not detecting any condensate anymore, a drain closing delay timer is started. The pilot valve will
still drain the condensate during the run of this timer to make sure that the remaining amount of
condensate is drained. The pilot valve is activated when the timer has expired, the outlet closes
quickly without wasting compressed air.
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for ZR compressors
Reference Description
1 Solenoid valve
2 Connector
3 Sensor
4 Bushing
5 Drain receiver
If the controller detects water in the intercooler or aftercooler drain receiver for too long a period,
a shutdown is generated. If water is detected on the integrated dryer drain receiver for too long a
period, a warning is generated.
The level switch is a capacitive sensor which generates a high signal when no water is present.
The solenoid valves of the intercooler and aftercooler/integrated dryer drains are different. The
solenoid valve of the intercooler drain has a high flow but cannot handle high pressures. The
solenoid valve on the aftercooler/integrated dryer drains has less flow but can handle higher
pressures. It is not allowed to open the valves as they can loose their set point. Special attention
must be paid to the correct wiring of the different level switches and solenoid valves.
The output of the level switch can be called up on the screen of the Elektronikon regulator. The
reading does not indicate whether the solenoid valve is open or closed, but indicates whether the
level switch is detecting water in the collector. Since there is a drain opening delay timer, the
display on the Elektronikon can show "Condensate Drain IC Open", while the solenoid valve is
still closed. Changes to the Elektronikon settings are not allowed. The "Always pressurized" bit
must be activated on aftercooler and integrated dryer drains. On the intercooler it is not allowed
to activate this bit.
A functionality test is possible through the Elektronikon regulator. By performing this test, all
solenoid valves will be opened for a short time (e.g. 15 seconds). Refer to the Elektronikon
chapter for more details.
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Instruction book
2.5 Oil system
Flow diagram
Flow diagram of ZR 110 up to ZR 275 compressors and ZR 132 VSD up to ZR 315 VSD compressors
Reference Name
AF Air filter
AO Air outlet
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Reference Name
AS Silencer
BV By-pass valve
Ca Aftercooler
Ci Intercooler
Co Oil cooler
CV Check valve
OF Oil filter
OP Oil pump
Description
Oil is circulated by pump (OP) from the sump of the gear casing through cooler (Co).
The oil passes through oil filter (OF) towards the bearings and timing gears.
By-pass valve (BV) opens if the oil pressure should rise above a given value.
2.6 Regulating system
General
The regulator keeps the net pressure within programmable pressure limits by automatically
loading and unloading the compressor depending on the air consumption.
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During unloading
If the air consumption is less than the air delivery of the compressor, the net pressure increases.
When the net pressure reaches the upper limit of the working pressure (unloading pressure),
solenoid valve (Y1) is de-energised. The plunger of solenoid valve (Y1) moves by spring force
shutting off the control air supply to unloader (UA).
Phase Description
1 Control pressure is vented from chamber (1) of unloader (UA) through solenoid valve
(Y1) and chamber (3) towards the inlet of compressor element (El).
2 As there is no longer any pressure difference between chambers (1 and 3), plunger (2)
returns by spring force keeping full-load/no-load valve (TV) closed and unloading valve
(UV) open.
3 Compressed air between check valve (CV) and valve (UV) is blown off through silencer
(US). Check valve (CV) closes.
4 As vacuum prevails in intercooler (Ci), diaphragm (4) switches to the left.
Air delivery is stopped (0%), the compressor runs unloaded.
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During loading
When the net pressure decreases to the lower limit of the working pressure (loading pressure),
solenoid valve (Y1) is energised. The plunger of solenoid valve (Y1) moves against the spring
force opening the control air supply port to unloader (UA).
Phase Description
1 Atmospheric pressure is allowed through solenoid valve (Y1) to chamber (1) of unloader
(UA). As this pressure is higher than the pressure in chamber (3), full-load/no-load valve
(TV) starts opening.
2 Intercooler pressure is building up causing diaphragm (4) to switch to the right. As the
pressure difference between chambers (1 and 3) increases, plunger (2) moves further
against the spring force until full-load/no-load valve (TV) is fully open and unloading
valve (UV) closed.
Air delivery is resumed (100%), the compressor runs loaded.
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3 Elektronikon regulator type overview
3.1 Elektronikon® controller type overview
Type overview
Depending on the manufacturing date or the ordered configuration, the compressor is equipped
with
• the Elektronikon controller
• the Elektronikon Graphic controller
• the Elektronikon GraphicPlus controller
Elektronikon controller
Elektronikon Graphic controller for fixed speed compressors
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Elektronikon Graphic controller for variable speed drive (VSD) compressors
Elektronikon GraphicPlus controller for fixed speed compressors
Elektronikon GraphicPlus controller for variable speed drive (VSD) compressors
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Instruction book
4 Elektronikon regulator
4.1 Elektronikon® regulator
Control panel
Introduction
In general, the Elektronikon regulator has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (made inactive)
Automatic control of compressor operation

The regulator maintains the net pressure between programmable limits by automatically loading
and unloading the compressor. A number of programmable settings, e.g. the unloading and
loading pressures, the minimum stop time and the maximum number of motor starts are taken
into account.
The regulator stops the compressor whenever possible to reduce the power consumption and
restarts it automatically when the net pressure decreases. In case the expected unloading period
is too short, the compressor is kept running to prevent too short standstill periods.
A number of time-based automatic start/stop commands may be programmed. Take into

account that a start command will be executed (if programmed and activated), even
after manually stopping the compressor.
Protecting the compressor

Shut-down
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Several sensors are provided on the compressor. If one of these measurements exceeds the
programmed shut-down level, the compressor will be stopped. This will be indicated on display
(1) and general alarm LED (2) will blink.
Remedy the trouble and reset the message. See also the Status data menu.
Before remedying, consult the Safety precautions.
Shut-down warning
A shut-down warning level is a programmable level below the shut-down level.
If one of the measurements exceeds the programmed shut-down warning level, a message will
appear on display (1) and general alarm LED (2) will light up, to warn the operator that the shut-
down warning level is exceeded.
The message disappears as soon as the warning condition disappears.
Service warning
A number of service operations are grouped (called Level A, B, C, ...). Each level has a
programmed time interval. If a time interval is exceeded, a message will appear on display (1) to
warn the operator to carry out the service actions belonging to that level.
Automatic restart after voltage failure

The regulator has a built-in function to automatically restart the compressor if the voltage is
restored after voltage failure. For compressors leaving the factory, this function is made inactive.
If desired, the function can be activated. Consult the Atlas Copco Customer Centre.
If activated and provided the regulator was in the automatic operation mode, the
compressor will automatically restart if the supply voltage to the module is restored
within a programmed time period.
The power recovery time (the period within which the voltage must be restored to have
an automatic restart) can be set between 1 and 3600 seconds or to “Infinite”. If the
power recovery time is set to “Infinite”, the compressor will always restart after a voltage
failure, no matter how long it takes to restore the voltage. A restart delay can also be
programmed, allowing e.g. two compressors to be restarted one after the other.
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Instruction book
4.2 Control panel
Elektronikon regulator
Control panel
Parts and functions
Reference Designation Function

1 Start button Button to start the compressor. LED (8) lights up
indicating that the Elektronikon regulator is
operative.
2 Display Shows messages about the compressor operating
condition, a service need or a fault.
3 Scroll keys Keys to scroll upwards or downwards through the
display.
4 Tabulator key Key to select the parameter indicated by the
horizontal arrow. Only the parameters followed by an
arrow pointing to the right can be modified.
5 Function keys Keys to control and program the compressor.
6 Voltage on LED Indicates that the voltage is switched on.
7 General alarm LED Is lit if a shut-down warning condition exists or
maintenance is required.
7 General alarm LED Flashes if a shut-down condition exists, if an
important sensor is out of order or after an
emergency stop.
8 Automatic operation LED Indicates that the regulator is automatically
controlling the compressor.
9 Stop button Button to stop the compressor. LED (8) goes out.
S2 Emergency stop button Push button to stop the compressor immediately in
the event of an emergency. After remedying the
trouble, unlock the button by pulling it out.
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4.3 Function keys
Control panel
Function keys
The keys (1) are used:
• To manually load/unload the compressor (not for VSD compressors)
• To call up or to program settings
• To reset a motor overload, shut-down or service message, or an emergency stop
• To access all data collected by the regulator
The functions of the keys vary depending on the displayed menu. The actual function is indicated
just above the relevant key. The most common functions are listed below:
Designation Function
“Add” To add compressor start/stop commands (day/hour)
“Back” To return to a previously shown option or menu
“Cancel” To cancel a programmed setting when programming parameters
“Delete” To delete compressor start/stop commands
“Help” To find the Atlas Copco internet address
“Limits” To show limits for a programmable setting
“Load” To load the compressor manually
“Mainscreen” To return from a menu to the main screen
“Menu” Starting from the main screen, to have access to the submenus
“Menu” Starting from a submenu, to return to a previous menu
“Modify” To modify programmable settings
“Program” To program modified settings
“Reset” To reset a timer or message
“Return” To return to a previously shown option or menu
“Unload” To unload the compressor manually
“Extra” To find the module configuration of the regulator
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4.4 Scroll keys
Control panel
The keys (1) allow the operator to scroll through the display.
As long as a downwards pointing arrow is shown at the utmost right position of the display, the
scroll key with the same symbol can be used to see the next item.
As long as an upwards pointing arrow is shown at the utmost right position of the display, the
scroll key with the same symbol can be used to see the previous item.
When the scroll key is kept pressed, the scrolling is continued.
4.5 Emergency stop button
Control panel
In case of emergency, press button (S2) to stop the compressor immediately.

At the occurrence of an emergency stop, the compressor element is stopped immediately and the
solenoid valve will be deactivated by Elektronikon ® regulator. No unload status is reached. The
check valve prevents oil flow back from reversed rotation of the compressor element.
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Before starting any maintenance or repairs, wait until the compressor has
stopped and open the isolating switch (customer's installation) to switch off the
voltage to the compressor.
Close the air outlet valve and open the manual condensate drain valves to
depressurize the air system.
Apply all relevant Safety precautions.
4.6 External compressor status indication
Warning
Stop the compressor and switch off the voltage before connecting external equipment.
Consult the Safety precautions.
Connections for external compressor status indication

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

Automatic operation K07 11-12 10 A / 230 V AC
Warning K08 13-14 10 A / 230 V AC
Shut-down K09 15-16 10 A / 230 V AC
Compressor loaded K11 19-20 10 A / 230 V AC
Compressor running K21 17-18 10 A / 230 V AC
4.7 Control programs
Description
In order to facilitate programming and controlling, menu-driven control programs have been
implemented in the regulator.
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Menu flow for ZR/ZT 110 up to ZR/ZT 275 and ZR 300 up to ZR 750 (simplified)
Main menu
Program Function
Main screen Shows in short the operation status of the compressor. Is the gateway to all
functions.
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Program Function
“Status data” Calls up the status of the compressor protection functions (shut-down, shut-down
warning, service warning and warning). Resets a shut-down, motor overload and
service condition.
“Measured data” Calls up the data currently measured and the status of a number of inputs.
“Counters” Calls up the running hours, regulator (module) hours and number of motor starts.
“Test” Display test.
“Modify parameters” Modifies the settings for:
• Parameters (e.g. loading and unloading pressures)
• Protections (e.g. temperature shut-down level)
• Service plans (timers for service plans)
• Clock functions (automatic compressor start/stop/pressure band commands)
• Configuration (time, date, display language,...)
“Service” Calls up service plans and resets the timers after carrying out the service actions
belonging to a plan.
“Saved data” Calls up the saved data: last shut-down, last emergency stop data.
“Unload/Load” Loads and unloads the compressor manually.
4.8 Calling up menus
Description
Control panel
When the voltage is switched on, the Main screen is shown automatically.
Example of Main screen of ZR 110 up to ZR 750
“Compressor Outlet” 7.5 bar

.
“Automatically Loaded”
“Menu” “Unload”
F1 F2 F3
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Instruction book
After pressing the “Menu” (F1) key, the option “Status Data” will be followed by a
horizontal arrow:
• Either press the tabulator key (2) to select this menu,
• or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow
and then press the tabulator key (2) to select this menu.
The arrow down key (1) can be used for a quick look at the actual compressor status.
4.9 Main screen menu
Function
Control panel
The Main screen menu shows the status of the compressor operation and is the gateway to all
functions implemented in the regulator.
Procedure
The Main screen is shown automatically when the voltage is switched on.
If the function or arrow keys (1, 2 and 3) are not used for some minutes, the regulator will
automatically return to the Main screen.
Whenever displayed on a submenu screen, press the “Mainscreen” (F1) key to return to the Main
screen.
Example of Main screen of ZR 110 up to ZR 750

.
“Automatically Loaded”
“Menu” “Unload”
F1 F2 F3
The display indicates:
34 APF178280
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• The name of the sensor and its actual reading

