Apf232438 en

APF232438
ZS 250 VSD
Instruction book
Atlas Copco
ZS 250 VSD
APF232438
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.
2018 - 10
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................5
1.1 SAFETY ICONS................................................................................................................................... 5
1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................5
1.3 SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 6
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 7
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 8
1.6 DISMANTLING AND DISPOSAL...............................................................................................................10
2 General description...................................................................................................... 11
2.1 INTRODUCTION.................................................................................................................................11
2.2 ELECTRICAL SYSTEM.........................................................................................................................13
2.3 REGULATION................................................................................................................................... 13
2.4 FLOW DIAGRAM AND COOLING SYSTEM..................................................................................................16
3 Elektronikon® GraphicPlus controller........................................................................18
3.1 CONTROLLER PANEL......................................................................................................................... 18
3.2 DIGITAL OUTPUT CONTACTS................................................................................................................19
3.3 ICONS USED.................................................................................................................................... 21
3.4 MAIN SCREEN..................................................................................................................................25
3.5 CONTROLLER MENU STRUCTURE..........................................................................................................29
3.6 WEB SERVER.................................................................................................................................. 32
4 Installation.....................................................................................................................41
4.1 DIMENSION DRAWING........................................................................................................................ 41
4.2 INSTALLATION PROPOSAL................................................................................................................... 43
4.3 ELECTRICAL CONNECTIONS.................................................................................................................45
4.4 QUALITY OF SAFETY COMPONENTS.......................................................................................................51
4.5 PICTOGRAPHS................................................................................................................................. 51
2 APF232438
Instruction book
5 Operating instructions................................................................................................. 54
5.1 INITIAL START-UP..............................................................................................................................54
5.2 BEFORE STARTING............................................................................................................................55
5.3 STARTING....................................................................................................................................... 56
5.4 DURING OPERATION.......................................................................................................................... 57
5.5 CHECKING THE DISPLAY.....................................................................................................................58
5.6 STOPPING.......................................................................................................................................59
5.7 STARTING AFTER EMERGENCY STOP OR SHUT DOWN............................................................................... 60
5.8 TAKING OUT OF OPERATION................................................................................................................61
6 Maintenance.................................................................................................................. 62
6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................62
6.2 MOTOR GREASING............................................................................................................................ 64
6.3 OIL SPECIFICATIONS..........................................................................................................................65
6.4 STORAGE AFTER INSTALLATION........................................................................................................... 65
6.5 SERVICE KITS.................................................................................................................................. 65
7 Servicing procedures................................................................................................... 66
7.1 AIR FILTER......................................................................................................................................66
7.2 OIL AND OIL FILTER CHANGE...............................................................................................................67
7.3 BLOW OFF...................................................................................................................................... 68
8 Problem solving............................................................................................................69
8.1 PROBLEM SOLVING........................................................................................................................... 69
9 Technical data...............................................................................................................71
9.1 READINGS.......................................................................................................................................71
9.2 SETTINGS FOR OVERLOAD RELAY AND FUSES......................................................................................... 71
9.3 REFERENCE CONDITIONS AND LIMITATIONS............................................................................................ 72
9.4 BLOWER DATA................................................................................................................................. 72
APF232438 3
Instruction book
10 Pressure equipment directives................................................................................... 73
11 Documentation..............................................................................................................74
4 APF232438
Instruction book
1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 General safety precautions

1. The operator must employ safe working practices and observe all related work safety
requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter
of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel. The personnel should apply safe working practices by use of
personal protection equipment, appropriate tools and defined procedures.
4. The compressor is not considered capable of producing air of breathing quality. For air of
breathing quality, the compressed air must be adequately purified according to the
applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any
electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
APF232438 5
Instruction book
9. If compressed air is used in the food industry and more specifically for direct food contact, it
is recommended, for optimal safety, to use certified Class 0 compressors in combination
with appropriate filtration depending on the application. Please contact your customer center
for advice on specific filtration.
1.3 Safety precautions during installation

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

1. The machine must only be lifted using suitable equipment in accordance with the applicable
safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is
strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and
deceleration must be kept within safe limits. Wear a safety helmet when working in the area
of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must
be taken; consult your supplier.
3. In case the device is a compressor, place the machine where the ambient air is as cool and
clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must
be taken to minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting
the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes,
vapors and particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by
people cannot be drawn in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to
expand under heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of
strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This
machine is remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the
electrical isolating switch is open, locked and labelled with a temporary warning before any
maintenance or repair. As a further safeguard, persons switching on or off remotely
controlled machines shall take adequate precautions to ensure that there is no one checking
or working on the machine. To this end, a suitable notice shall be affixed to the start
equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted air does not recirculate to the compressor air inlet or
cooling air inlet.
6 APF232438
Instruction book
12. The electrical connections must correspond to the applicable codes. The machines must be
earthed and protected against short circuits by fuses in all phases. A lockable power
isolating switch must be installed near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after
voltage failure is activated, a sign stating "This machine may start without warning" must be
affixed near the instrument panel.
14. In multiple compressor systems, manual valves must be installed to isolate each
compressor. Non-return valves (check valves) must not be relied upon for isolating pressure
systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure relieving device or devices as
required.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other
high temperature piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to
be protected by a safety device with set pressure according to the maximum cooling water
inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the
dryer, safety valves must be installed in the vessels of the dryer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation

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.
APF232438 7
Instruction book
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods
only, e.g. to carry out routine checks. Wear ear protectors when opening a door.
On machines without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or
exceeds 80 dB(A) shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not
rubbing
• No leaks occur
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in
good repair, free of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a
workroom, take precautions against air pollution and possible contamination of the breathing
air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must
be taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure shall be protected by a pressure relieving device or devices as
required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book
must be respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
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.
8 APF232438
Instruction book
3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all
damage or injuries caused by the use of non-genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached
to the starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting
or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all
sources of pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by
covering the parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be
completely purged, e.g. by steam cleaning, before carrying out such operations. Never weld
on, or in any way modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure
vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they
function properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating
pressures, temperatures and time settings are correct. Check that all control and shut-down
devices are fitted and that they function correctly. If removed, check that the coupling guard
of the compressor drive shaft has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of
the oil separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture
from entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on
the bodywork and in the air inlet and outlet systems of the compressor, is in good condition.
If damaged, replace it by genuine material from the manufacturer to prevent the sound
pressure level from increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate
bowls.
21. Only if applicable, the following safety precautions are stressed when handling
refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin
with water. If liquid refrigerant contacts the skin through clothing, never tear off or
remove the latter; flush abundantly with fresh water over the clothing until all refrigerant
is flushed away; then seek medical first aid.
APF232438 9
Instruction book
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.
10 APF232438
Instruction book
2 General description
2.1 Introduction
Product description
ZS(+) VSD (Variable Speed Drive) machines are air-cooled, low-pressure, electric motor-driven
screw blowers, which deliver oil-free, pulsation-free air. By continuously matching the speed of
the drive motor to the air net pressure, the blowers optimize energy consumption and reduce the
operating pressure band. The blowers are enclosed in a sound-insulated bodywork.
General views
Front view
APF232438 11
Instruction book
Rear view
Ref. Name
AF Air filter
AO Air outlet
Co Oil cooler
E Blower element
M1 Blower motor
OF Oil filter
PD Pulsation damper
SV/BLV Safety valve/blow-off valve
2 Vibration dampers
The blowers are enclosed in a sound-insulated bodywork.
The blowers include mainly