• Messages regarding the compressor operating condition
• Just above the function keys (3), the actual functions of these keys
4.10 Status data menu
Warning
Before starting any maintenance or repairs, press the stop button (4), wait until the
compressor has stopped, press the red emergency stop button and open the isolating
switch (customer's installation) to switch off the voltage to the compressor.
Close the air outlet valve and depressurize the air system.
Function
Control panel
The Status data submenu gives information regarding the status of the compressor protection
functions (shut-down, shut-down warning and service warning) and allows resetting of a shut-
down, motor overload and service condition.
Procedure
Starting from the Main screen (see Main screen menu):
• Press the key “Menu” (F1): the option “Status Data” will be followed by a horizontal arrow.
• Press the tabulator key (2).
No message exists
• General alarm LED (1) is out and the message on the display will indicate that all conditions
are normal:
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Instruction book
“All Conditions Are OK”

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

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

.
“Shutdown” “Maximum” 110˚C
“Menu”*** “Help” ***”Reset”
F1 F2 F3
• The indicators (***) are blinking. The screen shows the actual reading and the shut-down
setting.
• It remains possible to scroll through other menus, e.g. to check the values of other
parameters.
When returning to the “Status Data” menu, the option “Shutdowns” will blink. This option can
be selected by pressing the tabulator key (2) to return to the above shut-down screen.
Shut-down reset
• Switch off the voltage and remedy the trouble. After remedying and when the shut-down
condition has disappeared, switch on the voltage and press the key “Reset” (F3).
• Press the keys “Menu” and “Mainscreen” to return to the Main screen and restart the
compressor by means of start button (3).
A shut-down warning message exists

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

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

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

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

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

.
“*Service Required*”
“Menu”*** ***”Unload”
F1 F2 F3
• The indicators (***) are blinking and the service warning message appears.
• Press the key Menu (F1) and the tabulator key (2) to select the “Status data” menu: the
option “Service” is blinking.
• Scroll to this option and select it by pressing the tabulator key (2); two options may blink:
• “Inputs”: if the programmed service level of a component is exceeded (e.g. the
maximum pressure drop of the air filter).
• “Plan”: if a service plan interval is exceeded.
• Stop the compressor and switch off the voltage.
• In case the service message was referring to “Inputs” (air filter): replace the filter, switch on
the voltage, scroll in the “Status Data” menu to “Inputs” and press the “Reset” key to reset
the service message.
• In case the service message was referring to “Plan”: carry out the service actions related to
the indicated plans. Reset the timers of the related plans. Contact your Atlas Copco
Customer Centre. See Service menu.
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4.11 Measured data menu
Control panel
Function
To call up information regarding the actually measured data and the status of some inputs such
as the motor overload protection. Consult the menu flow in section Control programs.
Procedure
• Press the key “Menu” (F1).
• Press the arrow down key (1) until “Measured Data” is followed by a horizontal arrow.
• Activate the menu by pressing the tabulator key (2).
• By pressing the scroll keys (1), a number of actually measured data can be found.
• If one of the sensors is linked to a shut-down, service or warning function, both the actually
measured value as well as the corresponding shut-down, warning or service level can be
called up by pressing key (2).
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4.12 Counters menu
Control panel
Function
To call up:
• The running hours
• The loaded hours
• The number of motor starts
• The number of hours the regulator (module) has been under tension
• The number of load cycles
Procedure
• Press the arrow down key (1) until “Counters” is followed by a horizontal arrow.
• Press the tabulator key (2) to activate the menu.
• By pressing the arrow key (1), the above-mentioned data can be found.
Example of a Counters screen
.
“Running Hours” 2455 “hrs”
“Loaded Hours” 1973 “hrs”
“Motor Starts” 945
“Menu”
F1 F2 F3
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Instruction book
4.13 Test menu
Control panel
Function
To carry out a display test, i.e. to check whether the display and LEDs are still intact.
To test the Electronic Water Drains (EWD)
Procedure
• Starting from the Main screen (see Main screen menu), press the “Menu” (F1) key.
• Press arrow down key (1) until “Test” is followed by a horizontal arrow.
• Activate the menu by pressing the key (2).
To perform a display test:
• If necessary, scroll through the menu until “Display Test” is followed by a horizontal arrow.
• Press the key (2).
• During testing, the regulator will generate a series of patterns on the display which enable
the operator to check that each pixel still functions normally; the LEDs are lit at the same
time.
• Press the “Menu” key (F1) to return to the submenu.
To test the Electronic Water Drains (on compressors designed for an ambient temperature
of 40 ˚C (104 ˚F):
• Press the arrow down key until the option “Outputs” is followed by a horizontal arrow.
• Press the “Start” key.
• Check that the valve opens for condensate discharge.
• Release the “Start” key after testing.
• Press the “Back” key to return to the previous menu.
• Press the “Menu” key (F1) to return to the submenu.
40 APF178280
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4.14 Modify parameters menu
Function
To modify a number of programmable settings:
• Parameters (see section Modifying parameters).
• Protections (see section Modifying protections).
• Service plan settings (see section Modifying service plan settings).
• Clock function settings (see section Modifying clock function settings).
• Configuration settings (see section Modifying configuration settings).
4.15 Modifying parameters
Control panel
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
• Press the arrow down key (1) until “Modify Parameters” is followed by a horizontal arrow.
• The first item “Parameters” will be followed by a horizontal arrow.
• Press the tabulator key (2): the first items and their settings will appear.
• Press the arrow down key (1) until the parameter to be modified is followed by a horizontal
arrow.
Modifying the loading pressure setpoint

If desired, the operator can program two pressure bands (Loading pressure/Unloading
pressure and Loading pressure 2/Unloading pressure 2).
APF178280 41
Instruction book
• Consult the section Procedure to select “Loading Pressure”.

• The screen shows the current setting. To modify this setting, press the key “Modify” (F2); the
setting will blink.
• The key “Limits” (F2) can be used to find out the limitations for the parameter.
• Use the scroll keys (1) to change the setting.
• Press the key ”Program” (F1) to program the new value or the key “Cancel” (F3) to cancel
the modification operation.
• The procedure to modify other parameters pressure is similar.
The regulator will not accept new values beyond the limitations. Press the key “Limits” to
check the limitations for the parameter. Consult Programmable settings for the most
important settings.
4.16 Modifying protection settings
Control panel
Function
To modify protection settings:
• “Shutdown”, e.g. for the compressor element outlet temperature
• “Shutdown warning”, e.g. for the compressor element outlet temperature
• “Service warning”, e.g. for the maximum pressure drop over the air filter
To check various compressor conditions, e.g. the status of the emergency stop button. Some
parameters cannot be modified.
Procedure
• Press the “Menu” (F1) key.
• Press the arrow down key (1) until “Modify parameters” is followed by a horizontal arrow.
42 APF178280
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• Press the arrow down key (1) until “Protections” is followed by a horizontal arrow.
• Press the tabulator key (2): the first items will appear.
• Press the arrow down key (1) until the item to be modified is followed by a horizontal arrow
and press the tabulator key (2).
Modifying settings for the compressor element temperature

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

“Menu” “Modify”
F1 F2 F3
The regulator will not accept new values beyond the limits. Press the key “Limits” to check
the limits for the parameter. Consult Programmable settings for the most important settings.
4.17 Modifying service plans
Function
To modify the hour intervals for the service levels.
Service plans
The service actions to be carried out are grouped in plans called Service level A, B, C or D.
When reaching an interval, a message will appear on the screen indicating which Service plans
are to be carried out.
APF178280 43
Instruction book
Always consult your Atlas Copco Customer Centre in case any timer should be changed.
The intervals must not exceed the programmed nominal values.
4.18 Programming clock function
Control panel
Function
To program:
• Time-based start/stop commands for the compressor
• Time-based change-over commands for the net pressure band
Programming start, stop and pressure band commands

In this example, the compressor will be programmed as follows:
• On Monday at 06:15 starting in pressure band 1
• On Friday at 18:00 changing over to pressure band 2
• On Saturday at 18:00 stopping
• Press the arrow down key (1) until “Modify Parameters” is followed by a horizontal arrow.
• Activate the menu by pressing tabulator key (2).
• Use the arrow down key (1) to scroll until the option “Clock Function” is followed by a
horizontal arrow.
• Activate the menu by pressing tabulator key (2); following screen appears:
44 APF178280
Instruction book
“Clock Function”
“Not Activated”
.
“Menu” “Modify” “Delete”
F1 F2 F3
• Press the tabulator key (2), following screen appears:
“Monday”
“Tuesday”
“Wednesday”
“Menu” “Delete”
F1 F2 F3
• Use the scroll keys (1) until the day on which a command must be programmed is followed
by a horizontal arrow. Press the tabulator key (2); following screen appears:
--:-- ---------------------
--:-- ---------------------
--:-- ---------------------
F1 F2 F3
• Press the key “Modify” (F2). The first two dashes will flash. Use the scroll keys (1) to enter
“06”. Press the tabulator key (2) to jump to the following two dashes. Use the scroll keys to
enter “15”. Press the tabulator key to jump to the row of dashes. Use the scroll keys to enter
the command “Start Compressor”.
• Press the key “Program” to program the command : “06:15 Start Compressor”.
• Press the arrow down key (1): the horizontal arrow indicates that the second line is
accessible. Press the key “Modify” and modify this line in a similar way to the following
command: ”06:15 Pressure Band 1”.
• Press the key “Menu” (F1) and scroll to “Friday”:
“Thursday”
“Friday”
“Saturday”
F1 F2 F3
• Programming the command to change over at 18 o’clock to “Pressure Band2” is carried out
in a similar way as described above.
• Press the key “Menu” (F1) and scroll to “Saturday”. Programming the command “18:00
Compressor Stop” is carried out in a similar way as described above.
Activating/deactivating the timer

• The timer can only be activated if at least one start/stop command is programmed.
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Instruction book
• Starting from the Main screen, press the key “Menu” (F1).
• Use arrow down key (1) until the option “Modify Parameters” is followed by a horizontal
arrow.
• Use the arrow down key until the option “Clock Function” is followed by a horizontal arrow,
press the tabulator key (2), following screen appears:
“Not Activated”
.
F1 F2 F3
• Press the key “Modify”, “Not Activated” starts blinking.

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

the commands from Monday till Sunday, e.g.:
• 07.30 Start Compressor
• 07.30 Pressure Band 1
• 08.30 Pressure Band 2
• 18.00 Stop Compressor
Make sure that the timer function is activated (“Activated”). If not, the programmed start/
stop commands will not be executed.
The timer can be deactivated again. In this case, the programmed start/stop commands will
not be executed (but remain in the memory of the regulator).
Modifying a command
Suppose the command to stop the compressor on Saturday 18:00 is to be modified, i.e. stopping
at 17 o'clock instead of 18 o'clock.
• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key (1) until
the option “Modify Parameters” is followed by a horizontal arrow.
horizontal arrow. Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
46 APF178280
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“Monday”
“Tuesday”
“Wednesday”
F1 F2 F3
• Scroll through the display until “Saturday” is followed by a horizontal arrow. Press the
tabulator key (2). If necessary, scroll through the commands until the command to be
modified is followed by a horizontal arrow. Press the key “Modify”, the first two digits of the
command start blinking. Modify as required using the scroll keys, i.e. in the example above
change “18” into “17” using the arrow up key (1).
• If necessary, press the tabulator key (2) to go to the next field to be modified, the minutes
indication and the start/stop/pressure band indication.
• Press the key “Program” to program the new command or the key “Cancel” to quit without
reprogramming.
Adding a command at the end of an existing list

• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the
option “Modify Parameters” is followed by a horizontal arrow.
horizontal arrow. Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
Suppose the command to stop the compressor at 18:00 must be added to the list of Monday
“Monday”
“Tuesday”
“Wednesday”
F1 F2 F3
• Scroll through the display until “Monday” is followed by a horizontal arrow. Press the
tabulator key (2). Scroll through the compressor start/stop/pressure band commands until
the first empty command line is indicated by the horizontal arrow.
• Press the key “Modify”; the first two digits start blinking. Enter “18:00 Compressor Stop”
using the scroll keys (1) to modify a field and the tabulator key (2) to jump from one field to
another.
• Press the key “Program” to program the new command or the key “Cancel” to quit without
reprogramming.
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Adding a command between two existing commands

Suppose the command “17:00 Pressure Band 2” must be added to the following list:
• 06:00 Start Compressor
• 06:00 Pressure Band 1
• 18:00 Stop Compressor
The regulator does not allow to enter a new command which is situated before the last command
in the list timewise.
Scroll through the display until the command before which the new command must be entered is
followed by a horizontal arrow (in the example above: “18:00 Stop Compressor”) and press the
key “Modify”.
Change this command to the new command (in the example above “17:00 Pressure Band 2”)
Press the arrow down key and add the last command of the list (in the example above “18:00
Stop Compressor” and press the key “Program”.
Deleting a command
• Starting from the Main screen, press the key “Menu” (F1), press the arrow down key until the
option “Modify Parameters” is followed by a horizontal arrow.
• Use the scroll keys (1) to scroll until the option “Clock Function” is followed by a horizontal
arrow. Press the tabulator key, following screen appears:
“Not Activated”
.
F1 F2 F3
Deleting all commands