• Elektronikon® control system
• Air filter
• Blower element
• Pulsation damper
• Drive coupling
• Motor
• Gear casing
• Safety valve/ Blow-off valve
• Oil cooler with cooler fan
• Frame
• Bodywork
12 APF232438
Instruction book
Elektronikon ® control system

The blower is controlled by an electronic regulator which:
• Controls the operation of the blower
• Controls the motor speed (Variable Speed Drive)
• Reduces the power consumption
• Warns the operator in case of an abnormal operating condition
• Protects the blower
• Monitors components subject to service
• Automatically restarts the blower after voltage failure
Anti-condensation heaters for motor

Electric heaters are installed in the motor windings and connected to the compressor cubicle.
When the compressor is stopped, the heaters are automatically switched on. The heaters in the
motor will prevent condensation during stand-still.
PT 1000 thermal motor protection

The PT 1000 thermal protection provides protection for the drive motor. Five sensors are installed
in the motor, two to measure the temperature of the bearings and three to measure the
temperature of the windings. The readings can be called up on the display of the Elektronikon
regulator. A message will appear on the display and the general alarm LED will light up if one of
the temperatures exceeds the shut down warning setting.
Pipe connections
• DIN connections for flanges
• ISO for threaded pipes or pipe couplings
2.2 Electrical system
Description
The blowers are completely equipped and wired, and require only connection to the mains.
The system includes mainly:
• Elektronikon® control system including an electronic regulator and a control panel
• Pressure and temperature sensors
• Blower motor
• VSD cabinet including the variable speed drive unit
2.3 Regulation
Valve description
The start-up valve is an assembly of a main valve and a pilot valve. The maximum pressure is
pre-set and cannot be manipulated or adjusted (sealed). In case of damage or wrong valve
settings, the complete valve assembly has to be replaced by Atlas Copco.
APF232438 13
Instruction book
Main valve
The blow-off valve is mounted on the flanged opening on the pipe of the blower outlet. The inlet
opening and valve seat are located in the bottom base (1). The main valve is formed by the
metal/rubber bellows (2), which is fixed to the top base (3). The top base is firmly connected to
the bottom base (1) by guide rods (4). Pressure is fed from the inlet opening to the control valve
(5) by the tube (6). The movable base (7) fixed to the bottom of the bellows (2), moves on guide
rods (4) and forms the main valve disc. The inner area of the bellows (2) is connected to the
control valve (5). When getting pressurized with process air, the movable base (7) seals off the
valve seat. The pressure in the bellows (2) is relieved by releasing the air in the control valve (5).
Valve function
Starting valve function:
In the state without pressure, the main valve is open.
While the blower is starting, the valve ensures gradual pressure and torque increase.
14 APF232438
Instruction book
While the blower is starting, some pressure is generated in the space between the seat and the
movable base.
The pressure is then transported into the bellows through the control valve.
As the surface of the bottom of the bellows is larger than the seat surface and thus the force is
higher, the bellows will close within a few seconds due to the gradual pressure increase.
This will result in starting the blower with continuous load rise. The valve is open while it is not
under load.
If the valve was not open in the unloaded state, it would not be able to perform the starting valve
function.
Controlled blow-off valve

The unit can be unloaded by a solenoid valve. If the solenoid is activated, chamber X is
depressurized and the pressure in the bellows is relieved.
Pressure control mode
If the unit is operating in pressure control mode, the motor speed is adapted in function of the
pressure set point. The pressure in the air net is varying in function of the air consumption.
If the air consumption has been decreased until the motor speed can not be reduced any further
and if the air consumption will further be reduced, the pressure in the air net will rise up to the
indirect stop level (set value), the unit will be unloaded. If the unit stays unloaded for a certain
period of time (set value), the unit will stop. The machine will start again if the pressure in the air
net decreases below the pressure set point.
In case the net pressure should rise to the direct stop level (set value), the blower will be stopped
immediately. The machine will start again if the pressure in the air net decreases below the
pressure set point.
Speed control mode
If the unit is operating in speed control mode (e.g. 4-20 mA) in order to control the air volume
flow, the motor speed is adapted to the requested speed set point.
If the pressure in the air net will rise up to the indirect stop level (set value), the unit will overrule
the requested speed set point, slow down to minimum speed and go unload. If the pressure is
APF232438 15
Instruction book
above the indirect stop level and again below within a predefined time (set value), the unit will go
loaded again after the predefined time and follows the requested speed set point.
The unit will stop after the predefined time if the pressure is still above the indirect stop level. If
the pressure drops below the indirect stop level, the unit will be loaded again.
2.4 Flow diagram and cooling system
Flow diagram
Text on figure:
Drawing reference Description

(1) Air flow
(2) Oil flow
(3) Air inlet
(4) Flexible connection
(5) Oil filter
(6) By-pass valve
(7) Intake filter & silencer
(8) Air-cooled oil cooler
16 APF232438
Instruction book
(9) Gears & bearings lubrication

(10) Oil pump
(11) Oil reservoir
(12) Compensator
(13) Non return valve
(14) Blow-off valve
(15) Silencer
(16) Safety pressure switch
Air flow
Air drawn through the silencing air inlet and filter (7) is compressed in the blower element and
discharged through non return valve (13) and silencer (15) towards the air net. (16) is a safety
pressure switch to protect the unit in case of overpressure.
Oil system
Oil is circulated by pump (10) from the integrated oil reservoir (11) through cooler (8) and oil filter
(5) to the gear wheels, bearings and cooling jacket of the blower element. By-pass valve (6)
opens when the oil pressure rises above a given value.
Cooling system
The blower is provided with an air-cooled oil cooler (8), the cooling air is generated by an electric
motor driven fan.
APF232438 17
Instruction book
3 Elektronikon® GraphicPlus controller
3.1 Controller panel
Electronic controller
Controller panel
Parts and functions
Reference Designation Function