• Press the key “Delete” in the screen above. A question to confirm the deleting operation will
appear.
Deleting all commands of a specific day
• Scroll through the display until the desired day is followed by a horizontal arrow. Press the
key “Delete”, a question to confirm the deleting operation will appear.
Deleting a specific command
• Scroll through the display until the command to be deleted is followed by a horizontal arrow.
Press the key “Delete”, a question to confirm the deleting operation will appear.
48 APF178280
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4.19 Modifying configuration settings
Control panel
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
• Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to
the right.
• Press the arrow down key (1) to scroll until “Configuration” is followed by a horizontal arrow.
• Activate the menu by pressing tabulator key (2): the first item will appear. Scroll through the
display until the option to be modified is followed by a horizontal arrow. Select the option by
pressing the tabulator key (2).
• In case of the option “Time”, the second line on the screen indicates the actual setting, e.g.
“14:30”. To modify this setting, press the key “Modify” (F2); the first field “14” will blink.
• Use the scroll keys (1) to change the setting, then press the tabulator key (2) to go to the
next field “30”. The setting of this field can now be modified using the scroll keys (1).
• Press the key ”Program” (F1) to program the new value or the key “Cancel” (F3) to cancel
the modification operation (the original value will be retained).
• The procedure to modify other parameters is similar.
Programming compressor control modes

The compressor can be controlled locally, remotely or via a local area network (LAN).
Procedure
• Activate the menu “Configuration” as described above.
• Scroll through the display until the option “C.C.M.” is indicated and press the “Modify” key.
Following screen appears:
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.
“C.C.M.” “Local Control”
.
“Program” “Cancel”
F1 F2 F3
• “Local Control” is blinking, use the scroll keys (1) to select the desired control mode.
• Press the key “Program” to program the new control mode or “Cancel” to quit without
reprogramming.
4.20 Service menu
Control panel
Function
• To reset the service plans which are carried out.
• To check when the next service plans are to be carried out.
• To find out which service plans were carried out previously.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level stands
for a number of service actions to be carried out at the time intervals programmed in the
Elektronikon regulator.
When a service plan interval is reached, a message will appear on the screen, see section Status
data. After carrying out the service actions related to the indicated levels, the timers are to be
reset.
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Example
Service plans Intervals

Service plan A Every 4000 running hours
Service plan B Every 8000 running hours
Service plan C Every 16000 running hours
Service actions according to Intervals

Service plan A 4000 running hours
Service plan A and B 8000 running hours
Service plan A 12000 running hours
Service plan A, B and C 16000 running hours
... ...
Procedure
• Press the arrow down key (1) until “Service” is followed by a horizontal arrow.
• A screen similar to the one below appears:
“Service Timer”
“Running Hours”
7971 “hrs”
“Menu” “Reset”
F1 F2 F3
• The screen shows that the total compressor running time is 7971 hours.
“Next Timer”
“Level” AB
8000 “hrs”
“Back” “Reset”
F1 F2 F3
• The screen shows that the next service plans to be carried out are plans A and B and that
these plans are to be carried out every 8000 running hours.
• Press the arrow down key (1) to find out which service plans were carried out previously,
following screen appears:
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“Previous Timer”
“Level” A
4008 “hrs”
“Back”
F1 F2 F3
• The screen shows that plan A was carried out at 4008 running hours.
• Stop the compressor, switch off the voltage and carry out the service operations related to
the indicated service plans, see section Preventive maintenance schedule.
• Switch on the voltage and scroll to the “Next Timer” service screen.
• Press the “Reset” button (F3). Confirm the question for resetting.
The “Reset” button only appears when the “Next Timer” level is almost reached.
After pressing the arrow down key in the “Service Timer” screen, the “Life Time” hours are
shown, i.e. the number of hours elapsed since initial programming ex-factory. This timer is
not taken into account.
4.21 Saved data menu
Control panel
Function
To call up some data saved by the regulator. These data are:
• Last shut-down data
• Last emergency stop data
Procedure
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• Press the arrow down key (1) until “Saved Data” is followed by a horizontal arrow.
• The first option is shown “Last shutdown 1”.
• Press the tabulator key (2) to find out the date, time and other data reflecting the status of
the compressor at the last shut-down.
• If desired, scroll through the other items.
4.22 Programmable settings
Parameters
Minimum Factory Maximum

setting setting setting
Load delay time (star-delta) sec 3 10 30
Load delay time (no star-delta) sec 13 20 30
Minimum stop time sec 20 20 99
Programmed stop time sec 0 3 20
Power recovery time (ARAVF) sec 15 15 3600
Restart delay sec 0 3 255
Communication time-out sec 10 20 60
Permissive start function failure sec 0 30 255
Unloading pressure (8.6 bar compressors) bar(e) 4.0 7.0 8.6
Unloading pressure (10 bar Pack bar(e) 4.0 9.0 10.0
compressors)
Unloading pressure (145 psi Pack psig 58 130.5 145
compressors)
Loading pressure (8.6 bar Pack bar(e) 4.0 6.0 8.6
compressors)
Protections
ZR/ZT 110 up to ZR/ZT 275

Compressor outlet pressure (warning) bar(e) 0 14.0 17.0
Compressor outlet pressure (shut-down) bar(e) 0 15.0 17.0
Oil pressure (shut-down warning level) bar(e) 1.0 1.3 2.0
Oil pressure (shut-down level) bar(e) 1.0 1.2 2.0
Delay at start, oil pressure sec 15 15 20
Delay at signal, oil pressure sec 0 1 3
Compressor element 1 outlet temperature
(shut-down warning level) (7.0, 7.5 and 8.6
bar or 100, 110 and 115 psi compressors)
Compressors designed for a maximum ˚C 100 210 220
inlet temperature of 40 ˚C
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(shut-down level) (7.0, 7.5 and 8.6 bar or
100, 110 and 115 psi compressors)
(shut-down warning level) (7.0, 7.5 and 8.6
bar or 100, 110 and 115 psi compressors)
(shut-down level) (7.0, 7.5 and 8.6 bar or
100, 110 and 115 psi compressors)
Compressor element 2 inlet temperature ˚C 40 65 80
(shut-down warning level)
Compressor element 2 inlet temperature ˚C 66 70 80
(shut-down level)
Delay at signal (all compressor element sec 0 1 3
temperatures)
Oil temperature (shut-down warning level) ˚C 40 65 80
Oil temperature (shut-down level) ˚C 40 70 80
Delay at start, oil temperature sec 50 70 100
Delay at start, motor overload for sec 0 1 1
compressors with YD starter
Delay at start, motor overload for sec 0 0 0
compressors with DOL starter
Delay at signal, motor overload for sec 0 1 1
compressors with YD starter
Delay at signal, motor overload for sec 0 0 0
compressors with DOL starter
Delay at start, starter feed-back contact sec 0 18 33
(shut-down)
Delay at signal, starter feed-back contact sec 0 2 3
(shut-down)
Delay at start, compressor electronic sec 0 15 60
condensate drain (warning)
Delay at signal, compresor electronic sec 5 5 5
condensate drain (warning)
Service warning level for DP of air filter mbar 50 44 44
Delay at signal, DP of air filter sec 0 60 255
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Service plans

Service plan A (operating hours) hr See remark 4000 See remark
Service plan B (operating hours) hr See remark 8000 See remark
Service plan C (operating hours) hr See remark 16000 See remark
Service plan D (operating hours) hr See remark 40000 See remark
Service plan I (operating hours) hr See remark 2000 See remark
Remark
A number of service operations are grouped (Level A, Level B, ...). Each level stands for a
number of service operations to be carried out at the programmed intervals. Consult your Atlas
Copco Service Centre.
Terminology
Term Explanation
ARAVF Automatic restart after voltage failure. See Elektronikon regulator.
Compressor Element 1 is the low-pressure compressor element; element 2 is the high-pressure
elements 1/2 compressor element.
The regulator does not accept illogical settings, e.g. if the warning level is programmed
at 205 ˚C/401 ˚F, the minimum limit for the shut-down level changes to 206 ˚C/402 ˚F.
The recommended difference between the warning level and shut-down level is 10
˚C/18 ˚F.
Required stop Once the compressor has automatically stopped, it will remain stopped for the minimum
period/Minimum stop time (approx. 20 seconds), whatever the net air pressure. In automatic operation,
stop time the compressor will not be stopped by the regulator until a standstill period of at least
the sum of the minimum stop time and required stop period is expected. However, if the
decrease in net air pressure should require a new start of the compressor, the regulator
will start the compressor after the minimum stop time.
Power recovery Is the period within which the voltage must be restored to have an automatic restart. Is
time accessible if the automatic restart is activated. To activate the automatic restart function,
consult Atlas Copco.
Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is
Loading pressure programmed at 7.0 bar(e)/101 psig, the maximum limit for the loading pressure changes
to 6.9 bar(e)/100 psig. The recommended minimum pressure difference between
loading and unloading is 0.6 bar/9 psig.
Delay at shut- Is the time for which the signal must exist before the compressor is shut down. If it
down signal should be required to program this setting to another value, consult Atlas Copco.
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5 Elektronikon® GraphicPlus controller
5.1 Elektronikon® GraphicPlus controller
Control panel
Display of the Elektronikon® GraphicPlus controller
Introduction
The Elektronikon controller has following functions:
• Automatic compressor control
• Compressor protection
• Service warning
• Automatic restart after voltage failure (disabled)
Automatic compressor control

The controller keeps the net pressure between adjustable boundaries by automatically loading
and unloading the compressor. A number of adjustable settings, e.g. the (un)loading pressure,
the minimum stop time and the maximum number of motor starts are taken into account.
The controller switches the regime to unload when the selected unloading pressure is reached
and stops the compressor to reduce power consumption when it has been running unloaded for a
given time. In case the net pressure drops down to the loading pressure while the compressor is
running unloaded, the compressor is kept running and switches to load to avoid short standstills
and energy waste.
When the compressor has stopped automatically and the net pressure decreases, the controller
will start the compressor before the net pressure has dropped to the loading pressure to prevent
the net pressure from reaching the programmed minimum level. When stopping the compressor
manually, the controller will unload the compressor for a given time and then stop the
compressor.
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A number of time based automatic start/stop commands may be set. Be aware that a
start command will be executed (if set and enabled), even after manually stopping the
compressor unit with the controller.
Compressor protection
Shutdown warning
A shutdown warning level is set less critical than the shutdown level.
The compressor is equipped with several sensors to check pressures and temperatures. If one of
these measurements exceeds the set shutdown warning level, a message will be displayed and
the general alarm LED (next to the exclamation mark) will be lit to warn the operator.
The warning message disappears as soon as the measurement is below warning level.
Shutdown
If one of the sensors reaches a set shutdown level, the compressor will be stopped. This will be
displayed on the controller and the general alarm LED will blink.
Solve the problem and reset the message. See also the Inputs menu.
Before remedying, always check the applicable safety precautions.
Service warning
A number of service intervals are grouped into Service Plans, all with their own time frame. If a
service interval is reached, a message will appear on the controller display to warn the operator
to carry out the prescribed service actions stated in a certain Service Plan.
Automatic restart after voltage failure (ARAVF)

The controller allows automatic restart of the compressor unit if the supply is restored after
voltage failure. For compressors leaving the factory, this function is disabled. If desired, this
function can be enabled by your local Atlas Copco Customer Center.
Assuming the controller was running in automatic operation, the compressor unit will
restart when the supply voltage to the module is restored if ARAVF is enabled. As long
as the emergency stop is enabled, ARAVF is disabled.
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5.2 Control panel
Elektronikon regulator
Parts and functions
Reference Designation Function

1 Display Shows the compressor operating condition and a
number of icons to navigate through the menu.
2 Pictogram Automatic operation
3 Pictogram General alarm
4 General alarm LED Blinks when operating in shutdown warning
condition.
5 Pictogram Service
6 Service LED Lights up when service is needed.
7 Automatic operation LED Indicates that the controller runs in automatic mode.
8 Voltage on LED Lights up when supply is switched on. Compressor
unit might start automatically!
9 Pictogram Voltage on
10 Enter key Enter and confirmation key
11 Escape key To navigate to previous screen or to cancel current
action
12 Scroll keys Keys to scroll through the menu
13 Stop button Button to stop the compressor. LED (7) dims.
14 Start button Button to start the compressor. LED (7) lights up,
indicating that the Elektronikon controller is
operational.
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5.3 Digital output contacts
Warning
Voltage-free outputs may only be used to control or monitor functional systems.

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

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

K01 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K02 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K03 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
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Relay Connector Maximum load

K04 3 X 31 10 A / 250 V AC
10 A / 30 V DC
resistive load
K05 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K06 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K07 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K08 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K09 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K10 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K11 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K12 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K13 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K14 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K15 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
* = Resistor Capacitor
5.4 Icons used
Status icons
Name Icon Description
When the compressor is stopped, the icon is motionless.

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

Remote start / stop
Network control
Automatic restart after voltage

Automatic restart after voltage failure is enabled
failure
Week timer Week timer is active
Emergency stop
Active protection functions Shutdown
Warning
Service Service required
Main screen Displayed when 2 or 4 line layout is picked.
Displayed when chart layout is picked.
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Menu icons
Icon Description
Service
Alarms (warnings, shutdowns)
Week timer
Info
Test
Counters
Regulation setpoints
Inputs
Outputs
SPM readings
ESi
Event history (saved data)
Settings
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Input icons
Icon Description
Pressure
Temperature
Digital input
Special protection
System icons
Icon Description
Compressor element (LP, HP, ...)
Dryer
Fan (icon only visible when installed on compressor unit)
Drain(s) (icon only visible when Electronically Regulated Drain (ERD) is installed on
compressor unit)
Filter(s)
Motor
Expansion module (Failure)
Cooler
Energy Recovery
Network settings/problem
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General alarm
Oil circuit
Regulation
General settings
Access key / User password
Navigation arrows
Icon Description
Up
Down
5.5 Main screen
Control panel
Control panel
64 APF178280
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(1) Enter key

(2) Escape key
(3) Scroll keys
Function
The main screen shows the status of the compressor operation and is the gateway to all
functions implemented in the controller.
The main screen is shown automatically when the voltage is switched on and a key is pushed.
The display switches to sleep mode when no keys are pushed for several minutes.
Five different main screens can be chosen:
1. Two value lines
2. Four value lines
3. Chart (High resolution)
4. Chart (Medium resolution)
5. Chart (Low resolution)
Value views
Typical Main screen (Two value lines)
APF178280 65
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Typical Main screen (Four value lines)
Text on figures
(1) Compressor Outlet

(2) Loaded hours
(3) Text varies upon the compressor's actual condition
(4) Menu
(5) Running hours
(6) Compressor outlet
• 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:
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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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5.6 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:
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• 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.
5.7 Service menu
Control panel
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.
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When a service plan interval is reached, a message will be displayed.

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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5.8 Protections menu
Control panel
Menu icon, Protections
Function
• To display and reset the protections.
Before resetting a warning or shutdown message, always solve the problem. Frequently
resetting these messages without remedying may damage the compressor.
Procedure
Starting from the Main screen (see Main screen):
• Move the cursor to the Menu action button and push the enter key (2). Following screen
appears:
• Using the Scroll keys (1), move the cursor to the protections icon.
• Push the Enter key (2). Following screen appears:
A number of icons is shown, allowing to display and reset protections
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Typical example of a general alarm screen
Text on figure:
(1) General
(2) Compressor outlet
(3) Level high
(4) Shutdown warning
(5) Shutdown
(6) Reset
(7) Modify
The screen shows that the actual reading for the compressor outlet is 2.53 bar. The screen
shows also the settings for the shutdown warning (3.60 bar) and shutdown (3.70 bar).
On the bottom of the screen are two buttons:
• Reset: to reset the alarm after remedying the problem.
• Modify: to change the alarm settings
Depending on the machine type and the installed optional equipment less/more/different
icons and/or relevant underlying menus are displayed.
The displayed and resettable protections are :

•
General:
• Compressor outlet warning/shutdown level (High)
• Compressor outlet warning level (Low)
• Emergency stop status
• No valid pressure control: Triggered if the compressor outlet pressure sensor fails.
•
Element(s):
• Warning level (Low) of intercooler pressure
• Shutdown level (Low) of intercooler pressure
• Warning/shutdown level of element 1 outlet temperature
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• Warning/shutdown level of element 2 inlet temperature

• Warning/shutdown level of element 2 outlet temperature
•
Fan:
• Overload Fan Motor: Triggered if the overload of the fan motor trips.
•
Drain(s):
• Condensate Drain IC not ok (IC= Intercooler)
• Condensate Drain AC not ok (AC= Aftercooler)
• Condensate drain AC2 (AC2 = additional aftercooler for Full-Feature compressors
with energy recovery)
• Condensate drain RC in (RC = Regeneration cooler)
• Condensate drain RC out (RC = Regeneration cooler)
• Condensate drain MD (MD = MD Dryer )
•
Filters
• Warning/shutdown level (Low) of DP air filter (DP: delta pressure or pressure
drop)
• DP air filter service level (Low)
•
Main Motor
• Overload Motor
• Starter Feedback Contact Open: monitors position of the delta contactor
• Starter Feedback Contact Close: monitors position of the delta contactor
•
Expansion Module Communication

• Not triggered: if Triggered the communication between the Elektronikon and the
expansion module failed.
•
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
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5.9 Week timer menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Week timer
Function
• To program time-based start/stop commands for the compressor
• To program time-based net pressure band change commands
The timer function allows 4 different Week Action Schemes. These can be combined into a
sequence of 10 weeks in a Week Cycle.
Important notice:
The Elektronikon controller allows a number of successive commands. Be aware that 2
successive commands need at least 1 minute time lapse to ensure flawless operation.
For example Start Compressor: 5:00 AM, Pressure Setpoint change: 5:01 AM.
Procedure
Starting from the Main screen (see Main screen section),
• Move the cursor to the Menu action button and push the Enter key. Use the Scroll buttons to
select the Timer icon.
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• 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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(2) Week Action Scheme 1
• When entering a Week Action Scheme, the corresponding week is displayed. The selected
day is highlighted in grey and the desired action can be set by pushing Enter.

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
• 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.

(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

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

(2) Week 1
(4) Week 2
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(6) Week 3
(8) Off
(9) Modify
Push the Enter key twice to modify the first week.

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

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

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

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(3) Week Cycle

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

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

• After pushing the Enter key, the Remaining Running Time is confirmed and displayed. This
timer is prior to all Week Timer actions.
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5.10 Info menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Info
Function
To show the Atlas Copco internet address.
Procedure
• Move the cursor to the Menu action button and push the Enter key. Following screen
appears:
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• Scroll the cursor to the Info icon (see above, section Menu icon).
• Push the Enter key. The Atlas Copco internet address appears on the screen. At the bottom
of the screen, the More button is displayed. Push the button to display following additional
info:
• MAC address
• Expansion modules
• Boot software
• Operating system
• Application software
• PEG software
• Licence ESi
5.11 Test menu
Control panel
Menu icon, Test
Function
• To perform a safety valve test and a drain test. Both actions can only be performed by
authorized personnel and are protected by a security code.
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5.12 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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5.13 Modifying the pressure band
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Regulation
Function
The regulation menu allows tuning of 2 pressure bands and the selection of the current pressure
band.
Procedure
• The regulation menu is accessible in two ways:
a. select Menu action key using the Scroll keys and push the Enter key. Following screen
appears:
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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.
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To modify the settings, move the cursor to the action button Modify and push the Enter key.
• 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.
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5.14 Inputs menu
Control panel
(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:
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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:
Depending on the installed optional equipment less or more icons may appear.
Text on figure
(1) Inputs
(2) Cooler
• The inputs are categorized under a number of representative icons. Push the Enter key to
show the actual inputs.
• If an input reaches a warning or shutdown level, the original icon is replaced by the warning
or shutdown icon, respectively.
Setting an input as main chart (see section Main screen)

• Navigate to the input screen as described above.
• Push the Enter key; the first input on the screen will be highlighted in grey.
• Using the arrow keys, scroll to the input to be set as main chart.
• Push the Enter key; following screen appears:
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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
(3) Set as main chart signal
(4) Modify
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(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.

(2) Remove from main chart
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(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.
5.15 Outputs menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Outputs
Function
To display information regarding the current status of the digital outputs.
Procedure
appears:
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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.
• The outputs are categorized under a number of representative icons. Push the Enter key to
show the actual outputs.
• •
General
• Load/Unload
• Automatic operation
• General warning
• General shutdown
•
Drain(s)
• Condensate drain IC
• Condensate drain AC
• Condensate drain AC2 (AC2 = additional aftercooler for Full-Feature compressors
with energy recovery)
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• Condensate drain RC in (RC = Regeneration cooler)

• Condensate drain RC out (RC = Regeneration cooler)
• Condensate drain MD (MD = MD Dryer )
•
Main Motor
• Line contactor
• Star contactor
• Delta contactor
5.16 Event history menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Event History
Function
To display a list of all shutdowns, their causes and the status of counters and in/outputs at the
moment of shutdown.
Procedure
appears:
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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.
5.17 Modifying settings
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Settings
Function
To display and modify a number of settings (e.g. Time, Date, Date format, Language, units ...)
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Procedure
appears:
• Using the Scroll keys, move the cursor to the Settings icon (see above, section menu icon).
• Push the Enter key. A screen similar to the one below appears:
• The screen displays following icons:
Icon Function
Network settings
Regulation settings
General settings
Automatic restart after voltage failure settings
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Icon Function
Access key
User password
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:
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Screen for CAN settings
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:
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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.
• Push the Enter key, use the Scroll keys to select the setting to be modified and push the
Enter key again.
• A screen appears. Use the ↑ or ↓ key to select the required parameter and push the Enter
key to confirm.
Automatic restart
• Select the Automatic restart settings icon as described above and push the Enter key (2).
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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).
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Text on figure
(1) Main chart

(3) Chart range
(4) Minimum
(5) Maximum
(6) Chart band
(7) Low
(8) High
(9) Off
The screen shows the main chart signal, the current chart range and band settings. To modify
these settings, proceed as follows:
Push the Enter key, select chart range or chart band as desired and confirm.
Modifying the chart range
Select the chart range as described above and proceed as follows:
• Push the Enter key; the minimum setting becomes highlighted. Push the Enter key to modify
the minimum setting or use the arrow down key to modify the maximum setting.
• Push the Enter key to confirm the modification.
Modifying the chart band
Select the chart band as described above and proceed as follows:
• 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.
5.18 Programmable settings
Service settings
Factory
setting
Service
Service level A hr 4000
Service level B hr 8000
Service level C hr 16000
Service level D hr 40000
Service level E hr 60000
Service level I hr 2000
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Remark
A number of service operations are grouped (Level A, Level B, ...). Each level stands for a
number of service operations to be carried out at the programmed intervals. Consult your Atlas
Copco Service Center.
Other programmable settings
Min.
Unit (Pack Max.
version)
Pressure regulation (UN)LOAD level

mbar
8.6 bar (50 Hz) 4000 8605
Control timers
s
Unload time 3 20
Minimum stop time 20 99
Y-D starter
s
Y-D time 10 30
Load delay 3 30
Automatic Restart After Voltage Failure - ARAVF

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

All controllers have a built-in web server that allows direct connection to the company network or
to a dedicated PC via a local area network (LAN). This allows to consult certain data and settings
via a PC instead of the display of the controller.
Getting started
Make sure you are logged in as administrator.
• Use the internal network card from your computer or a USB to LAN adapter.
• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).
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Configuration of the network card

• Go to Network and Sharing Center (1).
• Click on Change adapter settings (1).
• Select the Local Area Connection, which is connected to the controller.
• Click with the right button and select Properties (1).
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• Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid
conflicts, uncheck other properties if they are checked. After selecting TCP/IPv4, click on the
Properties button (2) to change the settings.
• Use the following settings:

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

• Ask your IT department to generate a fixed IP address in your company’s network.
• That IP address will be excluded from the DNS server, so it will be reserved for the
controller.
• Also get the correct Gateway and Subnet mask settings. For example:
• IP = 10.25.43.200
• Gateway = 10.25.42.250
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• Subnet mask = 255.255.254.0

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

• Go to Main Menu
• Go to Settings (1)
• Go to Network (1)
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• Go to Ethernet (1)
• Switch Off (1) the Ethernet communication to allow editing the settings
• Adapt IP Address (1)

• Adapt Gateway IP (2)
• Adapt Subnet Mask (3)
• Switch On (4) the Ethernet communication
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• Wait a few minutes so the LAN network can connect to the controller
Configuration of the web server