1 Display Shows the unit operating condition and a number of
icons to navigate through the menu.
2 Pictograph Automatic operation
3 Pictograph General alarm
4 General alarm LED Flashes if a shut-down warning condition exists.
5 Pictograph Service
6 Service LED Lights up if service is needed
7 Automatic operation LED Indicates that the regulator is automatically
controlling the unit.
8 Voltage on LED Indicates that the voltage is switched on.
9 Pictograph Voltage on
10 Enter 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.
11 Cancel/Escape key To go to previous screen or to end the current action
12 Scroll keys Keys to scroll through the menu.
13 Stop button Button to stop the unit. LED (7) goes out.
18 APF232438
Instruction book
Reference Designation Function

14 Start button Button to start the unit. LED (7) lights up indicating
that the electronic regulator is operative.
The Voltage on LED should not be used as a voltage indicator during maintenance.
3.2 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 GraphicPlus (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 GraphicPlus (Mk5)
The digital output contacts have following specifications:
APF232438 19
Instruction book
Relay Connector Maximum load

K01 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K02 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K03 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K04 3 X 31 10 A / 250 V AC
10 A / 30 V DC
resistive load
K05 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K06 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K07 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K08 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
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
20 APF232438
Instruction book
3.3 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.
Compressor status Motor stopped
Running unloaded
Running loaded
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
APF232438 21
Instruction book
Service required
Service
Error
Main screen Displayed when 2 or 4 line layout is picked.
Main chart Displayed when chart layout is picked.
Menu icons
Icon Description
Converter(s)
Service
Alarms (warnings, shutdowns)
Week timer
Info
Test
Counters
Regulation setpoints
Inputs
Outputs
22 APF232438
Instruction book
Icon Description
Event history (saved data)
Settings
Input icons
Icon Description
Pressure
Temperature
Digital input
Special protection
System icons
Icon Description
Fan (overload)
Automatic restart (ARAVF)
Main chart
Compressor element (LP, HP, ...)
Filter(s)
Frequency converter
Motor
APF232438 23
Instruction book
Expansion module
Network settings/problem
General alarm
Oil circuit
Regulation
General settings
Access key
Remote start/stop (Password protected)
Navigation arrows
Icon Description
Up
Down
24 APF232438
Instruction book
3.4 Main screen
Control panel
Control panel
(1) Enter key

(2) Cancel / Escape key
(3) Scroll keys
Function
The main screen shows the status of the compressor and is the gateway to all functionality
implemented in the controller.
The main screen is shown automatically when the power is switched on. The display switches to
sleep mode when no keys are pushed for a programmable time.
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)
APF232438 25
Instruction book
Two and four value views
Typical Main screen (Four value lines)
Text on figures
(1), (2) Compressor Outlet

(3) Inlet Guide Vanes % Open
(4) Blow-Off Valve % Closed
(5) Starting
(6) Menu
(7) Unload
• Section A displays information regarding the compressor operation (e.g. outlet pressure,
temperature at compressor outlet ).
• 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:
26 APF232438
Instruction book
Local control
Remote control
Network control
• Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer,
automatic restart after voltage failure, etc.)
• Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To show more information about displayed icons, select the icon using the scroll keys and
push the Enter key.
• Section C is called the Status bar
This bar shows the text that corresponds to the selected icon.
• Section D shows the Action buttons. These buttons are used:
• to call-up or program settings
• to reset a shutdown, service message or emergency stop
• to have access to all data collected by the controller
The function of the buttons depends on the displayed menu. The most common functions
are:
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 Cancel / Escape key.
APF232438 27
Instruction book
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.
28 APF232438
Instruction book
3.5 Controller menu structure
Main menu
Press the Enter key to go to the main menu screen that is shown below.
Menu structure
Please find the tree structure on the 2 top levels below. The items are mentioned as they appear
on the screen from top to bottom and left to right. If questions regarding lower levels appear,
please consult your local Atlas Copco Customer Centre.
SERVICE PLAN
Topic Description
Overview Displays an overview of the running service plans
Service Plan Displays configuration of the service plans
Next Service Displays the next service task
History Displays a log of all automatic shutdowns that have appeared in the past
PROTECTIONS
Topic Description
General Displays a list of main protections
Fan Displays a list of overload fan motor protections
Filter(s) Displays a list of filter(s) protections
Expansion module Displays a list of expansion module communication protections
Element(s) Displays a list of protections related to the compressor stages
Convertor(s) Displays errors concerning frequency convertors
Main Motor Displays motor related protections to avoid motor damage
Oil Circuit Displays a number of protections in the oil circuit
WEEK TIMER
APF232438 29
Instruction book
Topic Description
Displays 4 programmable week action schemes
Week Action Schemes Each week action scheme contains 7 programmable days and these days can
contain a number of successive events on selected time slots.
Contains 10 weeks and each week can be selected as 1 of the 4 week action
Week Cycle
schemes
Status Displays the status (On/Off) of the week timer functionality
Remaining Running Allows to set a timer to keep the blower running for 1-240 minutes
Time
INFORMATION
Topic Description
Refers to the company website where more detailed info on the product can be
www.atlascopco.com found
More The More button displays the software versions, addresses, licenses, ...
TEST
Topic Description
Regreasing Test Allows to run the motor regreasing program
Allows a functionality check of the safety valve. (This feature can only be
Safety Valve Test
enabled by a service technician.)
COUNTERS
Topic Description
Displays the number of hours the blower has been running in unloaded & loaded
Running hours mode
Motor Starts Displays the number of motor starts
Load Relay Displays the number of load relay toggles (thus unload/load transitions)
Displays the number of hours the blower has been running between 1 % and 20
VSD 1 — 20 % RPM
%
Displays the number of hours the blower has been running between 20 % and
VSD 20 — 40 % RPM
40 %
VSD 40 — 60 % RPM
60 %
VSD 60 — 80 % RPM
80 %
VSD 80 — 100 % RPM
100 %
Accumulated air volume Displays the accumulated air volume
Module Hours Displays the number of hours the module has been powered
Direct stops Displays the number of blower stops
Emergency stops Displays the number of blower stops by use of the emergency stop
REGULATION
30 APF232438
Instruction book
Topic Description
Reduced setpoint The setpoint is reduced
Setpoint 1 Value of setpoint 1
Indirect stop level 1 Value of indirect stop level 1
Direct stop level 1 Value of direct stop level 1
Setpoint 2 Value of setpoint 2
Indirect stop level 2 Value of indirect stop level 2
Direct stop level 2 Value of direct stop level 2
Setpoint used Which setpoint is used
Regulation mode In which regulation mode is the compressor
Digital pressure band
selection Which pressure band is selected
Maximum speed factor Value of the maximum speed factor
INPUTS
Topic Description
General Displays a number of general readouts and bipolar states
Element(s) Displays a list of readouts related to the compressor stages
Fan Displays the status of the fan
Filter Displays the status of the filter
Converter(s) Displays the status of the converter(s)
Main Motor Displays a number of readouts and bipolar states concerning the main motor
Network Displays a number of bipolar states of remote signals
Oil Circuit Displays a number of readouts and bipolar states concerning the oil circuit
OUTPUTS
Topic Description
General Displays a number of analogue and digital outputs
Fan Displays the activation of the fan
Element(s) Displays the activation of the element(s)
Converter(s) Displays the activation of the converter(s)
Oil circuit(s) Displays the activation of the oil circuit(s)
SPM (Shock Pulse Method)
APF232438 31
Instruction book
Topic Description
Motor, drive end Displays the vibration level at the drive end of the motor
Motor, non-drive end Displays the vibration level at the non-drive end of the motor
Low pressure stage, Displays the vibration level at the drive end of the low pressure compressor
drive end stage (when option is chosen)
Low pressure stage, non- Displays the vibration level at the non-drive end of the low pressure compressor
drive end stage (when option is chosen)
Gearbox Displays the vibration level at the gearbox
EVENT HISTORY
Topic Description
Displays a log file of all shutdowns and shows the status of the type, counters,
-
inputs and outputs at the moment a shutdown appeared
SETTINGS
Topic Description
Network Displays the CAN and ethernet configuration
Regulation Displays settings concerning the compressed air flow regulation
General Displays settings concerning time, date, unit and display time-out
Only displayed when blower motor voltage < 690V and when ARAVF is
Automatic Restart available. Automatic Restart After Voltage Failure can only be enabled by a
service technician.
Access Key Displays the controller access level that can be modified with password input
Displays the availability to use a password to protect the controller from
User Password
unwanted manipulation
Main Chart Displays the input and the range of the main chart
Remote control Displays the remote control mode (Password protected)
3.6 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).
32 APF232438
Instruction book
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).
APF232438 33
Instruction book
• Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid
conflicts, uncheck other properties if they are checked. After selecting TCP/IPv4, click on the
Properties button (2) to change the settings.
• Use the following settings:

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

• Ask your IT department to generate a fixed IP address in your company’s network.
• That IP address will be excluded from the DNS server, so it will be reserved for the
controller.
• Also get the correct Gateway and Subnet mask settings. For example:
• IP = 10.25.43.200
• Gateway = 10.25.42.250
34 APF232438
Instruction book
• 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)
APF232438 35
Instruction book
• Go to Ethernet (1)
• Switch Off (1) the Ethernet communication to allow editing the settings
• Adapt IP Address (1)

• Adapt Gateway IP (2)
• Adapt Subnet Mask (3)
• Switch On (4) the Ethernet communication
36 APF232438
Instruction book
• 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!)
APF232438 37
Instruction book
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.
38 APF232438
Instruction book
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.
APF232438 39
Instruction book
40 APF232438
Instruction book
4 Installation
4.1 Dimension drawing
ZS 160 + VSD, ZS 200 VSD up to ZS 355 VSD
Dimension drawing (metric)
APF232438 41
Instruction book
Text on figure:
(1) Air-cooled
(2) Water-cooled
(3) Water in- & outlet
(4) Centre of gravity
(5) Cooling air outlet
(6) Blower air inlet
(7) Motor cooling air inlet
(8) Oil cooling air inlet
(9) Cubicle cooling air inlet
(10) Electrical cable entry
(11) 4 Slotted holes only for horizontally pulling unit out of container
(12) Compressed air outlet
42 APF232438
Instruction book
4.2 Installation proposal
Blower room example for ZS 160+ VSD, ZS 200 VSD, ZS 250 VSD, ZS 315 VSD, ZS 355 VSD
Room example (metric)
APF232438 43
Instruction book
Text on figure

(A) Air inlet grating of motor cooling
(B) Air inlet grating of oil cooling
(C) Inlet of blower air
(D) Outlet of cooling air of blower
(E) Inlet of cooling air of electrical cabinet
(F) Ventilation proposals
(G) Common ducting for multiple units is not allowed
(H) Inlet of cooling air of blower and oil cooler
Provide a grating on the inlet ducting to prevent obstructions at the inlet gratings of the
blower.
Warning
The maximum allowed pressure from the connected air net on the blower is 2 bar (29 psi).
Thermal insulation should be provided to protect against the high temperature of the air
outlet valve and air delivery pipe.
Blower units must not be used in a potentially explosive atmosphere.
Description
The numbered list items below refer to the balloon references in the installation proposal.
1. Install the blower on a level floor suitable for taking its weight.
Recommended minimum distance between the top of the bodywork and the ceiling is 1200
mm (47 in).
Distances between units and walls stated are minimum.
2. 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)
• d = inner diameter of the delivery pipe (in mm)
• dp = pressure drop (recommended maximum = 0.1 bar)
• L = length of delivery pipe (in m)
• p= absolute pressure at the blower outlet (in bar(a))
• Qc = free air delivery of the blower (in l/s)
3. Avoid recirculation and intake of hot air in compressed air inlet grating
4. Entry of the electrical supply (2 alternatives)
5. Outlet valve of blower air (supplied by the customer)
44 APF232438
Instruction book
The maximum allowed pressure from the connected air net on the blower is 1.3 bar (18.9
psi).
6. Compensator (supplied by the customer)
The outlet pipe should be connected stress-free to the blower unit.
7. Take measures to avoid noise radiation caused resonance of the discharge pipe:
• Consider the wall thickness of the discharge pipe.
• Apply acoustic insulation to the discharge pipe.
• Apply an anchoring method that avoids resonance transfer to the building.
• Carefully select the discharge pipe section to avoid resonance caused by air velocity.
8. Installation of acoustic insulation material to prevent sound reflections from the cooling air
intake.
9. If the installation is done without ducts, the ventilation flow can be calculated as follows:
For SI Units
Q = (0.139 x N + 2.2) / dT
• dT = Temperature difference between the blower room and outside temperature (°C)
• N = The installed blower power (kW)
• Q = The ventilation flow leaving the blower room (m³/s)
For a temperature difference of 5 °C, this results in following ventilation flow:
Model Ventilation flow (m³/s)