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

• The banner shows the unit type and the language selector. In this example, three languages
are available on the controller.
• On the left side of the interface, you can find the navigation menu.
If a license for ESi is foreseen, the menu contains 3 buttons.
• Machine: shows all generator settings.
• ES: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure unit.
Unit settings
All unit settings can be displayed or hidden. Put a check mark in front of each point of interest
and it will be displayed. Only the machine status is fixed and can not be removed from the main
screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference
button from the navigation menu.
Counters
Lists all current counter values from controller and unit.
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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.
Special protections
Lists all special protections of the unit.
Service plan
Displays all levels of the service plan and their status. This screen shot underneath only shows
the running hours. It is also possible to show the current status of the service interval.
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6 Installation
6.1 Dimension drawing
Dimensions
Dimension drawing of ZR 160 up to ZR 275 and ZR 250/315 VSD Pack compressors
Reference Name
1 Right side view
2 Front view
3 Motor cooling air outlet
4 Motor cooling + compressor air inlet
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Reference Name
5 Hot air version
6 Voltage supply entrance
7 Center of gravity
8 Left side view of energy recovery version
9 Left side view
10 Cooling water out
11 Compressed air outlet
12 Cooling water inlet
13 ANSI flanges, optional
14 M8 for ducting on roofs; for position, see top view
15 Automatic drain, aftercooler
16 Automatic drain, intercooler
17 Rear side view
18 Top view
19 Type
20 Net mass (approx.) of units (kg)
21 ZR no motor Arr. E
22 ZR no motor Arr. 1
23 Opening for transportation
24 4 slotted holes for pulling out of container
25 Water in/out
26 Prepared for MD with ER, water out
27 Prepared for MD with ER, water in
28 Automatic drain, dryer outlet
29 Automatic drain, regeneration outlet
30 Automatic drain, prepared for MD with energy recovery
31 Manual drain, dryer inlet
32 Compressor and cooling air outlet
33 Cooling + compressor air inlet
34 Cooling air inlet
35 Standard version
36 Voltage supply entrance, possibility 2
37 Voltage supply entrance, possibility 1
38 Cooling air outlet
39 Voltage supply entrance, possibility 1 only for ZT 160 - 275
40 Hole M8
41 Voltage supply entrance, possibility 1 only for ZR 160 - 275
42 Left side view, Hot air
43 Electric cable for water shut-off valve
44 Voltage supply entrance, possibility 1 only for VSD units
45 Cold water circuit, cooling water in
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Reference Name
46 Cold water circuit, cooling water out
47 Automatic drain, extra aftercooler
48 Energy recovery circuit, cooling water in
49 Energy recovery circuit, cooling water out
50 Automatic drain, dryer inlet
51 Detail X
52 Detail Y
53 Cooling water
54 From FD dryer: Tropicalized integrated dryer, see detail
55 To FD dryer: Tropicalized integrated dryer, see detail
56 Service cover for regeneration cooler of dryer
57 Full-Feature with energy recovery. Fresh water in
58 Full-Feature with energy recovery. Fresh water out
59 Access for PDP sensor
60 Low load option. Connection for regeneration air, see detail
61 For connection with pipe coupling , brand Victaulic
62 Access for control cable, water shut-off valve
63 For option energy recovery: closed circuit out
64 For option energy recovery: closed circuit in
65 Low load option/blow off
66 Compressor air inlet
67 Motor cooling air inlet
68 Separated air intake
69 Standard unit
70 To external dryer
71 From external dryer
72 Use coupling
73 Grating, only separate air intake
74 Circuit A
75 Circuit B
76 Automatic drain, regeneration inlet
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6.2 Installation proposal
Compressor room example
Installation proposal for ZR 160 up to ZR 275, ZR 250 VSD and ZR 315 VSD
(1) Minimum free area to be reserved.

(2) Ventilation proposal.
(3) Rear side view.
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(4) Ventilation proposal (without option separate air intake).

(5) Ventilation proposal (with option separate air intake).
(6) Common ducting for multiple units is not allowed.
(7) Reverse side view.
Description
The compressor must only be moved or lifted as described in the section Initial start-up.
1. Install the compressor on a level floor suitable for taking its weight. The recommended
minimum distance between the top of the body and the ceiling is 1200 mm (47 in).
2. Remove the plastic plug (if provided) from the compressor air outlet pipe and install an air
outlet valve. Close the valve and connect it to the air net.
3. The maximum total length of the air delivery pipe can be calculated as follows:
For SI Units:
Lmax= (dp x d5 x p) / (450 x Qc1.85)
Symbol Explanation
d Inner diameter of the outlet pipe in mm
dp Pressure drop (recommended maximum = 0.1 bar)
L Length of outlet pipe in m
p Absolute pressure at the compressor outlet in bar(a)
Qc Free air delivery of the compressor in l/s
It is strongly recommended to make the connection of the compressor air outlet pipe on top
of the main air net pipe in order to minimize carry-over of possible condensate residue.
As a rule of thumb, the following formula can be used to calculate the recommended volume
of the air net:
V = (30 x C x p x Q) / dp
Symbol Explanation
C Correction factor
dp Pressure difference between unloading and loading pressures in bar (recommended
minimum = 0.6)
p Compressor inlet pressure in bar absolute
Q Free air delivery of compressor in l/s
V Recommended air net volume in l
Air consumption divided by compressor free air Correction factor C

delivery
0.9 0.10
0.8 0.15
0.7 0.20
0.5 0.25
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Air consumption divided by compressor free air Correction factor C

delivery
0.3 0.20
0.2 0.15
0.1 0.10
4. The inlet grids and ventilation fan should be installed in such a way that any recirculation of
cooling air to the compressor is avoided. The maximum air velocity through the grids is 5
m/s (16.5 ft/s).
The required ventilation capacity (per compressor installed) to limit the compressor room
temperature can be calculated as follows:
For ZR compressors:
• For SI Units: Qv = 0.1 N/dT
Symbol Explanation
dT Temperature increase in compressor room
• For SI Units: in °C
N Shaft input of compressor
• For SI Units: in kW
Qv Required ventilation capacity
• For SI Units: in m3/s
If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is 30
Pa (0.12 in wc). Common ducting for several compressors is not allowed.
5. Lay out the drain piping from the condensate outlets towards the condensate collector. The
drain pipes must not dip into the water in the collector. It is recommended to provide a funnel
to allow visual inspection of the condensate flow.
6. Elektronikon control system with control panel.
7. See Electric cable size, fuses and cable length for the recommended size of the supply
cables.
Check that the electrical connections meet local codes. The installation must be earthed and
protected against short circuits by fuses in all phases. An isolating switch must be installed
near the compressor.
8. Install a condensate drain valve in the lower part of the air net piping.
9. On ZR compressors, remove the plastic plugs (if fitted) from the compressor water pipes (WI
and WO) and connect the pipes to the cooling water circuit. Fit a valve in the compressor
water inlet pipe and outlet pipe.
6.3 Installation requirements for rubber compensators
Types and sizes

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

A Atlas Copco compressor pipe end
B Customer installation pipe end
Angular misalignments Δα are NOT allowed!
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Misalignment tolerances
• Single direction misalignments
Axial 1: ΔL mm 20
Lateral: ΔR mm 20
Δα2 ° 0
1 = stretch or compression
2 = NO angular misalignment is tolerated!
• Combined direction misalignments

(1) Compression
(2) Stretch
Do NOT operate outside of the black polygon.
Do NOT exceed the misalignment tolerances to avoid compensator damage! The piping
system of the customer should be designed to fit the misalignment tolerances both during
standstill and operation.
Temperature correction factors
Medium temperature Correction factor for maximum working pressure of

(°C) the compensator
0 1
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Medium temperature Correction factor for maximum working pressure of

(°C) the compensator
50 1
80 1
85 0.92
90 0.83
95 0.75
100 0.67
105 0.6
110 0.54
Torque values
Compensator bolts should be torqued in 3 successive steps
• Step 1: Hand-tighten each bolt.
• Step 2: Torque the bolts crosswise up to the value mentioned in the table below and allow a
stabilization period of 30 minutes before moving to step 3.
• Step 3: Torque the bolts crosswise up to the value mentioned in the table below.
• Mind the parallelism of the sealing.

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

(mm) (Nm) (Nm)
20 – 80 hand tight 50 80
100 – 300 hand tight 50 100
350 – 500 hand tight 50 130
Do's and don'ts

The supplied compensators are NOT designed:
• to carry the weight of the mounted customer pipe end.
• to work as a damper for unanchored pipe ends.
• to carry the thrust forces of the compressed air.
Therefore, adequate supporting and anchoring of the customer pipe end should be foreseen to
avoid compensator damage.
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The compensator loads (Fg and Ft) that are mentioned on the drawing are strictly forbidden:
• Weight loads Fg
• Thrust forces Ft
For the design of piping and supporting structures, use an approved standard code (e.g. EN
13480 or ASME 16.5/B31.3).
Mind that the connected pipe at customer side does not create any flow restriction
caused by e.g. section reduction.
While installing the compensator, please mind the following check points to avoid sealing
damage.
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Situation Description
A Flat DIN flanges prevent damage of the rubber sealings.
B Collared flanges prevent premature wear.
C Add a flat sealing or if necessary a metal disc with flat seal in case of damage risk.
D Avoid excessive torque to prevent damage to the bended pipes or the sealings.
Rubber sealings will get damaged when the inner pipe diameter exceeds the inner sealing
E diameter.
F Rough pipe ends will damage the rubber sealing.
G Avoid contact between the pipe end and the rubber sealing.
Refer to the pictures below for a visual overview of 5 do's and don'ts when installing rubber compensators:
• WRONG installation!
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• CORRECT installation!
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(1) Larger than maximum allowed installation length.
(2) Less than or equal to maximum allowed installation length
(3) Minimum 1 mm of free space
Do NOT:
• Paint the rubber bellows of the expansion joint since:
• Solvents can damage the rubber cover.
• The colored coating avoids decent visual inspection of the rubber condition.
• Weld, cut or grind without protecting the rubber bellows
• Expose the compensator to permanent radiation heat above 90 °C (194 °F)
6.4 Electric cable size, fuses and cable length
General
Local regulations remain applicable if they are stricter than the values proposed below.
The voltage drop must not exceed 10 % of the nominal voltage. It may be necessary to
use cables with a larger size than those stated to comply with this requirement.
IEC compressors
• Cables calculated according to IEC 60364-5-52
• Mounting type: E (Multicore cables in free air)
• Multiple circuit arrangement:
• 4 (Single layer on a perforated horizontal or vertical tray system)
• Use 90 °C (194 °F) cables (Type H07V2-K)
• Cables have to be recalculated if the fuses that are used are bigger than the fuses that are
proposed.
Abbreviation Description
FLA Full Load Ampacity
MCA Minimum Circuit Ampacity
Icc Rated conditional short circuit current
SCCR Short Circuit Current Rating
500 V - 50 Hz IEC
Compressors designed for a maximum ambient temperature of 40 °C (104 °F) with IE2 motors
Type Cables (H07V2-K) IEC 60364-5-52:

E&4 Fuses gL/gG Maximum cable length
mm2 (A) (m)
ZR/ZT 110 2 x (3x 120 + 70) 2X (3X 250) 325
ZR/ZT 132 2 x (3x 120 + 70) 2X (3X 250) 325
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Type Cables (H07V2-K) IEC 60364-5-52:

E&4 Fuses gL/gG Maximum cable length
mm2 (A) (m)
ZR/ZT 145 2 x (3x 120 + 70) 2X (3X 250) 325
ZR/ZT 160 2 x (3x 120 + 70) 2X (3X 250) 325
ZR/ZT 200 4 x (3x 95 + 50) 2X (3X 315) 235
ZR/ZT 250 4 x (3x 120 + 70) 2X (3X 400) 230
ZR/ZT 275 4 x (3x 120 + 70) 2X (3X 400) 230
Compressors designed for a maximum ambient temperature of 40 °C (104 °F) with IE3 motors
Type FLA MCA Proposed cable Maximum Proposed Maximum Icc

(mm²) cable fuses (A) fuse (A)
length (m) (gL/gG) (gL/gG)
ZT/ZR 110 184 202 2 X (3 X70+35) 306 2 x(3 X 160) 315 50 kA
ZT/ZR 132 219 240 2 X (3 X70+35) 306 2 x(3 X 160) 315 50 kA
ZT/ZR 145 236 259 4 X (3 X35+16) 140 2 x(3 X 200) 315 50 kA
ZT/ZR 160 285 313 4 X (3 X70+35) 233 2 x(3 X 250) 315 50 kA
ZT/ZR 200 348 383 2 X (3 X120+70) 323 2 x(3 X 250) 400 50 kA
ZT/ZR 250 428 471 4 X (3 X 95+50) 233 2 x(3 X 315) 400 50 kA
ZT/ZR 275 (7.5 469 515 4 X (3 X 95+50) 233 2 x(3 X 315) 500 50 kA
bar)
ZT/ZR 275 (8.6 524 576 4 X (3 X 120+70) 232 2 x(3 X 400) 400 50 kA
and 10 bar)
FLA and MCA based on an air-cooled full option compressor.