ZS 250 VSD 7.33
4.3 Electrical connections
General
Important
• The voltage on the blower terminals must not deviate more than 10% of the nominal
voltage.
It is however highly recommended to keep the voltage drop over the supply cables at
nominal current below 5% of the nominal voltage (IEC 60204-1). If cables are grouped
together with other power cables, it may be necessary to use cables of a larger size
than those calculated for the standard operating conditions.
• Use the original cable entry. See section Dimension drawings.
To preserve the protection degree of the electric cubicle and to protect its
components from dust from the environment, it is mandatory to use a proper
cable gland when connecting the supply cable to the blower.
• Local regulations remain applicable if they are stricter than the values proposed
below.
General instruction for the electrical installation of VSD blowers

• Electrical equipment from Atlas Copco Compressor is designed in accordance with the
safety regulations described in IEC60204-1 and CENELEC EN60204.
APF232438 45
Instruction book
• It is the responsibility of the customer to install the compressor unit according to the safety
regulations in order to protect people from electric shocks from direct or indirect contact.
• In drives with frequency converters, leakage currents occur along the RFI filter and the cable
capacities, especially during the motor start. Class A leakage detection protections would
switch off the machine. Therefore it is not recommended to use class A detection systems
on frequency converters.
Installation instructions for TN, TT, IT

In each network system (TN, TT or IT), the customer has to protect the installation using
overcurrent protection by means of fuses or automatic circuit breaker protection.
With respect to the power distribution system, additional installation instructions are given.
Network type TN (TN-S, TN-C and TN-C-S)

No additional protections need to be installed. If the customer wishes to or needs to install a
leakage detection device, it should be of type B and should comply with IEC755 Amendment 2
"General requirements for residual current-operated protective devices". Atlas Copco advises
customers to install the following earth leakage detection device: BENDER RCMA 470LY with
external current transformer: http://www.bender.org/prod.html
Network type TT
In the case of TT-systems, safety regulations mostly stipulate the use of an earth leakage circuit
breaker (e.l.c.b). In combination with frequency converters, type B residual current-operated
protective devices should be used. Atlas Copco advises customers to install the following earth
leakage detection device: BENDER RCMA 470LY with external current transformer: http://
www.bender.org/prod.html
Network type IT
In IT-network systems, it is permissible for the power supply to continue in the event of an initial
earth leakage fault of a motor phase. However, the customer must detect the initial earth leakage
fault. The fault must be indicated as an alarm. If this is not the case, the initial earth leakage fault
must trigger automatic disconnection of the power supply (EN 60204-1 par.: 6.3). However, the
high frequency capacitive leakage currents caused by frequency converters cannot be detected
by standard earth leakage detection systems. Atlas Copco recommends that customers install:
BENDER IRDH 275/435 http://www.bender.org/prod.html.
Atlas Copco strongly recommends that customers do not connect the neutral conductor from the
power supply to the compressor unit. The exposed conductive parts of the installation must be
earthed locally. (EN 60204-1 par.: 7.2.3)
Power distribution systems (TN, TT, IT)

According to IEC 60950, there are three main types of power distribution systems: TN, TT and IT.
The electrical installation instructions depend on the type of network of the customer's power
supply.
Network type TN (Terra Neutral) :
The TN power distribution system provides a direct earth to the exposed conductive parts of the
installation. The connection is made through the PE-conductor. Within the TN power distribution
46 APF232438
Instruction book
system, there are three sub-types: TN-S, TN-C and TN-C-S, identified according to neutral and
protective earth conductors. Nearly 85 % to 90 % of industrial networks are TN type.
Network type TN-S (Terra Neutral-Separate) :
The TN-S power distribution system provides separate neutral and direct earth conductors.
A Power system earth

B Exposed conductive parts
Network type TN-C (Terra Neutral-Combined) :

In the TN-C power distribution system, the neutral and the protective earth functions are
combined in a single conductor.

Network type TN-C-S (Terra Neutral-Combined-Separate) :

In the TN-C-S power distribution system, the neutral and the protective earth functions are
combined to some degree in a single conductor, a direct earth to the exposed conductive parts of
the installation exists in part. The connection is achieved through the PEN conductor.
APF232438 47
Instruction book

Network type TT (Terra Terra) :

The TT power distribution system has one point that is directly earthed. In addition, the exposed
conductive parts of the installation are connected to earth electrodes that are independent from
the power system's earth.

Network type IT (Impedance Terra) :

The IT power distribution system has no direct connection to Protective Earth (PE). It is earthed
via a high ohmic impedance, so that the network is effectively behaving like an unearthed floating
network. The exposed conductive parts of the installation are directly connected to earth. In the
event of an initial earth leakage fault of a motor phase, the power supply continues. However, the
customer must detect the initial earth leakage fault. The fault must be indicated as an alarm.

C Impedance
48 APF232438
Instruction book
IEC versions
For IEC designed control panels, the below suggested cable sections are calculated according
to EN 60364-5-52 electrical installations of buildings, part 5: selection and erection equipment,
section 52: current-carrying capacities in wiring systems.
Standard conditions refer to loose copper conductors or multi-core cable with 70˚C PVC
insulation in free air or on open cable trays (installation method C) at 30˚C ambient temperature
and operating at nominal voltage. The cables may not be grouped with other power circuits or
cables.
Worst case conditions refer to:
• ambient temperature > 30˚C (86 ˚F)
• cables in closed raceway, conduit or trunking system (installation method B2) at 40 ˚C
ambient temperature
• cables not grouped with other cables
Fuse calculations for IEC are done according to EN 60364-4-43 electrical installations of
buildings, part 4: protection for safety- section 43: protection against overcurrent. Fuse sizes are
calculated in order to protect the cable against short circuit. Fuse type aM is recommended but
gG/gL is also allowed.
APF232438 49
Instruction book
Electrical connections

(1) Customer's installation
(2) Main drive motor
Please refer to the electrical cabinet door for the entire service diagram.
50 APF232438
Instruction book
Required cable size and maximum fuses for 50 Hz IEC blowers
Model Supply voltage (V) Required cable sections Maximum fuses (A)
ZS 250 VSD 400 3x (3x95mm²+50mm²) 3x800
4.4 Quality of safety components

When installing a remote emergency button or a motor contactor, the following B10d values are
advised:
• Emergency stop button: 500 000
• Main contactor: 1 333 333
4.5 Pictographs
Pictographs
APF232438 51
Instruction book
Reference Name
1 Pictograph, Automatic start - Read manual - No service with voltage and pressure on
2 Pictograph, warning: blow off
3 Pictograph, warning: under tension
4 Pictograph, warning: hot surface
5 Pictograph, transport instructions
6 Stop the blower before maintenance or repair
7 Pictograph, earthing
8 Rotation direction arrow
9 Only use Roto-Z oil
10 Check the air flow direction
11 CAUTION: capacitive voltage above 50 V may remain for 5 min after power
disconnection
12 Disconnect from the electrical supply before opening
Pictographs on control panel
Reference Name
1 Alarm
2 Service
3 Automatic operation
4 Voltage on
5 Enter
6 Escape
7 Scroll keys
8 Stop
9 Start
52 APF232438
Instruction book
Torque instruction
Please refer to the label in the electrical cabinet for the torque values of the electrical
connections.
APF232438 53
Instruction book
5 Operating instructions
5.1 Initial start-up
Safety precautions
The operator must apply all relevant Safety precautions.
Outdoor/altitude operation
If the blower is installed outdoors or if the air inlet temperature can be below 0 ˚C/32 ˚F,
precautions must be taken. If this is the case, or if the blower is being operated at high altitudes,
consult the Atlas Copco Customer Center.
Moving/lifting
In order not to damage the frame, the blower must be moved either by a lift truck or by using
lifting equipment as described below.
When moving the blower 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 blower 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 blower. The lifting equipment must be placed in such a way that the blower is lifted
perpendicularly. Lift gently and avoid twisting.
General preparation
Make sure that the compressor is installed correctly. Refer to Dimension drawing , Installation
proposal and Electric cable size .
Please follow the instructions mentioned on the sticker next to the control panel.
Preparation for initial start-up

1. Install the blower, refer to following sections:
• Electrical connections
• Installation proposals
• Dimension drawings
2. The blower and motor are secured to the frame immobilizing the vibration dampers during
transport.
3. Check that the oil sump of the blower is filled with oil: oil must be visible in oil level sight-
glass (1).
54 APF232438
Instruction book
4.Check the voltage selecting wires at transformer (T1) for correct connection.
5.Check that the electrical installation meets local regulations.
6.Check the overload setting (F21). Switch on the voltage.
7.Check that the gear casing is filled with oil.
8.Start the motor and stop it immediately.
9.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. Refer to the Lock
Out — Tag Out (LOTO) procedure in the safety precautions.
10. Run the compressor for a few minutes.
11. Stop the compressor and check the oil level. On a ZS unit, the oil level must be in the upper
field of the green range of the sight-glass (1). Top up, if necessary, with the correct type of
oil.
5.2 Before starting
Attention
Procedure
1. Check the oil level, which must be in the middle of sight-glass. Top up, if necessary, with the
correct type of oil.
APF232438 55
Instruction book
2. Open the air outlet valve (customer's installation).

3. Switch on the voltage and check that voltage on LED (6) lights up.
5.3 Starting
Control panel
Control panel, MKV regulator
Starting
• If the motor is stopped and automatic operation LED (8) is alight, the motor may start
automatically.
• On blowers with MKV regulator, if the week timer is active, the blower can start
automatically, even if it was stopped manually.
• Open the air outlet valve.

• Press start button (1).
• The blower starts running and automatic operation LED (8) lights up.
Manual restarting
In automatic operation, the regulator limits the number of motor starts.
56 APF232438
Instruction book
5.4 During operation
Control panel
Procedure
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 blower can start automatically, even if it was stopped
manually.
Check the readings on display (2).
APF232438 57
Instruction book
5.5 Checking the display
Control panel
Procedure
Before carrying out any maintenance, repair or adjustment work, stop the blower, press
emergency stop button (S3), switch off the voltage and depressurize the blower.
58 APF232438
Instruction book
Step Action
1 Regularly check the display for readings and messages. Normally, the main display is
shown, indicating the blower outlet pressure, the status of the blower 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 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.
4 Regularly press the arrow down key to call up the actual blower condition:
• The blower control status (automatic or manual, local or remote)
• The status of the blower start/stop timer (active or not). The blower 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 outlet temperature
• The temperature of the blower element
• The oil temperature
• The status of the drive motor and fan motor overload protection (normal or not)
• The total running hours
5.6 Stopping
Control panel
APF232438 59
Instruction book
Description
• Press stop button (9).
• Close the air outlet valve.
Emergency stopping
• To stop the blower immediately, press emergency stop button (S3). Alarm LED (7) starts
blinking.
• Close the air outlet valve.
• After remedying the trouble, unlock the emergency stop button by pulling it out or by turning
it to the right (depending on the model of the switch).
5.7 Starting after emergency stop or shut down
Control panel
Control panel
Procedure
Step Action
1 Press the emergency stop button (if not yet done).
2 Switch off the voltage and then depressurize the blower.
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.
60 APF232438
Instruction book
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 blower 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 restarting
In automatic operation, the controller limits the number of motor starts.
On blowers with a medium-voltage or high-voltage motor, the number of motor starts is limited to
3 starts per day.
5.8 Taking out of operation
Procedure
At the end of the service life of the blower, proceed as follows:
Step Action
1 Close the air outlet valve, stop the blower and press the emergency stop button.
2 Switch off the voltage and disconnect the blower from the mains.
3 Shut off and depressurize the part of the air net which is connected to the outlet valve.
4 Disconnect the blower air outlet pipe from the air net.
5 Drain the oil, catch the oil in a receptacle. Dispose of the oil according to local
regulations.
6 Also read section Used material for the disposal of used material.
APF232438 61
Instruction book
6 Maintenance
6.1 Preventive maintenance schedule
Safety precautions
Before carrying out any maintenance, repair work or adjustment, proceed as

follows:
• Stop the compressor.
• Press emergency stop button (S2).
• Close the air outlet valve and open the manual condensate drain valves.
• Switch off the voltage.
• Open and lock the isolating switch (installed by the customer).
• Repairs inside the start and speed regulation cabinet may only be carried out by
Atlas Copco.
• Wait at least 6 minutes before starting any electrical repairs as hazardous high
voltage remains on the condensers of the start and speed regulation unit for 6
minutes after the voltage is switched off.
Service agreements
Atlas Copco Customer Centres have a range of service agreements to suit your needs:
• An Inspection plan
• A Preventive maintenance plan
• A Total responsibility plan
Contact your Customer Centre to agree on a tailor-made service agreement. It will ensure
optimum operational efficiency, minimize downtime and reduce the total life cycle costs.
Warranty-Product Liability
Use only authorized spare parts. Any damage or malfunction caused by the use of unauthorized
parts is not covered by Warranty or Product Liability.
Service kits
Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits.
Service kits comprise all parts needed for servicing components and offer the benefits of genuine
Atlas Copco parts while keeping the maintenance budget low.
Regular checks
To ensure safe operation and long service life carry out following operations at the interval
(period or running hours) which comes first. The longer interval checks must also include the
shorter interval checks. The local Atlas Copco Customer Centre may overrule the maintenance
schedule depending on the environmental and working conditions of the compressor.
Period Running hours Operation