Icc only achieved with recommended fuses.
FLA and MCA based on an air-cooled full option compressor.
Icc only achieved with recommended fuses.
6.5 Electric connection
Attention
For the selection of the correct cables, refer to: Electric cable size, fuses and cable
length .
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Electric connections
Electric connections for compressors with star-delta starter (Model year 2003)
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Electric connections for compressors with star-delta starter (Model year 2014)
Text on figures
Reference Text on figure

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

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

When installing a remote emergency button or a motor contactor, the following B10d values are
advised:
• Emergency stop button: 500 000
• Main contactor: 933 333
6.7 Cooling water requirements
General
Cooling water needs to fulfill requirements in order to avoid problems of scaling, fouling,
corrosion or bacterial growth. 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 anti-
freeze products. They should be provided with suitable stabilizers and inhibitors.
Specifications also depend on the criteria mentioned below:
• the type of cooling circuit:
• open
• Single Pass
• recirculation with cooling tower
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• closed loop
(1) Machine
(2) Heat exchanger
(3) Cooling tower
(4) Make up water
(5) Blowdown
(6) Standard Atlas Copco specification
• the application:
• standard (max water temperature 65°C / 149°F at the outlet)
• Energy Recovery (water temperature up to 95°C / 203°F)
A full instruction for handling cooling water data is available at Atlas Copco.
In case water is not in line with recommended values or if any doubt, please refer to Atlas Copco.
Technical specifications
Parameter Unit Single Pass Single Pass Recirculating Closed Closed

(65°C / (95°C / (65°C / 149°F) System System
149°F) 203°F) (65°C / (95°C /
149°F) 203°F)
1 pH 6.8 - 9.3 6.8 - 9.3 6.8 - 9.3 7.5 - 9.3 7.5 - 9.3
2 Conductivity µS / cm < 1500 < 600 < 4000 < 1500 50 - 600
3 Total Dissolved mg / L TDS to be measured for calculating RSI.
Solids
4 Ca-hardness ppm < 500 <2 < 500 < 1000 < 50
CaCO3
5 Total Alkalinity ppm No limits indicated. To be measured for calculating RSI.
CaCO3
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Parameter Unit Single Pass Single Pass Recirculating Closed Closed

(65°C / (95°C / (65°C / 149°F) System System
149°F) 203°F) (65°C / (95°C /
149°F) 203°F)
6 Ryznar Stability 5.6 - 7.5 N.A. 5.6 - 7.5 5.6 - 7.5 5.6 - 7.5
Index (RSI)
7 Chlorine ppm < 0.5 — < 0.5 — —
8 Chlorides ppm < 500 (*) < 100 < 500 (*) < 500 (*) < 100
9 Nitrates ppm No limits indicated. To be measured for calculating RSI.
10 Sulphates ppm < 1000 < 200 < 1000 < 400 < 200
11 Chemical <5 <1 <5 <1 <1
Corrosion Index
12 Iron ppm <1 < 0.2 <1 <1 < 0.2
13 Manganese ppm < 0.2 < 0.05 < 0.2 < 0.2 < 0.05
14 Copper ppm <1 < 0.2 <1 <1 < 0.2
15 Ammonium ppm < 0.5 < 0.5 < 0.5 < 0.5 < 0.5
16 Suspended ppm < 10 <1 < 10 < 10 <1
Solids (max
10µ)
17 Oil or Grease ppm <1 <1 <1 <1 <1
18 Biology CFU / < 10 5 < 10 3 < 10 5 < 10 3 < 10 3
mL
Remarks on the technical specifications
Parameter Remarks
1 pH For stainless steel systems without other materials, pH can be
down to 6.
For closed loop systems, higher pH values are possible
2 Conductivity Conductivity and TDS linked with conversion factor (theoretical
factor possible, but practical determination recommended at
least once)
6 Ryznar Stability Index (RSI) Recommended actions : see table for RSI
7 Chlorine or shock treatment max. 2 ppm for 30 min/day
8 Chlorides (*) Limit 200 ppm applicable when RSI < 5.6 or RSI > 7.5
10 Sulphates Rejection < 2000 ppm. To be measured for calculating RSI.
11 Chemical Corrosion Index Index = (Chlorides + Sulphates + Nitrates) / (M-Alkalinity) (all
expressed in meq/l)
15 Ammonium limit not applicable for Cu-free systems
16 Suspended Solids (max No particles > 10µ allowed. (Particles <0.5µ not considered).
10µ)
18 Biology Anaerobic biology in closed system never allowed.
Ryznar Stability Index (RSI)

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

pHs = (9.3 + A + B) - (C + D)
Symbol Calculation
A (10log(TDS) - 1) / 10
B 13.12 x 10log(°C+273) + 34.55
C 10
log(Ca2+) - 0.4 (Ca2+ expressed as ppm CaCO3)

D 10
log(M-Alkalinity) (M-Alkalinity expressed as ppm CaCO3)
RSI and chloride limitation

Single Pass system
RSI Chloride Water condition Maximum 65°C / Maximum 95°C / 203

limit 149°F °F
RSI<3.9 200 ppm Very high scale formation Water cannot be used. Not applicable.
4.0<RSI<5.5 200 ppm High scale formation Regular control and Not applicable.
descaling operation
necessary.
Not recommended for
plate heat exchangers
5.6<RSI<6.2 350 ppm Slight scale formation Water treatment not Not applicable.
necessary.
Occasional inspection
recommended.
6.3<RSI<6.8 500 ppm Neutral water Water treatment not Water treatment not
necessary. necessary.
Occasional inspection Occasional inspection
recommended. recommended.
6.9<RSI<7.5 350 ppm Slight corrosion Water treatment not Water treatment not
Occasional inspection Occasional inspection
recommended. recommended.
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RSI Chloride Water condition Maximum 65°C / Maximum 95°C / 203

limit 149°F °F
7.6<RSI<9.0 200 ppm Strong corrosion Regular control Regular control
Avoid interruption of Avoid interruption of
operation operation
9.1<RSI<11 200 ppm Very strong corrosion Regular control Regular control
operation operation
RSI>11 200 ppm Very strong corrosion Regular control Regular control
operation operation
Recirculating system, with cooling tower
RSI Chloride Water condition Maximum 65°C / 149°F

limit
RSI<3.9 200 ppm Very high scale formation Water cannot be used.
4.0<RSI<5.5 200 ppm High scale formation Regular control and descaling
operation necessary.
Not recommended for plate
heat exchangers
5.6<RSI<6.2 350 ppm Slight scale formation Water treatment not
necessary.
recommended.
6.3<RSI<6.8 500 ppm Neutral water Water treatment not
necessary.
recommended.
6.9<RSI<7.5 350 ppm Slight corrosion Water treatment not
necessary.
recommended.
7.6<RSI<9.0 200 ppm Strong corrosion Regular control necessary.
Use of corrosion inhibitor
recommended
9.1<RSI<11 200 ppm Very strong corrosion Regular control necessary.
recommended
RSI>11 200 ppm Very strong corrosion Water cannot be used.
Closed loop system
RSI Chloride Water condition Maximum 65°C / 149°F and

limit 95°C / 203°F
RSI<3.9 200 ppm Very high scale formation Water cannot be used.
4.0<RSI<5.5 200 ppm High scale formation Treat water to reduce scaling
character
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RSI Chloride Water condition Maximum 65°C / 149°F and

limit 95°C / 203°F
5.6<RSI<6.2 350 ppm Slight scale formation Water treatment not
necessary.
recommended.
6.3<RSI<6.8 500 ppm Neutral water Water treatment not
necessary.
recommended.
6.9<RSI<7.5 350 ppm Slight corrosion Water treatment not
necessary.
recommended.
7.6<RSI<9.0 200 ppm Strong corrosion Regular control necessary.
recommended
9.1<RSI<11 200 ppm Very strong corrosion Regular control necessary.
recommended
RSI>11 200 ppm Very strong corrosion Water cannot be used.
6.8 General pictographs
Pictographs
Reference Name
1 Condensate valve, intercooler
2 Automatic condensate outlet, intercooler
3 Automatic condensate outlet, aftercooler
4 Condensate valve, aftercooler
5 Warning: under tension
6 Read Instruction manual before starting the compressor
7 Switch off the voltage and depressurize the compressor before maintenance or repair
8 Before connecting the compressor electrically, consult the Instruction manual for the
motor rotation direction
9 Torques for steel (Fe) or brass (CuZn) bolts
10 Consult the Instruction manual before greasing
11 Switch off the voltage before removing the protecting cover inside the electric cabinet
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Reference Name
12 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)
13 Consult the Instruction manual before maintenance or repair
14 Cooling water outlet
15 Cooling water inlet
6.9 Pictographs, Elektronikon control system
Control panel of Elektronikon Controller
Reference Name
1 Start
2 Stop
3 Automatic operation
4 Alarm
5 Voltage on
6 Emergency stop
7 Key to go to next field on display
8 Keys to scroll through display
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Control panel of Elektronikon GraphicPlus Controller
Reference Name
1 Alarm
2 Service
3 Automatic operation
4 Voltage on
5 Enter
6 Escape
7 Scroll keys
8 Stop
9 Start
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7 Operating instructions
7.1 Initial start-up
Safety precautions
The operator must apply all relevant Safety precautions.
Ambient conditions / altitude opeartion

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

The compressor and motor are secured to the frame, immobilizing the vibration dampers during
transport. All transport fixtures are painted red and must be removed.
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Transport fixtures on the motor side in ZR/ZT 110 up to ZR/ZT 275
On the motor side, the dampers are secured by means of bolts/spacers. Remove the bolts and
spacers (1 and 2).
Transport fixtures on the gear casing side in ZR/ZT 110 up to ZR/ZT 275
On ZR/ZT 110 up to ZR/ZT 275, a transport support (1) is fitted to the gear casing. Remove the
support.
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Silica gel bags
Position of silica gel bags on ZR 160 up to ZR 275
Remove flange (1) and take out the silica gel bags. Refit the flange.
Water circuit of ZR compressors
Step Action
1 Fit the water drain plugs that are attached to the water pipe of one of the compressor
elements in a plastic bag. The plugs are painted green and their positions are shown on
the illustrations above.
2 Check that the cooling water drain valves (customer's installation) in the inlet and outlet
lines are closed.
3 Open the water inlet valve and outlet valve (customer's installation) and check for water
flow.
4 Check the water flow.
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Oil circuit
Position of oil level sight-glass on ZR 110 up to ZR 275
Check that oil is visible in sight-glass (SG).
Start-up
1. Check that the voltage selecting wires on transformer T1 are connected correctly. An
instruction label is provided.
2. Check that the electrical installation meets local regulations.
3. Switch on the voltage.
4. Check that the gear casing is filled with oil.
5. Start the motor and stop it immediately.
6. Check that the direction of rotation is correct (as indicated by the arrow): anti-clockwise
looking at the motor drive shaft (there may also be an arrow on the coupling housing). A
grating through which the coupling can be observed is fitted. If the direction of rotation is
wrong, switch off the voltage and reverse two electric inlet connections.
7. Run the compressor for a few minutes.
8. Stop the compressor and check the oil level.
On ZR/ZT 110 up to ZR/ZT 275, the oil level after stopping must be in the middle of the
sight-glass (in the case of longer standstill, the oil level in the sight-glass may increase).
Top up, if necessary, with the correct type of oil.
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7.2 Before starting
The operator must apply all relevant Safety precautions.

If the water system has been drained, close the drain valves and fit the drain plugs or
pipe.
Oil level
Oil system components, ZR 110 up to ZR 275
On ZR/ZT 110 up to ZR/ZT 275, the oil level must be in the middle of the sight-glass (SG) after
stopping (in the case of longer standstill, the oil level may increase in the sight-glass).
Top up, if necessary, with the correct type of oil.
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Condensate drains
Drain connections on ZR 160 Pack up to ZR 275 Pack
AO Compressed air outlet
Daa Automatic drain, aftercooler
Daea Automatic drain, extra aftercooler (for Energy Recovery option only)
Dai Automatic drain, intercooler
WI Water inlet
WO Water outlet
Open the water inlet valve and outlet valve (customer's installation).
On ZR compressors, opening of the water outlet valve can be overlooked if, after
previous operation, the setting of this valve has not been disturbed.
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7.3 Routine starting
Control panel
Control panel of Elektronikon controller
Procedure
Step Action
1 Open the air outlet valve (customer's installation).
2 Switch on the voltage and check that voltage on LED (6) lights up.
3 Press start button (1). The compressor starts running in unloaded condition and
automatic operation LED (8) lights up.
4 Approx. 25 seconds later (programmable), the compressor starts running loaded. The
message on display (2) changes from “Automatically unloaded” to “Automatically
loaded”.
5 On ZR compressors, regulate the water flow with the compressor running loaded.
See section Readings for the cooling water temperature.

See section Compressor data for the cooling water consumption.
If the motor is stopped and automatic operation LED (8) is alight, the motor may start
automatically.
If the start/stop timer is active, the compressor can start automatically, even if it was
stopped manually.
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Control panel
Control panel of Elektronikon GraphicPlus controller
Procedure
Step Action
1 Open the air outlet valve (customer's installation).
2 Switch on the voltage and check that voltage on LED (8) lights up.
3 Press start button (14). The compressor starts running in unloaded condition and
automatic operation LED (7) lights up.
4 Approx. 25 seconds later (programmable), the compressor starts running loaded.
See section Readings for the cooling water temperature.