Daily 8 Check the readings.
62 APF232438
Instruction book
Period Running hours Operation

Daily -- Check the oil level.
Before starting, the level should be in the middle of the sight-glass.
Weekly -- Drain condensate from the air receiver, if installed
Every 3 months -- Clean blower.
Every 3 months -- Check for possible leaks.
Every 3 months 500 Check the cooler; clean if necessary.
When displayed -- Carry out service actions according to the displayed service plans
Service plan
A number of service operations are grouped (called level A, level B, level C, ...). Each level
stands for a number of service actions to be carried out at the time intervals programmed. See
part General settings of section Minimum requirements for safe regulation.
Activity Visit I Visit A Visit B Visit C Visit D

2000 h 4000 h 16000 h 24000 h 48000 h
Take service reading (temperature
and pressure of air and oil) X X X X X
Check cooler functions; clean if
necessary X X X X X
Check for air and oil leakage X X X X X
Check sensitive bolt/coupling
connections X X X X X
Check/adjust safety valve and
switches X X X X
Check for presence of water in lube oil X X X X X
Change compressor oil X X
Change compressor oil filter X X X X
Check condition of air intake chamber X X X X X
Check air filter elements X
Inspect/change air filter elements X X X X
Check filter elements of gear case
breather X
Replace gear case breather kit X X X X
Check cycle of start-up/blow-off valve X X X X X
Replace O-ring kit of check valve X X
Check functioning of check valve X X X
Replace check valve X X
Grease main drive motor bearings X X X X
Clean fan cowl of main electric motor X X X X
Clean the fan cowl of the oil cooler fan
motor X X X X
Overhaul main drive motor X
Clean cooler block (int/ext) X
APF232438 63
Instruction book
Activity Visit I Visit A Visit B Visit C Visit D

2000 h 4000 h 16000 h 24000 h 48000 h
Check rubber inserts of drive coupling
(arr E) X X
Replace rubber inserts of drive
coupling (arr E) X X
Check condition of drive gear teeth X X X
Replace main shaft bearings (second
overhaul) X
Replace anti-vibration pads X
Take full set of S.P.M. readings X X X X X
Blast clean VSD cubicle with dry air
(maximum 1 bar) X X X X
Check for loose wiring and
connections in cubicle X X X X
Replace carbon brush X X
Replace converter fan (32000-40000
h) X
Change converter filters X X X X
Overhaul oil pump X
Check oil level X X X X X
Check loose wiring and connections in
motor box X X X
Replace shaft seal X
Inspect/Clean fan of oil cooler X X X X
Replace fan motor of oil cooler X
Overhaul oil-bypass X
6.2 Motor greasing
ZS 250 VSD
Motor type: WEG W22 315 L

Interval: 4000 hours
Quantity: Front bearing (drive side) 27 g (0.95 oz)
Rear bearing (non-drive side) 34 g (1.20 oz)
Type: Roto Glide Blue
64 APF232438
Instruction book
6.3 Oil specifications
Roto-Z lubricating oil

Use only Atlas Copco Roto-Z oil which is specially developed for oil-free rotary blowers. This oil
has a long service life and ensures optimum lubrication.
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
6.4 Storage after installation
Procedure
Run the blower, e.g. twice a week, until warm.
If the blower is going to be stored without running from time to time, protective measures
must be taken. Consult the Atlas Copco Customer Center.
6.5 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. All service kits are indicated in the
relevant Parts Lists.
APF232438 65
Instruction book
7 Servicing procedures
7.1 Air filter
Procedure
The filters must be serviced regularly. Consult section preventive maintenance

schedule.
Never install damaged or clogged filters.
1. The filter must be serviced as soon as the service warning appears on the display.
2. Stop the blower, press the emergency stop button and switch off the voltage. Never remove
the elements while the blower is running.
3. Open the doors (4) and remove the covers (1).
4. Remove the air filters (2). Take care that no dirt drops into the inlet pipe.
5. Clean and inspect the element sealing surface of each filter chamber.
6. Install the new or cleaned filters (2), fit the covers (1) and close the doors (4). Never install
damaged or clogged filters.
7. Open door (3) of the electrical cabinet and clean/replace the filter mat.
8. Switch on the voltage, unlock the emergency stop button and reset the air filter service
warning.
66 APF232438
Instruction book
7.2 Oil and oil filter change
Oil system
Procedure
Step Action
1 Run the blower until warm.
2 Stop the blower, press the emergency stop button.
3 Switch off the voltage.
4
5 Remove the oil filter. Clean the filter seat, oil the gasket of the new filter and screw the
filter into place until the gasket contacts the seat. Then tighten by hand.
6 See section 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 blower for a few minutes.
10 Stop the blower, check that the oil level is in the upper field of the green range of sight-
glass (1).
11 Top up, if necessary.
APF232438 67
Instruction book
7.3 Blow off
Description
When the blower runs loaded, the main valve disk is closed. The bellows and outlet pipeline are
connected with the control valve. If the pressure exceeds the limits, a pressure switch stops the
unit. No warning is shown on the display.
Never run the blower without safety switches.

No adjustments are allowed.
68 APF232438
Instruction book
8 Problem solving
8.1 Problem solving
Before carrying out any maintenance, repair or adjustment work, stop the blower, switch
off the voltage and close the air outlet valve. Press the emergency stop button. Open
and lock the isolating switch.
Control panel
Faults and remedies
Condition Fault Remedy

Blower capacity or working Air consumption exceeds Check pneumatic plant
pressure lower than normal capacity of blower
Starting valve leaking Have valve inspected
Oil pressure too low Oil level too low Top up level to the middle of the oil level
sight-glass
Oil filter clogged Replace filter
Oil temperature above normal Oil shut-down temperature Correct setting to trip at the specified
incorrectly set temperature
Insufficient cooling air flow Check the cooling fan
APF232438 69
Instruction book
Condition Fault Remedy