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

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

The compressor will not be allowed to restart within a programmed time (20 s) after a stop for any
reason at all. A start command given during the minimum stop time will be memorized; automatic
operation LED (7) lights up. The compressor will start when the minimum stop time has run out.
Manual restart
In automatic operation, the regulator limits the number of motor starts.
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On compressors with a low-voltage motor, observe a minimum interval of 20 minutes between

two manual starts.
7.5 During operation
Control panel
Procedure
When automatic operation LED (8) is alight, starting and stopping of the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
Step Action
1 Check the readings on display (2).
2 When reaching the preset unloading pressure, shown on display (2), the compressor will
start running unloaded. From now on, the electronic control module will calculate the
optimum moment to stop and restart the compressor motor automatically, depending on
the maximum permissible number of motor starts and on the air consumption.
3 To unload the compressor manually, press the key “Unload” (5).
To put the compressor back into automatic operation, press the key “Load” (5).
If the “Load” or “Unload” function is not indicated on the bottom line of the display (2),
press key “Menu” (5) until the function “Main Screen” appears above key (F1). Then
press the key “Main Screen”.
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Control panel
Procedure

When automatic operation LED (7) is alight, starting and stopping of the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
Step Action
1 Check the readings on display (1).
2 When reaching the preset unloading pressure, shown on display (1), the compressor will
start running unloaded. From now on, the electronic control module will calculate the
optimum moment to stop and restart the compressor motor automatically, depending on
the maximum permissible number of motor starts and on the air consumption.
3 To unload the compressor manually, select Unload on the display using the cursor keys
and press the Enter key.
To put the compressor back into automatic operation, select Load on the display using
the cursor keys and press the Enter key.
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7.6 Checking the display
Control panel
Procedure
Before carrying out any maintenance, repair or adjustment work, stop the compressor,
press emergency stop button (S2), switch off the voltage and depressurize the
compressor.
Step Action
1 Regularly check the display for readings and messages. Normally, the main display is
shown, indicating the compressor outlet pressure, the status of the compressor and the
functions of the keys below the display.
2 Always check the display and remedy the trouble if alarm LED (7) is alight or flashing.
3 The display will show a service message if one of the monitored components is to be
serviced. Replace the component, change the oil or grease the drive motor as required.
Reset the relevant timer.
4 Check:
• The compressor control status (automatic or manual, local or remote)
• The status of the compressor start/stop timer (active or not). The compressor is
automatically started/stopped if these start/stop commands are programmed and
activated.
• The maximum working pressure
• The outlet pressure
• The pressure drop over the air filters
• The oil pressure
• The intercooler pressure
• The outlet temperature
• The temperatures of the compressor elements
• The cooling water temperatures
• The oil temperature
• The status of the drive motor overload protection (normal or not)
• The total running and loading hours
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Whenever a warning, service request, sensor error or motor overload message is

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

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Control panel
General
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads,
stops and restarts the compressor automatically. LED (8) is then alight.
If required, the compressor can be unloaded manually. In this case, the compressor is switched
out of automatic operation, i.e. the compressor remains running unloaded unless it is loaded
again manually.
Manual unloading
Press the key “Unload” (5). LED (8) fades. The message “Manually Unloaded” appears on the
display.
Manual loading
Press the key “Load” (5). LED (8) lights up. The “Load” command does not force the compressor
in loaded condition, but it will switch the compressor to automatic operation again, i.e. the
compressor will be loaded if the air net pressure drops below the programmed level.
If the “Load” or “Unload” function is not indicated on the bottom line of display (2), press
“Menu” (5) until “Main Screen” appears above key (F1), then press “Main Screen”.
156 APF178280
Instruction book
Control panel
General
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads,
stops and restarts the compressor automatically. LED (7) is then alight.
If required, the compressor can be unloaded manually. In this case, the compressor is switched
out of automatic operation i.e. the compressor remains running unloaded unless it is loaded
again manually.
Manual unloading
Starting from the main screen, move the cursor so that Unload is highlighted in grey. When the
Enter key is pressed, the compressor starts running unloaded and LED (7) fades. The message
Manual Unload appears on the display.
Manual loading
Starting from the main screen, move the cursor so that Load is highlighted in grey. When the
Enter key is pressed, LED (7) lights up and the compressor starts running loaded in case the air
net pressure drops below the programmed level. The message Load appears on the display.
If the Load or Unload buttons are not displayed on the bottom line of the screen, make
sure to return to the Main screen first.
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Instruction book
7.8 Stopping
Control panel
Procedure
Frequently stopping the compressor using the emergency stop button may damage the
compressor. Only use the emergency stop button in case of emergency.
Step Action
1 Close the air outlet valve.
2 Press stop button (9). The compressor will run unloaded for 3 seconds and then stop.
3 To stop the compressor in case of emergency, press the emergency stop button (S2).
Alarm LED (7) starts flashing. After remedying the trouble, unlock the emergency stop
button by pulling it out.
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Instruction book
Control panel
Procedure

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

Close the cooling water inlet valve after stopping.
If the compressor is installed in a room where freezing temperatures are expected, drain
the cooling system completely:
• By opening the main drain valves in the water inlet and outlet pipes (customer's installation)
• By removing the drain plugs. The following plugs (painted green) are provided:
• DP7 and DP8 underneath the cooler casing
• On ZR 160 up to ZR 425, drain plug (DP9) underneath the cooler casing
• DP2 and DP5 underneath the compressor elements
• DP6 on the oil cooler
APF178280 159
Instruction book
Cooler casing on ZR 160 up to ZR 275
Cooler casing on ZR 160 up to ZR 275
160 APF178280
Instruction book
Drain plugs on high-pressure compressor element
Drain plugs on low-pressure compressor element
APF178280 161
Instruction book
Water drain plug on oil cooler on ZR 110 up to ZR 275
7.9 Taking out of operation
Procedure
At the end of the service life of the compressor, proceed as follows:
Step Action
1 Close the air outlet valve and stop the compressor.
On compressors with an Elektronikon regulator, press the emergency stop button.
2 Switch off the voltage and disconnect the compressor from the mains.
3 Shut off and depressurize the part of the air net which is connected to the outlet valve.
4 Disconnect the compressor air outlet pipe from the air net.
5 Drain the oil and condensate circuits. Catch the oil in a receptacle.
6 Disconnect the compressor condensate piping from the condensate drain net.
7 On ZR compressors, drain the cooling water system and disconnect the cooling water
pipes from the compressor.
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Instruction book
8 Maintenance
8.1 Preventive maintenance schedule
Safety precautions
• Before starting any maintenance or repairs, stop the compressor.

• Depressurize the air system as follows:
• Close the air outlet valve.
• Press the emergency stop button.
• On compressors equipped with Electronic Water Drains (EWD), press the
test buttons on top of the electronic water drains.
• Open the isolating switch (customer's installation) to switch off the voltage to the
compressor, and lock it (Lock Out - Tag Out procedure, LOTO).
• Repairs inside the speed regulation cabinet must only be carried out by Atlas
Copco.
• Wait at least 6 minutes before starting any electrical repairs as hazardous high
voltage remains on the condensers of the variable speed drive for 6 minutes after
switching off the voltage.
• The operator must apply all relevant safety precautions.
Service agreements
Atlas Copco Customer Centers have a range of service agreements to suit your needs:
• An Inspection plan
• A Preventive maintenance plan
• A Total responsibility plan
Contact your Customer Center to agree on a tailor-made service agreement. It will ensure
optimum operational efficiency, minimize downtime and reduce the total life cycle costs and
ensure that all warranties are validated.
Warranty-Product Liability
Use only authorized parts at the correct intervals (check with your local Atlas Copco Service
center). Any damage or malfunction caused by the use of unauthorized parts or unqualified
personnel is not covered by Warranty or Product Liability. In the event of any extended warranty,
the end user must ensure that all required maintenance actions are performed when indicated on
the Elektronikon display (see table below) or, alternatively, use an Atlas Copco Service
agreement.
Service kits
Atlas Copco Customer Centers will be glad to provide you with a wide range of service kits.
Service kits comprise all parts needed for servicing components and offer the benefits of genuine
Atlas Copco parts while keeping the maintenance budget low.
Regular checks
The following checks should be carried out regularly to ensure safe operation and long service
life. Depending on the environmental and working conditions of the compressor, the local Atlas
APF178280 163
Instruction book
Copco Service center may overrule the standard maintenance schedule; always check if in
doubt.
Period Running hours Operation

Daily 8 Check the Elektronikon display for warnings.
Daily 8 Check that condensate is discharged from the drain receivers during
loading.
Daily -- Before stopping:
• drain the aftercooler drain receiver
• drain the intercooler drain receiver
Weekly -- Check the oil level. See section Before starting.
Weekly -- Drain condensate from the air receiver, if installed.
Weekly -- Check for leaks.
When displayed -- Carry out service actions according to the displayed service
warnings or service plans as shown below.
Please keep following checks in mind:

• Regularly test the water drains
• When operating in a dusty atmosphere, inspect the air filters more frequently. Always
use Atlas Copco filters to guarantee the performance of your compressor.
• Grease the motor bearings at the correct interval and with the correct grease type and
quantity as mentioned on the motor data plate. If in doubt, consult your Atlas Copco
Service center.
Service plan
A number of service operations are grouped (called level A, level B, level C, ...). Each level
stands for a number of service actions to be carried out at the time intervals programmed in the
Elektronikon regulator.
When a level is reached, a message will appear on the screen. After carrying out all service
actions, reset the interval timers using the "Reset" key in the "Service" menu.
Activities Level A Level B Level C

Take service readings (air, oil, water temperature and X X X
pressure)
Check cooler functions (approach temperature) X X X
Change intercooler condensate check valve X X X
Service intercooler blowdown valve X
Check for air, water and oil leakage X X X
Check operation of safety valves X X
Check for presence of water in lube oil X X X
Change Roto Z oil (16000 hrs or 2-yearly) NA NA X
Change compressor oil filter (4000 hrs or annually) X X X
Inspect/change air filter element(s) X X X
Replace filter element of gear case breather X X X
Check cycle of air intake throttle valve X X X
164 APF178280
Instruction book
Activities Level A Level B Level C

Replace diaphragm of air throttle valve X X
Replace bearing block (air intake valve) X X
Overhaul air intake valve X
Check functioning of check valve (8000 hrs or annually) X
On Z 55 up to ZR/ZT 275 and Z 75 up to Z 315 VSD, X
overhaul check valve
Check condition of balance piston diaphragm X
Change balance piston diaphragm X
Check/Service condensate drain(s) X X X
Clean fan cowl of electric motor X X X
Check rubber inserts of drive coupling (arr. E) X X
Replace inserts of drive coupling (arr. E) X
Take and record all S.P.M. readings. On VSD compressors X X X
also register the motor speed
Inspect electrical contactors X X
Check all electrical connections X
On VSD compressors, if necessary, clean cubicle with X X
vacuum
On VSD compressors, if applicable, replace motor carbon X
brush
8.2 Motor greasing
General
Stop the compressor and follow the LOTO procedure (Lock Out - Tag Out) (refer to
General Safety Precautions) before greasing.
Never mix greases of different brands or types.
Main motor bearings

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

The bearings of the fan motor are greased for life.
8.3 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.
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Instruction book
Atlas Copco Roto-Z oil can be ordered in following quantities:
Quantity (l) Ordering number

5 l can 2908 8503 00
20 l can 2908 8501 01
209 l drum 2908 8500 00
8.4 Storage after installation
Run the compressor, e.g. twice a week, until warm.

If the compressor is going to be stored without running from time to time, protective measures
must be taken. Consult Atlas Copco.
166 APF178280
Instruction book
9 Servicing procedures
9.1 Air filters
Location of the air filters
Air filter of ZR/ZT 110 up to ZR/ZT 275
Procedure
The filters must be serviced regularly; consult section Preventive maintenance schedule.
Never install damaged or clogged filters.
Procedure for ZR/ZT 110 up to ZR/ZT 275 and ZR/ZT 132 VSD up to ZR/ZT 315 VSD
Step Action
1 Stop the compressor and press the emergency stop button.
2 Switch off the voltage and follow the LOTO procedure. (Refer to the Safety Precautions
before acting.)
3 Remove nuts (1).
4 Loosen clamps (2).
5 Take out filter housing (3) with filter element (4).
6 Replace the dirty filter element with a new one.
7 Put the filter housing with the filter element back into place.
8 Tighten clamps (2) and nuts (1).
9 Switch on the voltage.
10 Unlock the emergency stop button and reset the air filter service warning.
APF178280 167
Instruction book
9.2 Oil and oil filter change
Oil system
Oil system components, ZR 110 up to ZR 275
Procedure
Step Action
1 Run the compressor until warm.
2 Stop the compressor.
Press the emergency stop button.
3 Switch off the voltage and follow the LOTO procedure. (Refer to the Safety Precautions
before acting.)
4 The filler plug and drain points are painted yellow.
Remove filler plug (FC). Drain the compressor sump by opening drain valve (Dmo).
On ZR compressors, drain the oil cooler by opening drain valve (Dmc).
Close the drain valves and tighten the drain plugs after draining.
5 Remove the oil filters (OF). Clean the filter seats, oil the gaskets of the new filters and
screw the filters into place until the gaskets contact the seats. Then tighten by hand.
6 On ZR 110 up to ZR 275, fill the compressor sump to the middle of the oil level sight-
glass (SG).
See Oil specifications for the correct type of oil.
7 Reinstall the filler plug.
8 Switch on the voltage.
Unlock the emergency stop button and reset the oil and oil filter service warnings.
9 Run the compressor for a few minutes.
10 Stop the compressor.
168 APF178280
Instruction book
Step Action
11 On ZR 110 up to ZR 275 and ZT 110 up to ZT 275, check that the oil level is in the
middle of sight-glass (SG) after stopping (at longer standstill the level may rise in the
sight-glass).
Top up, if necessary.
9.3 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.
APF178280 169
Instruction book
10 Problem solving
10.1 Problem solving
• Before starting any maintenance or repairs, stop the compressor.

• Depressurize the air system as follows:
• Close the air outlet valve.
• On compressors equipped with Electronic Water Drains (EWD), press the
test buttons on top of the electronic water drains.
• Press the emergency stop button.
• Open the isolating switch (customer's installation) to switch off the voltage to the
compressor, and lock it (Lock Out - Tag Out procedure, LOTO).
• Repairs inside the speed regulation cabinet must only be carried out by Atlas
Copco.
• Apply all relevant safety precautions.
• Wait at least 6 minutes before starting any electrical repairs as hazardous high
voltage remains on the condensers of the variable speed drive for 6 minutes after
switching off the voltage.
Control panel
170 APF178280
Instruction book
Faults and remedies
Condition Fault Remedy

Compressor starts running,
Pressure in air net is above Compressor will load when pressure in air
but does not load after a delay
pre-set loading pressure net drops to pre-set loading pressure
time
Loading solenoid valve
Check and replace the valve as necessary
inoperative
Full-load/no-load valve
Have the valve inspected
malfunctioning
Compressor capacity or
Air consumption exceeds
working pressure lower than Check pneumatic plant
capacity of compressor
normal
Check for leaks. Tighten leaking
Leaking connections and
connections and replace damaged/leaking
damaged/leaking parts
parts.
Top up level as described in section Before
Oil pressure too low Oil level too low
starting.
Oil filters clogged Replace filters
Inlet temperature too high due
Improve ventilation in compressor room
Air temperature above normal to bad room ventilation or
and prevent recirculation of cooling air
recirculation of cooling air
On ZR compressors, Check water temperature and increase
insufficient cooling water flow cooling water flow
On ZR compressors,
restriction in cooling water
Consult the Atlas Copco Customer Center
system due to formation of
scale or dirt deposits
On ZT compressors, coolers
Refer to the Coolers section.
clogged
APF178280 171
Instruction book
Condition Fault Remedy

Unloading pressure incorrectly
Check the controller setting.
set
On ZT compressors,
insufficient cooling air or
Check and correct.
cooling air temperature too
high
Condensate is not discharged
from condensate traps during Drain/pipe clogged Check and correct
operation
Frozen drain piping Check and correct
Venting lines not/badly
Check and correct
assembled
Only on IC drain : intercooler
condensate check valve
Check and correct
defect/dirty/wrongly
assembled
Solenoid valve defect/dirty Check and correct
Manually operated solenoid
Set valve to automatic operation
valve
Level sensor defect/dirty Clean sensor or replace as necessary
Damaged/poor assembled
Drain continuously discharges
condensate drain (housing/ Check and correct
air
seals/valve/…)
Solenoid valve defect/dirty Check and correct
Level sensor defect/dirty Clean sensor or replace as necessary
172 APF178280
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11 Technical data
11.1 Readings
Important
The readings below are indicative values when operating at reference conditions. Check
the section Reference conditions. These values are no rejection limits. In case of doubt,
consult your Atlas Copco Customer Center.
For the maximum working pressure and the outlet pressure, consult the section Compressor
data.
Pressure readings
Item Reading
dp of air filter Below 0.044 bar
Intercooler pressure (loaded condition) 1.7-3 bar(e)
Intercooler pressure (unloaded condition) (-0.65)-(-0.70) bar(e)
Oil pressure (depends on climatic conditions) 1.8-3.5 bar(e)
Temperature readings for ZR compressors
Item Reading
Oil temperature Approx. 40 ˚C
Air outlet temperature Approx. 25 ˚C
Cooling water inlet temperature Below 40 ˚C
Cooling water outlet temperature Below 50 ˚C
11.2 Settings of safety valves
Item Opening
pressure
Low-pressure safety valve(s) for 7 up to 10.4 bar (101.5 up to 3.7 bar(e)
151 psi) compressors
High-pressure safety valve(s) for 7 and 8.6 bar (101.5 and 125 9.3 bar(e)
psi) compressors
11.3 Settings for overload relay
50 Hz compressors
ZR 200 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F
APF178280 173
Instruction book
Supply voltage Maximum overload relay setting

(V) (A)
500 170
11.4 Reference conditions
Absolute inlet pressure 1 bar(a)

Ambient temperature 20 °C
Air inlet temperature 20 °C
Effective working pressure 7 bar(g) for 7/7.5/8.6 bar compressors
Temperature of cooling medium (water or air) inlet 20 °C
Temperature rise of cooling water of ZR Pack 15 °C
compressors
ZR / ZT 160-275
Motor shaft speed for 50 Hz fixed speed compressors 1485
(rpm) - except for ZR / ZT 275 7.5 bar (109 psi)
11.5 Limitations
Pressure limitations
Item Limit
Maximum effective working pressure See the section
Compressor data.
Maximum cooling water inlet pressure 10 bar(e)
Temperature limitations
Item Limit
Maximum air inlet temperature for compressors designed to 40 ˚C
operate at ambient temperatures up to 40 °C (104 °F)
Minimum ambient temperature 0 ˚C
Maximum cooling water temperature at inlet on ZR 40 ˚C
compressors
Maximum cooling water temperature at outlet on ZR 50 ˚C
compressors
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11.6 Compressor data
Important note
The values below are valid at reference conditions. See Reference conditions.
The sound pressure level is measured according to ISO 2151: 2004 using ISO 9614-2.
ZR 8.6 bar - 50 Hz compressor
Unit ZR 200
Maximum working pressure bar(e) 8.6
Nominal working pressure bar(e) 7
Air temperature at outlet valve, approx., ˚C 23
Pack compressor
Motor shaft speed r/min 1485
Power input, Pack compressor kW 194
Oil capacity l 60
Sound pressure level, Pack Arr. E dB(A) 67
compressor
Cooling water consumption for Pack l/s 2.77
compressor at a temperature rise of 15 ˚C /
27 ˚F
APF178280 175
Instruction book
12 Pressure equipment directives

ZR/ZT 110 Pack up to ZR/ZT 275 Pack compressors are a pressure assembly of cat. I according
to 2014/68/EU.
Parts of article 4.3 of 2014/68/EU are subject to Sound Engineering Practice (SEP).
Parts of category I according to 2014/68/EU are integrated into the machine and fall under the
exclusion of article 1.2, (f)(i).
Parts subject to the Simple Pressure Vessel Directive 2014/29/EU are excluded from 2014/68/EU
according to article 1.2 (c).
The following pressure bearing parts are of category higher than I :
Compressor type Pressure bearing part

ZR/ZT 110 up to ZR/ZT 275 Safety valve: Category IV
• Design code: AD-Merkblätter, A2
ZR/ZT 160 up to ZR/ZT 200 IMD 400: Category III
• Design pressure 13.7 bar(e), content 199 l
• Design standard: ASME section VIII div. 1.
176 APF178280
Instruction book
13 Documentation
Declaration of conformity
Typical example of a Declaration of Conformity document
(1): Manufacturer
(2): Applicable directives
(3): Standards used
(4): Technical file holder
APF178280 177
Instruction book
(5): Contact address of the manufacturer

On the Declaration of Conformity, the harmonized and/or other standards that have been used
for the design are shown and/or referred to.
The Declaration of Conformity is part of the documentation that is supplied with this device.
178 APF178280
We stand by our responsibilities towards our customers, towards the environment and
the people around us.
We make performance stand the test of time.
This is what we call - Sustainable Productivity.
Atlas Copco Airpower

Oil-free Air Division, Boomsesteenweg 957, 2610 Wilrijk, Belgium
Phone: +32 (0)3 870 21 11
Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.

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Z 160 200 250

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

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

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

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

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

1.6 DISMANTLING AND DISPOSAL............................................................................................................... 11

2.2 AIR SYSTEM.....................................................................................................................................15

2.3 COOLING AND CONDENSATE DRAIN SYSTEM............................................................................................ 17

2.4 ELEKTRONIKON REGULATED DRAIN (ERD)............................................................................................. 18

2.5 OIL SYSTEM.....................................................................................................................................20

2.6 REGULATING SYSTEM.........................................................................................................................21

3 Elektronikon regulator type overview.........................................................................24

3.1 ELEKTRONIKON® CONTROLLER TYPE OVERVIEW....................................................................................... 24

4.1 ELEKTRONIKON® REGULATOR.............................................................................................................. 26

4.2 CONTROL PANEL...............................................................................................................................28

4.3 FUNCTION KEYS................................................................................................................................29

4.4 SCROLL KEYS.................................................................................................................................. 30

4.5 EMERGENCY STOP BUTTON................................................................................................................. 30

4.6 EXTERNAL COMPRESSOR STATUS INDICATION ......................................................................................... 31

4.7 CONTROL PROGRAMS........................................................................................................................ 31

4.8 CALLING UP MENUS........................................................................................................................... 33

4.9 MAIN SCREEN MENU.......................................................................................................................... 34

4.10 STATUS DATA MENU.......................................................................................................................... 35

4.11 MEASURED DATA MENU......................................................................................................................38

4.12 COUNTERS MENU..............................................................................................................................39

4.13 TEST MENU..................................................................................................................................... 40

4.14 MODIFY PARAMETERS MENU................................................................................................................41

4.15 MODIFYING PARAMETERS....................................................................................................................41

4.16 MODIFYING PROTECTION SETTINGS....................................................................................................... 42

4.17 MODIFYING SERVICE PLANS.................................................................................................................43

4.18 PROGRAMMING CLOCK FUNCTION......................................................................................................... 44

4.19 MODIFYING CONFIGURATION SETTINGS...................................................................................................49

4.20 SERVICE MENU.................................................................................................................................50

4.21 SAVED DATA MENU............................................................................................................................52

4.22 PROGRAMMABLE SETTINGS................................................................................................................. 53

5 Elektronikon® GraphicPlus controller....................................................................... 56

5.1 ELEKTRONIKON® GRAPHICPLUS CONTROLLER........................................................................................ 56

5.2 CONTROL PANEL...............................................................................................................................58

5.3 DIGITAL OUTPUT CONTACTS.................................................................................................................59

5.4 ICONS USED.....................................................................................................................................60

5.5 MAIN SCREEN.................................................................................................................................. 64

5.6 CALLING UP MENUS........................................................................................................................... 69

5.7 SERVICE MENU.................................................................................................................................70

5.8 PROTECTIONS MENU..........................................................................................................................75

5.9 WEEK TIMER MENU........................................................................................................................... 78

5.10 INFO MENU...................................................................................................................................... 88

5.11 TEST MENU..................................................................................................................................... 89

5.13 MODIFYING THE PRESSURE BAND......................................................................................................... 92

5.14 INPUTS MENU................................................................................................................................... 95

5.15 OUTPUTS MENU................................................................................................................................99

5.16 EVENT HISTORY MENU..................................................................................................................... 101

5.17 MODIFYING SETTINGS...................................................................................................................... 102

5.18 PROGRAMMABLE SETTINGS............................................................................................................... 108

5.19 WEB SERVER.................................................................................................................................109

6.1 DIMENSION DRAWING....................................................................................................................... 118

6.2 INSTALLATION PROPOSAL.................................................................................................................. 121

6.3 INSTALLATION REQUIREMENTS FOR RUBBER COMPENSATORS.....................................................................123

6.4 ELECTRIC CABLE SIZE, FUSES AND CABLE LENGTH..................................................................................130

6.5 ELECTRIC CONNECTION.................................................................................................................... 131

6.6 QUALITY OF SAFETY COMPONENTS......................................................................................................134

6.7 COOLING WATER REQUIREMENTS........................................................................................................134

6.8 GENERAL PICTOGRAPHS................................................................................................................... 139

6.9 PICTOGRAPHS, ELEKTRONIKON CONTROL SYSTEM..................................................................................140

7 Operating instructions............................................................................................... 142

7.1 INITIAL START-UP............................................................................................................................ 142

7.2 BEFORE STARTING.......................................................................................................................... 146