Blower does not start or Service switch (SS) is Switch off the service switch (the drive
shows the converter fault 0X1 switched on panel will show REM)
Blower starts running, but Pressure in air net is above Blower will load when pressure in air net
does not load after a delay pre-set loading pressure drops to pre-set loading pressure
time
Loading solenoid valve Check and, if necessary, replace the valve
inoperative
Start up valve malfunctioning Contact your local Atlas Copco service
center
The service switch may only be used for a test run and not for continuous running.
70 APF232438
Instruction book
9 Technical data
9.1 Readings
Important
The readings below are valid when operating at reference conditions. See Reference
conditions.
Readings on display
For the maximum working pressure and the outlet pressure, consult sections Specific data.
The readings depend on the blower type. The values given below are average values and may
differ depending on the blower type.
Item Reading
Outlet pressure Depends on blower type
dp of air filter Below -0.044 bar
Oil pressure 2.5 bar(e)
Air outlet temperature 98 ˚C
Oil temperature Approx. 40 ˚C
9.2 Settings for overload relay and fuses
Attention
Type 1: disturbance of contactor and/or overload relay may occur (if damaged, the
component must be replaced).
50 Hz blowers
Maximum fuses for 50 Hz IEC blowers
Model Supply voltage (V) F1-2 (A) F10-11-12 (A) F15 (A)
ZS 250 VSD 400 2 10 4.4
APF232438 71
Instruction book
9.3 Reference conditions and limitations
Reference conditions
Item Condition
Absolute inlet pressure 1 bar(a) (14.5 psi)
Relative air humidity 0%
Air inlet temperature 20 ˚C (68 ˚F)
Nominal effective working pressure 1.2 bar (17.4 psi)
Limitations
Item Limit
Maximum effective working pressure 1.2 bar (17.4 psi)
Minimum effective working pressure 0.3 bar (4.4 psi)
Maximum air inlet temperature 40 ˚C (104 ˚F)
Minimum air inlet temperature -20 ˚C (-4 ˚F)
Minimum ambient temperature 0 ˚C (32 ˚F)
9.4 Blower data
ZS 160+ VSD and ZS 200 VSD up to ZS 355 VSD

Values at reference conditions, unless otherwise stated and according to ISO 1217, fourth
edition, annex C.
Specification ZS 250
VSD
Nominal / maximum working pressure bar 1.2
Total electrical power input (1) kW 287.3
Outlet temperature °C 116
Mean sound pressure level (2) (dB(A)) 79.2
Oil capacity (approx.) l 103
Mass kg 5970
Footnotes
• (1) Supply voltage: 400 V (for 50 Hz units), 440 V (for 60 Hz units). Data may differ 0.5%
maximum at other supply voltages.
• (2) A-weighted emission sound pressure level at the work station (LpWSAd). Measured
according to ISO 2151: 2004 using ISO 9614/2 (sound intensity method). A total correction
factor for uncertainties of 3 dB has to be added conform the test code. Possible noise from
discharge line, accessories and/or ancillary equipment is not included.
72 APF232438
Instruction book
10 Pressure equipment directives

The machines are pressure assemblies of cat. II 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

ZS 160+ VSD and ZS 200 • Pressure switch: Category IV
VSD up to ZS 355 VSD • Design code according to 2014/68/EU; EN 12263
• Silencer: Category II
• Design pressure 1.3 bar(e), content 424 liter
• Design standard: ASME section VIII div. 1.
APF232438 73
Instruction book
11 Documentation
Declaration of conformity
Typical example of a Declaration of Conformity document
(1): Manufacturer
(2): Applicable directives
(3): Standards used
(4): Technical file holder
74 APF232438
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.
APF232438 75
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.

Apf232438 en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Apf232438 en

Uploaded by

Copyright:

Available Formats

APF232438

1.1 SAFETY ICONS................................................................................................................................... 5

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

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

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

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

1.6 DISMANTLING AND DISPOSAL...............................................................................................................10

2.2 ELECTRICAL SYSTEM.........................................................................................................................13

2.4 FLOW DIAGRAM AND COOLING SYSTEM..................................................................................................16

3 Elektronikon® GraphicPlus controller........................................................................18

3.1 CONTROLLER PANEL......................................................................................................................... 18

3.2 DIGITAL OUTPUT CONTACTS................................................................................................................19

3.3 ICONS USED.................................................................................................................................... 21

3.4 MAIN SCREEN..................................................................................................................................25

3.5 CONTROLLER MENU STRUCTURE..........................................................................................................29

3.6 WEB SERVER.................................................................................................................................. 32

4.1 DIMENSION DRAWING........................................................................................................................ 41

4.2 INSTALLATION PROPOSAL................................................................................................................... 43

4.3 ELECTRICAL CONNECTIONS.................................................................................................................45

4.4 QUALITY OF SAFETY COMPONENTS.......................................................................................................51

5.1 INITIAL START-UP..............................................................................................................................54

5.2 BEFORE STARTING............................................................................................................................55

5.4 DURING OPERATION.......................................................................................................................... 57

5.5 CHECKING THE DISPLAY.....................................................................................................................58

5.7 STARTING AFTER EMERGENCY STOP OR SHUT DOWN............................................................................... 60

5.8 TAKING OUT OF OPERATION................................................................................................................61

6.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................62

6.2 MOTOR GREASING............................................................................................................................ 64

6.3 OIL SPECIFICATIONS..........................................................................................................................65

6.4 STORAGE AFTER INSTALLATION........................................................................................................... 65

6.5 SERVICE KITS.................................................................................................................................. 65

7.1 AIR FILTER......................................................................................................................................66

7.2 OIL AND OIL FILTER CHANGE...............................................................................................................67

7.3 BLOW OFF...................................................................................................................................... 68

8.1 PROBLEM SOLVING........................................................................................................................... 69

9.2 SETTINGS FOR OVERLOAD RELAY AND FUSES......................................................................................... 71

9.3 REFERENCE CONDITIONS AND LIMITATIONS............................................................................................ 72

9.4 BLOWER DATA................................................................................................................................. 72

10 Pressure equipment directives................................................................................... 73

1.1 Safety icons

1.2 General safety precautions

1.3 Safety precautions during installation

Precautions during installation

1.4 Safety precautions during operation

Precautions during operation

1.5 Safety precautions during maintenance or repair

Precautions during maintenance or repair

1.6 Dismantling and disposal

Disposal of electrical and electronic appliances (WEEE)

Disposal of other used material

The blowers are enclosed in a sound-insulated bodywork.

The blowers include mainly

Elektronikon ® control system

Anti-condensation heaters for motor

PT 1000 thermal motor protection

2.2 Electrical system

Controlled blow-off valve

2.4 Flow diagram and cooling system

Drawing reference Description

(9) Gears & bearings lubrication

3 Elektronikon® GraphicPlus controller

3.1 Controller panel

Parts and functions